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performance
1 spindle design
Performance features
To increase productivity and performance of spindles, certain features that are to considered are as follows:
Desired spindle power both peak and continuous.
Cost considerations
Market demands
3 spindle design
Benefits of spindles
Machine tool spindles reduce the number of cuts in mfg by half. Spindles provide position and transmit power to a tool They hold a rotating workpiece . They hold cutting tools and spin them at high torque and speed. Spindles support many key machining tasks. Allow flexibility in cutting a variety of materials.
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Uses of spindles
Spindles are used to perform variety of tasks like as follows:
Other Factors The dimensional accuracy and surface finish of the work being machined, as well as the rate of metal removal of a machine tool, are among other factors directly governed by the static, dynamic and thermal behavior of the spindle bearing unit.
The deformation of the a spindle depends not only on its own stiffness, but also upon the stiffness of its bearing and that of the housing.
spindle design
Spindle Mounting
Forces acting on a machine tool spindle 1. Cutting force F acts at the spindle nose. This force has a radial Fcr and axial Fa, respectively. 2. Driving force Fd, acts radially, between bearings The reaction of the radial component at each spindle bearing can be calculated simply. The axial component is taken only by one bearing, either he front or rear bearing.
Fixed (locating) bearing: is the bearing that takes the axial force component. It should prevent the spindle from moving axially in both directions. (source of heat generation). Floating (Non locating) bearing: takes a radial force component only. It can not prevent spindle from moving axially.
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Spindle-bearing arrangement with front fixed point is commonly used in machine tools. It leads to:
spindle design
Spindle Design
Design Criteria
1. Static Criteria: stiffness strength 2. Dynamic criteria: Natural frequency - Damping Mode Shape dyn. Amplitude Machine spindle may be classified into two categories: 1. Hollow of stepped cross section: Ex. Horizontal milling machine, vertical milling machine, lathe, turret lathe. 2. Solid of uniform cross section: Ex. Boring machine, Drilling machine, Grinding machine. In the following analysis, for simplicity, it will be be assumed that: 1. the spindle has a uniform cross section (hollow or solid).
2. The effect of the driving force is neglected. 3. The reactive moment of the fixed bearing is neglected
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Y = y1 + y 2 + y 3
Where: y 1 : the contribution due to shaft deflection y2 : the contribution due to bearing deflection y3 : the contribution due to housing deflection
Because of the series connection of the individual contributions to the total flexure, the total flexibility at the point of force application is given by:
= y/F
spindle design
yr = Rr /kr = Fcr.c/l.Kr
Third: From triangle similarity in the lower figure
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( y2 yr ) l c ( y f yr ) l l c y2 ( y f yr ) yr l
spindle design
It is clear from the previous equations that the total spindle nose deflection and also the total spindle bearing system depends upon the combined effect of: The bearing stiffness, The span; the center distance between bearings l, The length of the overhang length c and The geometry of the spindle.
The experiment studies showed that : 1.The front bearing stiffness kf has great effect on the total flexibility of a particular spindle-bearing system 2.Also, a bearing stiffness kf >750 N/m
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spindle design
SHAFTING, Hollow vs. Solid Sect. When comparing a solid shaft with a hollow shaft of equal section modulus, both will transmit the torque with equal stress levels, but the hollow shaft will be stiffer, or rather will deflect less under the same overhung moment. The following is an engineering analysis to support this statement: Section modulus = I /c Where I = Moment of Inertia c= Distance to extreme fiber = D/2 Hollow Shaft : O.D.= 6.625, I.D. = 5.761 Moment of inertia for hollow shaft I = 0.049087 x (OD4 ID4 ) = 40.4904 Section modulus for hollow shaft = I / c = 12.2 4.99 dia. Solid Shaft: Moment of inertia for 4.99 solid shaft =0.785398 x R4 = 30.4349 Section modulus for 4.99 solid shaft = I / c = I / R = 12.2
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Exercise
1. Go to the machining workshop