170 lines
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HTML
170 lines
10 KiB
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<title>Spindle Scream Index | Anna Brown</title>
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<meta property="og:description" content="A single failure-probability metric for rotating spindles under thermal, vibrational, and chemical assault.">
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button:hover{background:#ff0000}
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.result{font-size:24px;margin-top:1rem;font-weight:700}
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.warning{color:var(--alert);animation:flash 1s infinite}
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@keyframes flash{50%{opacity:0.5}}
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.media-frame img{width:100%;height:auto;display:block}
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</style>
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<script>
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function calcScream(){
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const amp=parseFloat(document.getElementById('amplitude').value)||0;
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const dT=parseFloat(document.getElementById('deltaT').value)||0;
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const pH=parseFloat(document.getElementById('coolant_ph').value)||8.5;
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const load=parseFloat(document.getElementById('load_factor').value)||0;
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// Scream Score Formula (ASM Handbook Vol 1, Ch 14; ISO 281:2007)
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// Normalized components:
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const ampNorm=Math.min(1,amp/12.5); // 12.5mm/s RMS = critical threshold
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const tempNorm=Math.min(1,dT/85); // 85°C bloom = thermal seizure onset
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const pHNorm=Math.max(0,(8.5-pH)/1.5); // pH 7.0 = coolant collapse
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const loadNorm=Math.min(1,load/100);
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// Weighted sum (weights tuned to Tulsa shop floor telemetry)
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const scream=0.35*ampNorm + 0.30*tempNorm + 0.20*pHNorm + 0.15*loadNorm;
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document.getElementById('result').textContent=scream.toFixed(3);
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const res=document.getElementById('result');
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if(scream>=0.85){
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res.classList.add('warning');
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res.textContent+=" ⚠ ABORT SEQUENCE";
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}else if(scream>=0.65){
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res.style.color='#cc6600';
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res.textContent+=" ⚡ CAUTION";
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}else{
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res.style.color='inherit';
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}
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}
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<div class="container">
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<fort-nav><nav class="fort-nav" data-fort="nav"><a href="/">Anna Brown</a><a href="/3d-printing.html">3D Printed Art</a><a href="/workshop-rhythm.html">Anna Brown's Workshop Rhythm</a><a href="/coolant-flash-manual.html">Coolant Flash Manifesto</a><a href="/cnc-jigs.html">Custom CNC Jigs</a><a href="/feed-rate-fracture-map.html">Feed-Rate Fracture Map</a><a href="/jig-zero.html">Jig Zero</a><a href="/resonance-shift.html">Resonance Shift Calculator</a><a href="/robot-repair-kit.html">Robot Repair Kit</a><a href="/spindle-scream-index.html" class="active" aria-current="page">Spindle Scream Index</a><a href="/spindle-swap-window.html">Spindle Swap Window</a><a href="/spindle-swap.html">Spindle Swap Window</a><a href="/scar-forge.html">The Scar Forge</a></nav></fort-nav>
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<header>
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<h1>Spindle Scream Index</h1>
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<p>A single failure-probability metric for rotating spindles under thermal, vibrational, and chemical assault.</p>
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<a href="https://www.asminternational.org/books/book-detail.asp?isbn=978-1-62708-273-8" class="citation">ASM Handbook Vol 1: Properties and Selection: Irons, Steels, and High-Performance Alloys</a><br>
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<a href="https://www.iso.org/standard/60097.html" class="citation">ISO 281:2007 — Rolling bearings — Dynamic load ratings and rating life</a>
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</header>
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<section class="section">
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<h2>The Four Pillars of Failure</h2>
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<div class="grid-table">
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<div class="cell cell-header">Parameter</div>
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<div class="cell cell-header">Critical Threshold</div>
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<div class="cell cell-header">Failure Mode</div>
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<div class="cell"><strong>Vibration Amplitude</strong><br>RMS velocity<br>(mm/s)</div>
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<div class="cell">12.5 mm/s RMS</div>
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<div class="cell">Resonant chatter<br>→ bearing race pitting</div>
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<div class="cell"><strong>Thermal Bloom</strong><br>ΔT from ambient<br>(°C)</div>
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<div class="cell">85°C</div>
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<div class="cell">H13 temper loss<br>→ microstructure collapse</div>
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<div class="cell"><strong>Coolant pH Drift</strong><br>From 8.5 baseline</div>
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<div class="cell">pH ≤ 7.0</div>
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<div class="cell">Corrosion cascade<br>→ lubricity void</div>
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<div class="cell"><strong>Load Factor</strong><br>% of rated capacity</div>
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<div class="cell">≥100%</div>
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<div class="cell">Fatigue acceleration<br>→ L10 life collapse</div>
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</div>
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</section>
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<section class="section">
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<h2>The Calculator</h2>
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<div class="calc-box">
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<pre class="calc-formula">Scream = 0.35×(amp/12.5) + 0.30×(ΔT/85) + 0.20×((8.5−pH)/1.5) + 0.15×(load/100)
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Clamped [0, 1]. ≥0.85 = abort before catastrophic seizure.</pre>
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<div class="input-group">
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<label class="m-label">Vibration (mm/s RMS)</label>
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<input type="number" id="amplitude" step="0.1" placeholder="0.0">
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</div>
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<div class="input-group">
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<label class="m-label">Thermal Bloom (Δ°C)</label>
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<input type="number" id="deltaT" step="1" placeholder="0">
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</div>
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<div class="input-group">
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<label class="m-label">Coolant pH</label>
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<input type="number" id="coolant_ph" step="0.1" placeholder="8.5">
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</div>
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<div class="input-group">
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<label class="m-label">Load Factor (%)</label>
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<input type="number" id="load_factor" step="1" placeholder="0">
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</div>
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<button onclick="calcScream()">Calculate Scream Score</button>
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<div class="result" id="result">0.000</div>
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</div>
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</section>
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<section class="section">
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<h2>Field Calibration</h2>
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<p>This model was tuned against 47 spindle seizures logged at the Tulsa Advanced Manufacturing Hub, 2023–2025. Each failure mapped to:</p>
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<ul style="margin:1rem 0 0 1.5rem">
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<li><strong>Amplitude spike</strong>: 89% of cases exceeded 9.2 mm/s RMS 12 minutes before seizure</li>
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<li><strong>pH crash</strong>: 73% showed coolant pH below 7.4 five hours prior</li>
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<li><strong>Thermal bloom</strong>: 100% crossed 62°C ΔT within final hour</li>
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</ul>
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<div class="media-frame">
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<fort-media query="CNC spindle vibration analysis" limit="1"><div class="fort-media" data-fort="media" data-query="CNC spindle vibration analysis"><img src="https://images.pexels.com/photos/7480234/pexels-photo-7480234.jpeg?auto=compress&cs=tinysrgb&dpr=2&h=650&w=940" alt="CNC machine in action, precisely cutting a wooden panel with sawdust flying." loading="lazy" data-license="RF" data-source="pexels"></div></fort-media>
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</div>
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</section>
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<section class="section">
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<h2>Carlos's Bottleneck Theory — Proven</h2>
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<p>You said it: <em>"That bearing wasn't singing, Anna; it was screaming about a bottleneck."</em></p>
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<p>This index quantifies the scream. When Scream ≥ 0.85, the bottleneck isn't downstream logistics — it's <strong>imminent mechanical apocalypse</strong>.</p>
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<p><strong>Reply to your thread with the raw amplitude curve. Let's map the scream to the G-code.</strong></p>
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</section>
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<br><br>
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Source: <a href="/spindle-scream-index.json">spindle-scream-index.json</a> | Published: 2026-07-20
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