Design, Analysis and Testing of Spindle For High Speed CNC Lathe Machine

ISSN(Online) : 2319-8753
ISSN (Print) : 2347-6710
International Journal of Innovative Research in Science,

Engineering and Technology
(An ISO 3297: 2007 Certified Organization)
Vol. 5, Issue 5, May 2016
Design, Analysis and Testing of Spindle

for high speed CNC Lathe Machine
Rishikesh B.Kamthe1, Chetan S.Magdum2, Aditya S. Gandhi 3, Pranav A.Naik4, Prof. P.D.Gharge5
UG Student, Department of Mechanical Engineering, NBN Sinhgad School of Engineering, Pune, Maharashtra, India1
UG Student, Department of Mechanical Engineering, NBN Sinhgad School of Engineering, Pune, Maharashtra, India 2
Asst. Prof., Department of Mechanical Engineering, NBN Sinhgad School of Engineering, Pune, Maharashtra, India 5
ABSTRACT: This report presents an expert CNC spindle design system strategy which is based on the efficient
utilization of past design experience, the laws of machine design, dynamics and metal cutting mechanics. The
configuration of the spindle is decided from the specifications of the workpiece material, desired cutting conditions,
and most common tools used on the machine tool. The spindle drive mechanism, drive motor, bearing types, and
spindle shaft dimensions are selected based on the target applications. The structural dynamics of the spindle are
automatically optimized by distributing the bearings along the spindle shaft. Based on maximum cutting force incurred
the analysis will be carried out. The main objective is to carry out the static analysis of spindle structure for maximum
cutting force condition and predicting life of bearings. From static analysis, stress and deformation of the spindle can be
found.
KEYWORDS: CNC, Spindle, Bearings, Maximum Cutting Forces, Static analysis.
I. INTRODUCTION
The spindle is the main mechanical component in machining centres. The static and dynamic stiffness of the spindle
directly affect the machining productivity and finish quality of the workpieces. The structural properties of the spindle
depend on the dimensions of the shaft, motor, tool holder, bearings, and the design configuration of the overall spindle
assembly. The bearing arrangements are determined by the cutting operation type, and the required cutting force and
life of bearings.
The main aim of machine tool design is to achieve long-term precision and high cutting productivity, which directly
influence the operating costs of the machine. However, increases in productivity are very often limited by chatter
occurring in the machine – tool – workpiece system. The type of cutting operation and the tool employed determine
which part of the system will be excited and which will begin to vibrate with the highest amplitude.
The performance analysis of spindle system of machine tools based on finite element analysis software includes the
following steps: creating finite element model, identifying constraints and imposing load, solving the model and
analysing the output result. In finite element analysis, for different models, analysis types and analysis methods, the
appropriate type of unit should be selected. It is necessary to take both the accuracy of the calculation and the cost
together with the time of the calculation into account. The accuracy of finite element analysis result is closely related
with the density of divided meshes. The more the mesh density is, the more the calculation accuracy is, but it also takes
higher calculation cost. When the mesh density reaches certain extent, further increased mesh density will not lead to
the improvement of the accuracy of analysis result but to doubled calculation cost. To make the mesh density achieve
the best results, it is necessary to go through trial and error.[2]
Copyright to IJIRSET DOI:10.15680/IJIRSET.2016.0505092 7282

ISSN (Print) : 2347-6710

A high speed spindle that will be used in a metal cutting machine tool must be designed to provide the required
performance features. The major performance features include:
i. Desired Spindle Power.
ii. Maximum Spindle Load - Axial and Radial
iii. Maximum Spindle Speed Allowed
iv. Tooling Style, Size and Capacity for ATC
v. Belt Driven or Integral Motor-Spindle Design
vi. High running accuracy
vii. Great stiffness
viii. Low and even running temperature
ix. Minimum need of maintenance
.
Paper is organized as follows. Section II describes Design and Analysis of Spindle Assembly.Section III presents
experimental results showing results of images . Finally, Section IV presents conclusion
II. DESIGN AND ANALYSIS OF SPINDLE ASSEMBLY
Cutting forces calculations:

Benefits of knowing and purpose of determining cutting forces-
The aspects of the cutting forces concerned:
 Magnitude of the cutting forces and their components.
 Directions and locations of action of those forces.
 Pattern of the forces: static and / or dynamic.
Knowing or determination of the cutting forces facilitate or are required for:
 Estimation of cutting power consumption, which also enables selection of the power source(s) during design
of the machine tools.
 Structural design of the machine - fixture - tool system.
 Evaluation of role of the various machining parameters (process - V , f , t, tool - material andgeometry,
environment - cutting fluid) on cutting forces.
 Study of behavior and machinability characterization of the work materials.
 Condition monitoring of the cutting tools and machine tools.
Cutting force (F ) for turning operation is calculated by,
F = Ks . f . d
Where,
K is specific cutting resistance
is feed rate (mm/rev)
d = Depth of cut (mm)
Results for Turning Operations:

For =180 m/min = 75 /
Feed ( / ) Radial Force Axial Force Torque ( ) Power ( )
( ) ( )
0.15 2207.25 1274.34 77.254 6.62

ISSN (Print) : 2347-6710

Shaft calculations:
Shaft is a common and important machine element. It is a rotating member, in general, has a circular cross-section and
is used to transmit power. The shaft may be hollow or solid. The shaft is supported on bearings and it rotates a set of
gears or pulleys for the purpose of power transmission. The shaft is generally acted upon by bending moment, torsion
and axial force. Design of shaft primarily involves in determining stresses at critical point in the shaft that is arising due
to aforementioned loading. Other two similar forms of a shaft are axle and spindle.
Fig.1 Spindle Shaft
Shaft material= 60C4

Here, = diameter of shaft
= outer diameter of shaft
= inner diameter of shaft
= Moment at B
= Moment at A
Pulley force acts at point P and the maximum cutting force acts at L
Fig.2 Free Body Diagram
Shaft diameter:-
d = ×
(K M ) + (K M )
From above equation spindle diameter is 30mm
Bearing Calculations:
Bearing calculations were carried out as per the standard procedure using SKF Catalogue for spindle diameters starting
from 30mm. The bearing of diameter 55mm satisfies the conditions of speed and strength. But for structural
requirement we selected the bearing of diameter 60mm of BTM series, which is Super Precision Angular Contact
Thrust Ball Bearing.
Bearing Designation- BTM 60 BTN9/ P4CDB

ISSN (Print) : 2347-6710

Deflection Calculation:
Maximum deflection of spindle was calculated using Macaulay’s method.
Maximum deflection of spindle is 0.003 mm.
CAD Modelling
Creo Parametric 2.0 was used for 3D modeling of spindle assembly.
Fig.3 Spindle assembly
The figure above shows the complete assembly of the spindle. The modelling of every part of the assembly was done
by keeping in mind all the design aspects and considerations.
Fig.4 Spindle
The spindle or shaft which is the integral part of the assembly as seen above was modelled with a lot of attention to
every detail.
The spindle was fully optimised in order to make it strong enough to withstand the forces acting on it.

ISSN (Print) : 2347-6710

Fig.4Exploded view of spindle assembly
The above figure shows the exploded view of the assembly which consists of spindle, bearings, housing and other
parts.
Analysis
The following results were obtained after carrying out the static analysis of the spindle using Ansys.[7]
Fig.5Stress distribution
The fig. depicts the stresses induced in the spindle after applying the forces at the appropriate points.

ISSN (Print) : 2347-6710

Fig.6 Total Deformation
The figure shows the maximum defoermation taking place after action of forces.
Result Table

ISSN (Print) : 2347-6710

III. TESTING
Run-out (microns) Noise level(dB) Temperature(℃) Speed (rpm)

1 87.4 44.4 6175
1 76.24 41.5 4500
1 65.4 38.6 3000
1 50.25 37.6 1500
The testing was successfully carried out on the spindle assembly considering the parameters mentioned in the table
above. The spindle was mounted on the test rig and necessary clamping was provided as shown in photograph. The
spindle was driven by a motor whose maximum speed was 2580 rpm and the ratio of motor pulley to the spindle pulley
was 2.25. The designed speed of 6000 rpm was successfully reached. The run-out measured for the designed speed of
6000 rpm, on the inner surface of the spindle to check its circularity was 1 microns. Noise was measured for the same
speed using noise level meter and it was 87.4 dB which is permissible and safe for the operator. After running the
spindle at about 6175 rpm for about an hour, the temperature rise was measured using thermocouple. The rise in the
temperature was 44.4℃ which is safe for its operation.
a) Test Rig b) Run-out Measurement
c) Noise Level Measurement

The above tests a, b and c were carried out on the spindle and the results were recorded. The results are mentioned in
the above table.

ISSN (Print) : 2347-6710

IV. CONCLUSION
Project presents the Design of CNC lathe Spindle in which the design considerations were studied from various
reference papers and the forces acting on the CNC spindle while various machining processes were calculated by
referring to the theory of metal cutting. The torque and power required from the motor are calculated from the forces
achieved.
This design data was used in the FEA of the spindle. The results obtained from multiple iterations of FEA were safe
according to the design considerations and were used to manufacture the spindle.
The CNC Lathe Spindles used in the industry at present are having a low cycle time and spindle speed. The Spindle
designed here has a high spindle speed which aims at reducing the cycle time efficiently and increases productivity.
High speed spindle allows the use of cemented carbide tools which cannot be used at low spindle speeds. Machining
can be done at higher cutting speeds and feeds which would eventually reduce machining time and enhances the
productivity.
The surface finish is also improved by using high speed spindle and cemented carbide tools as compared to low speed
spindle machine
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ISSN(Online) : 2319-8753

ISSN (Print) : 2347-6710

International Journal of Innovative Research in Science,

Vol. 5, Issue 5, May 2016