The static and dynamic characteristics of the spindle system significantly influence machining accuracy and efficiency. High static and dynamic stiffnesses and thermal stability are required for high-precision and high-efficiency machining. The dynamics of spindle systems are affected by centrifugal forces and thermal expansion in response to spindle rotation. A noncontact electromagnetic loading (EML) system has great potential for measuring spindle characteristics under rotational conditions. This study presents a state-of-the-art design and performance of the EML system, which is an improvement on the system used in previous studies. Detailed experimental design and signal processing are shown for static and dynamic performance measurements, including advanced hardware-in-the-loop simulation of the intermittent milling process using the developed EML system. Some of the representative results of each test are presented, and future research questions are discussed.

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