IJSRD - International Journal for Scientific Research & Development| Vol.

4, Issue 05, 2016 | ISSN (online): 2321-0613

Static Analysis of VMC Spindle for Maximum Cutting Force

Mahesh M. Ghadage1 Prof. Anurag V. Karande2
1
Student 2Assistant Professor
1,2
Department of Mechanical Engineering
1,2
DGOI FOE, Bhigwan, Pune
Abstract— Spindle of VMC450 machine is an important Rotational speed of spindle could only be varied by
component of a vertical machining center. The spindle shaft changing either the transmission ratio or the number of
rotates at different speeds and holds a carbide tool cutter, driven poles by electrical switches. The machine tool
which machines a work piece attached to the machine tool spindle is the most important mechanical component in
table. The stiffness of spindle directly affects the VMC removing metal During machining operations. The machine
machining productivity and finish excellence of work pieces. tool spindle leads to unstable vibrations, cutting forces and
Spindle shaft is the weakest point in machine tool structure, tensions in the belt and pulleys. The motorized spindle
increasing its stiffness will increase machine tools accuracy introduces huge amount of heat into the spindle systems as
and machining product quality. High productivity needs well as mass to the system.
machine tools with high speed machining proficiency, which High Rigidity of machine tool spindle is required
leads into unavoidable dynamic effects that occur in the to obtain efficient rough cutting and fine finishing
machine tools spindle during production process such as capabilities. High speed spindle requires the preload control
regenerative chatter. The objective of this dissertation is to according to spindle rotation speed to prevent bearing from
optimize the parameters inducing the stiffness of the high burning and to ensure sufficient rigidity for machining.
Speed VMC spindle. In this dissertation work, the significant Magnetic loading device used to measure Rigidity of
parameters of the spindle bearing spam, diameter, over machine tool spindle. The magnetic loading device is used
hanging length, torque are considered while modeling the to apply dynamic force to the spindle. The basic structure of
spindle. The Modeling as well as the analysis of the spindle VMC machine tool consists of base and column
is done by using ANSYS ® software. arrangement which serves as a balancing support for the
Key words: Analysis of VMC Spindle, VMC Spindle entire machine. The machine is built of cast iron & steel
parts. The base of the machine is rigid and usually is of cast
I. INTRODUCTION iron. For the analysis of structure the lowest deflection
Spindle is the main mechanical component in VMC. The region near loading point is considered
spindle shaft rotates at different speeds and holds a cutter,
which machines a job attached to the machine tool table. II. LITERATURE REVIEW
The Static and Dynamic stiffness of spindle directly affect Many researchers had conducted analysis on the VMC
the machining productivity and finish quality of work Spindle of various type of machine. V.V.Kulkarni et al[1]
pieces. Spindle shaft is the weakest point in machine tool completed Analysis on CNC lathe spindle for maximum
structure, increasing its stiffness will increase machine tools Cutting force condition and bearing life using FEM. This
accuracy and machining product quality. work deals with static, fatigue analysis of lathe spindle
High productivity needs machine tools with high structure for maximum cutting force condition and
speed machining competence, which leads into inescapable predicting life of bearings. Finite element result had shown
dynamic effects that occur in the machine tools spindle that Stress obtained from the stress analysis was less than
during production process such as regenerative chatter. the yield strength of the material and total deformation of
Stiffness of Spindle is greatly affected by factor such as type the lathe spindle was very less. Equivalent alternating stress,
of surface finish, Geometry of spindle, Bearing factor of safety and life of the lathe spindle is found by
Arrangement. Therefore, the analysis of the Spindle for fatigue analysis and results are closely matches with the
stiffness is the basic objective of this dissertation. analytical values.
Deping Liu et al [2] presented a method to
investigate the characteristics of a high-speed motorized
spindle system. The geometric quality of high-precision
parts was highly dependent on the dynamic performance of
the entire machining system, which is determined by the
correlated dynamics of machine tool mechanical structure
and cutting process. This paper taking the milling spindle of
CX8075 produced by Anyang Xinsheng Machine Tool Co.
Ltd. as an example, a FEA model of the high-speed
motorized spindle is derived and presented [2]. The model
takes into account bearing support contact interface, which
was established by spring-damper element COMBIN 14.
Furthermore, the modal analysis, static analysis, thermal
Fig. 1: Sectional view of a motor spindle analysis and harmonic analysis were done by means of
The bearing arrangement is determined by the type ANSYS commercial software. The results show that the
of operation and the required cutting force and life of the extreme rotating speed of the motorized spindle was far
bearings. smaller than the natural resonance section speed, and the

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 Static Analysis of VMC Spindle for Maximum Cutting Force
(IJSRD/Vol. 4/Issue 05/2016/213)

static stiffness of the milling spindle can meet the Hence stiffness of VMC spindle is given by
requirements of design. following equation
Anandkumar Telang [3] presented static stiffness K = Fz/δ (1)
analysis on high frequency milling spindle. The objective of Where
this work was to optimize the parameters influencing the Fz = force in Z direction
stiffness of the high frequency milling spindle running at δ = deflection of spindle
12000 rpm with power rating of 10 KW[3]. Theoretical
A. Cutting force in VMC spindle
analysis has been carried out to evaluate the spindle stiffness
and to minimize deflection at the nose by varying Bearing Milling is a cutting process that uses a carbide milling
arrangement, overhang of spindle nose from the front cutter to remove material from the surface of a job. The
bearing and Spindle diameter between the bearings. Finite milling cutter is cutting tool, often with multiple cutting
element analysis result had shown that the diameter of the points. The cutting action is shear deformation; the metal is
spindle between the bearings has more influence on the pushed off the job in tiny clumps that hang together to more
rigidity. or less extent (depending on the metal type) to form chips.
A. Damodar [4] presented Static and Dynamic Maximum cutting force in VMC is given by
Analysis of Spindle of a CNC Machining Centre. In this following equation,
6120 ×N ×9.81
work, an attempt has been made to study the static and Pz = (2)
V
dynamic behavior of spindle of a CNC horizontal machining Where,
center using finite element analysis. The geometric model of N=Power of the motor
spindle is created in UNIGRAPHICS software as per the V=Cutting speed
drawing [4]. This model is imported to HYPERMESH
through IGES format and FEA model with converged mesh B. VMC Spindle Rigidity
is developed. To this Finite element model various loading The static rigidity is the force required to obtain a deflection
conditions like static and dynamic analysis and operating of the spindle due to its own bending under the force in
conditions are applied using ANSYS® software to obtain addition to the deflection caused due to bearing elasticity[4].
the deflections and stresses. The max deflection of 64.3
microns is computed at cutting point which is 40mm away
from spindle nose when 63 gear teeth acts likes a driver for
125 diameter cutter[4].
Dr. S. Shivakumar investigated Analysis of lathe
spindle using ANSYS. This work deals with design and
analysis of Spindle in which the material used for the
spindle was alloy steel. The spindle is supported by two Fig. 3: Deflection of VMC spindle
1 𝑎+𝐿 2 1 𝑎 𝑎2 𝐿 𝑎
bearings separated by different spans. Bearings consist of δ = Fz [ ( ) + ( )2 + ( + )] (3)
𝑆𝐴 𝐿 𝑆𝐵 𝐿 3𝐸 𝐼𝐿 𝐼𝑎
balls with definite stiffness, which acts as a cushioning Where,
effect for the spindle and hence can be considered as a δ1= Deflection due to radial yielding of the bearings in mm
spring in the software for analysis [5]. Finite element result δ2= Deflection due to elastic bending of the spindle in mm
had shown that Optimal bearing span of 240 mm is a= Length of overhang in mm
considered for fixing distance between front and rear L= Bearing span in mm (varying)
bearings [5]. The vibration analysis showed that no E= Young's modulus of Spindle material in N/mm2
resonance occurs expected results are verified with models. Fz= Cutting force in N
SA=Stiffness of the front bearing in N/mm
III. THEORETICAL ANALYSIS OF VMC SPINDLE SB=Stiffness of the rear bearing in N/mm
IL= Mass moment of inertia of the shaft at the bearing span
in mm4
C. Optimum Bearing Span Length
1
1 1 6𝐸𝐼𝑎
Lo = [6𝐸𝐼𝐿 ( + )+( ) 𝑄]3 (4)
𝑆𝐴 𝑆𝐵 𝑎𝑆𝐴
Where,
Lo= Static optimum Bearing Span Length in mm
E = Young’s modulus
a = Length of overhang
SA=Stiffness of front bearing
SB = Stiffness of rear bearing
Ia = Moment of inertia of the shaft at the overhang
Fig. 2: Cutting force Component Milling Operation
IL =Moment of inertia of the shaft at the bearing span
Static stiffness is one of the important performances
Q = Trial value for iterative determination of L0=4xa
parameter of VMC machine tool. Stiffness of the spindle is
defined as its capability to resist deflection under the action
of cutting force [4]. As shown in Fig. 1 when a force exerted
on the spindle nose is Fz [4], the displacement at the
spindle-nose is ‘δ’

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 Static Analysis of VMC Spindle for Maximum Cutting Force
(IJSRD/Vol. 4/Issue 05/2016/213)

IV. ANALYSIS OF VMC SPINDLE BY FEA and strain capabilities. The SOLID 187 have mixed
formulation capability for simulating deformations of nearly
A. Modeling of Spindle
incompressible as to plastic materials.
D. Boundary conditions
Two supports are provided at bearing location in FEA
model. Total bearing span of spindle is173 mm and total
Overhang of spindle is 55 mm.

Fig. 4: 3-D model of VMC Spindle

A 3-D model of spindle is created by using ANSYS ®
Software as shown in Fig. 4. 3-D model that has been
generated from 2-D drawing. The filets and chamfers of the
VMC spindle are removed in the models used for the
analysis in order to reduce the complexity of the models and
the runtime.
Fig. 6: Boundary condition
B. Material of Spindle
E. Loading
The raw material for the spindle is 20MnCr5. The 20MnCr5
Maximum cutting load for the spindle are applied on the Fz
has good wearing resistance compared to another material.
negative direction shown in Fig. 6. The maximum force on
The property of the material is presented in Table1.
the VMC 450 spindle is 3102.0085 N.
Physical Properties Values
Ultimate Strength 682 MPa (N/mm2)
Yield Strength 375 MPa
Young’s Modulus 190×103 N/mm2
Poisson’s Ratio 0.27-0.3
Density 8030 kg/m3
Table 1: Material properties
C. Meshing
The initial step in Meshing is to select an element which
closely represents the physical behavior of the structure. A
FEA model can be constructed out of several types of
elements like spring, spar, beam, plate, shell, membrane,
pipe, solid etc.
Fig. 7: Load on VMC spindle

V. RESULTS AND DISCUSSION

The deflection of the spindle nose is function of bearing
span length, diameter of the spindle and overhang length of
spindle. The deflection of the spindle affects the machining
accuracy.
Theoretical Ansys
Bearing
Deflection Deflection
Span in Stiffness Stiffness
at spindle at spindle
mm N/μm N/μm
nose μm nose μm
172 13.46 230.32 10.35 299.71
173 13.43 230.93 10.38 298.84
Fig. 5: Mesh Model of VMC spindle 178 13.26 233.89 10.39 298.55
The model is meshed as the SOLID 187 element
183 13.10 236.69 10.41 297.98
type as shown in Fig. 4 The size of each element is set to 4
Table 2: Comparison of Theoretical & FEA values for
mm. the Patch Conforming mesh method is used in s
deflection and stiffness at the spindle nose when the span
ANSYS ® software to mesh the VMC spindle. The
length varies from 172 mm to 183 mm for the spindle
SOLID187 is defined by eight nodes having 3 DOF at each
diameter of 70mm and overhang length 55mm.
nodes .The element have plasticity, stress stiffening, creep

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 Static Analysis of VMC Spindle for Maximum Cutting Force
(IJSRD/Vol. 4/Issue 05/2016/213)

Fig. 11: Stiffness at the spindle nose for different Spindle

Fig. 8: Deflection at the spindle nose for different Bearing diameter.
Span. Theoretical Ansys
Overhang
Deflection Deflection
length in Stiffness Stiffness
at spindle at spindle
mm N/μm N/μm
nose μm nose μm
55 13.43 230.93 10.38 298.84
58 13.99 221.64 10.98 282.51
60 14.38 215.69 10.99 282.28
65 15.38 201.62 12.14 255.51
70 16.44 288.64 12.83 241.77
Table 4: Comparison of Theoretical & FEA values for
deflection and stiffness at the spindle nose when the
overhang length of spindle varies from 55 mm to 70 mm for
the bearing span of 173mm and diameter 70mm
Fig. 9: Stiffness at the spindle nose for different Bearing
Span.
Theoretical ANSYS
` Deflection Deflection
Stiffness Stiffness
at spindle at spindle
N/μm N/μm
nose μm nose μm
60 14.65 211.75 11.70 265.12
62 14.30 216.86 11.11 279.20
65 13.90 223.16 10.61 292.36
68 13.59 228.16 10.41 297.98
70 13.43 230.93 10.38 298.84
Table 3: Comparison of Theoretical & FEA values for Fig. 11: Deflection at the spindle nose for different
deflection and stiffness at the spindle nose when the Overhang length.
diameter of spindle varies from 60 mm to 70 mm for the
bearing span of 173mm and overhang length 55mm.

Fig. 12: Stiffness at the spindle nose for different Overhang

length.
Fig. 10: Deflection at the spindle nose for different Spindle
Diameter.

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 Static Analysis of VMC Spindle for Maximum Cutting Force
(IJSRD/Vol. 4/Issue 05/2016/213)

VI. CONCLUSION
The diameter of the VMC spindle between the bearings has
more influence on the rigidity as is evident from the results.
This diameter could be varied to the extent of a maximum of
70 mm from the practical considerations of the bearing
speeds. At this diameter the stiffness of the VMC spindle
has a value of around 230.93N/μm and the defection of the
spindle nose based on FEA analysis is around 10.38 μm.

REFERENCES
[1] Santosh Arali, V.V.Kulkarni, “Analysis of CNC Lathe
Spindle for Maximum Cutting Force Condition and
Bearing Life”, International Journal of Innovative
Research in Advanced Engineering, pp 346-352, 2014.
[2] Deping Liu, Hang Zhang, Zheng Tao and Yufeng Su,
“Finite Element Analysis of High-Speed Motorized
Spindle Based On ANSYS”, Open Mechanical
Engineering Journal, pp 1-10, 2011.
[3] Anandkumar Telang, “Static Stiffness Analysis of High
Frequency Milling Spindle”, International Journal of
Research in Engineering and Technology, pp 577-585,
2014
[4] A.Damodar, D.Kondayya & Bvss Prasad, “Static and
Dynamic Analysis of Spindle of a CNC Machining
Centre”, International Journal of Mechanical
Engineering, pp165-170, 2013
[5] Dr. S. Shivakumar “analysis of lathe spindle using
ansys” International Journal of Scientific & Engineering
Research, Volume 4, Issue 9, September-2013 431ISSN
2229-5518
[6] CharnontMoolwanet al, “Failure Analysis of a Two
High Gearbox Shaft”, Social and Behavioral Sciences,
pp 154 – 163, 2013
[7] CMTI Hand Book, Machine Tool Design Hand Book,
Tata McGraw-Hill Company Limited, 1983,421-588
[8] Spindle Basics, 2008, www.spindlesworld.com.
[9] TIMKEN, Machine Tool Spindle, 1M-07-02 No. 5911,
www.timken.com.

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