Journal of Material Science and Mechanical Engineering (JMSME)

Print ISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 2; January-March, 2015 pp. 153-157
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A Review on Design and Analysis of

Machine Tool Spindle
Shivaraj S. Vadgeri1 and S.R. Patil2
1
PG Student, Mechanical Design Engineering AISSMS College of Engineering, Pune-01
Savitribai Phule Pune University, Pune Maharashtra, India
2
Mechanical Engineering Department AISSMS College of Engineering, Pune-01
Savitribai Phule Pune University, Pune Maharashtra, India
E-mail: [email protected], [email protected]

Abstract—This paper describes a review on Design and Analysis of and pinion arrangements, linear guide ways and bearings etc.
machine tool spindle.Machine tool spindle is the most important The machine is made up of heavy steel material and iron
mechanical component in removing metal during machining parts.The spindle of the machine is hollow[13].
operations. Spindle is a rotating axis of the machine and machine
tool spindle includes front and rear bearings to support. The stiffness
of the spindle directly affectson machining productivity and finish Requirements of spindle are spindle should rotate with high
quality of the work pieces. Machine tool spindles lead to unstable degree of accuracy, spindle unit must have high dynamic
chatter vibrations, cutting forces and uneven tensions in the belt and stiffness and damping, spindle unit must have high static
pulleys. This paper also includes the literature on static and fatigue stiffness, wear resistance of mating surface should be as high
analysis of spindle by considering different forces acting on the as possible, spindle bearing should be selected in such a way
machine tool spindle during the turning operation. Generally during that the initial accuracy of the unit should be maintained
the lathe turning operation, forces acting on the spindle are cutting during the service life of the machine tool. For design
forces, tension in the belt and reactions due to bearing support to optimization of spindle cutting forces are plays very important
spindle.Cutting Forces generated during turning operation can be
role.
determined by experimentally using dynamometer for different tool
geometry and cutting parameters.From static analysis stress and
deformation of the spindle will be obtained. The purpose of this paper
is to determine the life of the spindle and factor of safety by fatigue
analysis.

Keywords: Spindle, Spindle Design, Bearings, Cutting Forces, Static

and Fatigue analysis.

1. INTRODUCTION
Machine tool spindle is the most important mechanical
component in removing metal during machining operations.
The structural dynamics of spindle are evaluated at the tool tip
since it directly affects the material removing rate [13]. Fig. 1: Block diagram of lathe machine [13].
Spindle is a rotating axis of the machine, which frequently
used has a shaft at its heart. The shaft itself is called spindle. The main components of the lathe machine are illustrated in
Machine tool spindles lead to unstable chatter vibrations, Fig. 1. The lathe spindle drive generates a rotary motion to the
cutting forces and uneven tensions in the belt and pulleys [12]. work piece. The X-axis drive system is used to develop a
This paper presents static and fatigue analysis by considering longitudinal motion of the table over the slide-ways. DC
cutting forces and tensions in the belt and pulleys. motor connected to a gearbox, which transfers the motion to
the spindle shaft using a pulley and belt mechanism.
Depending on the machining processes, the tool is fixed in the
tool post and the work piece is held on the chuck of a typical
lathe structure. The relative motion is achieved by the
movements parallel to the three spatial axes. This can be
achieved by the axial movements are along the screws, rack
154 Shivaraj S. Vadgeri and S.R. Patil

2. FORCES ACTING ON A MACHINE TOOL

SPINDLE

Fig. 3: Design variables for bearing locations[1].

Chi-Wei Lin et.al[2]discussed that Development of high speed

spindle technology is critical to the implementation of High
Fig. 2: Loading condition of spindle[12]. speed machining (HSM). As Compared to the conventional
spindles, motorized spindles are equipped with a built-in
Above Fig. shows the forces acting on the lathe spindle during motors for good power transmission but the built in motors
the turning operation, these forces are cutting force, tension in produces large amount of heat into the spindle system as well
the belt, torque and reactions due to front and rear bearing as extra mass to the spindle shaft, thus it affect to the dynamic
support. Out of the forces cutting forces are plays very behavior of the spindle. The author presents an integrated
important role, which may vary as the tool cutting tool model with experimental validation and sensitivity analysis for
geometry and cutting parameters vary. Some of the important studying various thermo mechanical dynamic spindle
parameters are depth of cut, cutting speed, and tool geometry behaviors at high speeds and the fallowing effects are
such as rake angle, approach angle, entering angle, type of observed that is the bearing preload effects on bearing
insert and nose radius of insert etc. Tension in the belt is stiffness, and overall spindle dynamics, high speed rotational
mainly depends on power of the driving mechanism. And this effects. The results of this paper shows that a motorized
power depends on cutting forces. The purpose of this paper is spindle softens at high speed because of the centrifugal effect
to provide a vision for determine the life of the spindle and on the spindle shaft.
factor of safety for these force conditions.
Dr. S. Shivakumar et.al[3] discussed the Design and analysis
3. LITERATURE SURVEY of lathe spindle in which alloy steel material was used for the
spindle. Two bearings were supported by spindle with
Literature survey plays an imported part in formulating any different spans. Bearings consist of balls with the certain
work. There are many papers available for the analysis of amount of stiffness, which acts as cushioning effect to the
spindle of which few are selected based on the relevance of spindle so they considered the spring in the Ansys for the
the statement of this paper. Based on these research papers, a analysis and also carried out static analysis and dynamic
different methodology will be chosen which is suitable for analysis of a spindle supported by the front and rear bearing.
analysis of spindle. The referred papers are explained in brief Bearing stiffness value was calculated by an iteration
as below. procedure and using numerical relations life of bearings was
calculated.
Osamu Maedaet.al[1] discussed an Expert spindle design
system strategy which is based on the efficient utilization of
the laws of machine design, dynamics and metal cutting
mechanics. The configuration of the spindle is based on the
specification of the work piece material, necessary cutting
conditions and commonly used tools on the machine tool. The
spindle drive mechanism, driving motor, bearing type and
spindle shaft dimensions were selected based on the required
applications. They iteratively find out the Frequency Response
Functions (FRF) of the spindle at the tool tip using the Finite
Element Method (FEM).This work predicted the cutting
operation at the required speed and depth of cut for different
flutes of cutters. The arrangement of bearings was optimized
using Sequential Quadratic Programming (SQP). Fig. 3 shows Fig. 4: Graph of bearing span v/s radial deflection[3].
the design variables for bearing locations.

Journal of Material Science and Mechanical Engineering (JMSME)

Print ISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 2; January-March, 2015
A Review on Design and Analysis of Machine Tool Spindle 155

It can be decided from above graph that the optimum bearing Engine components. In this paper static and modal analysis
span having length 240 mm has got minimum deflection. was performed on the connecting rod and the S-N approach by
modified Goodman criterion for predicting fatigue life of the
Tobias Maier et.al[4] discussed modeling of the thermo connecting rods is presented. The model was created using
mechanical process effects on machine tool structures, in Solid modeling software-Solidworks2013. Further author
machine tools thermally induced deviations are key issues conducted finite element analysis using Ansys14 Workbench
specially when considering the actual trends of high to determine the von-mises stresses and strains, fatigue life
performance and dry cutting. The interactions between the and modal frequencies under different loading conditions.
cutting process and the machine tool structure are significant
boundary conditions for the numerical prediction of the R. A. Gujar, S. V. Bhaskar [8]presented paper on Shaft design
thermo mechanical machine behavior. This paper presents an under fatigue loading by using modified Goodman method. In
approach for the atomistic modeling of process effects, it this paper, shaft was used in an inertia dynamometer rotated at
includes process of heat, cutting forces and increased load on 1000 rpm. Considering the different parameters like torque
feed and main drives. Author provided an empiric data for the acting on a shaft, forces it helps to calculate the stresses
relation between cutting forces and active drive power. induced. With the help of FEA stress analysis carried out and
the results which were obtained from FEA compared with the
A.Ertuk et.al[5] discussed the Effect analysis of bearing and theoretical values. Consider the stress concentration factor to
interface dynamics on tool point FRF for chatter stability in find the fatigue life.
machine tools by using new analytical model for spindle tool
assemblies. It is observed that the bearing dynamics is Wojciech Stachurski, Stanis law Mideraet.al [9] discussed the
controlled by rigid body modes of the assembly, where as the effect of processing conditions on the value of the cutting
first mode is affected by spindle holder interface dynamics and force (Fc), during straight turning operation. The process is
second mode that is elastic mode is affected by holder tool based on equations in the form of power polynomials which
interface dynamics. Individual bearing and interface were obtained from the results of experimental tests. The tests
translational stiffness and damping values control the natural were conducted while turning C45 carbon steel metal with and
frequency and the peak of their relevant modes respectively. without the use of cutting fluid. Here cutting forces were
From this paper it is concluded that rotational contact determined by using three-component piezoelectric
parameters do not affect the resulting FRF considerably. In dynamometer. Fig. 5 shows the influence of cutting
this paper, the analytical method was presented for modeling parameters on cutting force.
spindle–holder–tool assemblies and predicted the tool point
FRF. By using this model, the effects of bearing and interface
dynamics on the tool point FRF were studied.

Tugrul Ozel, Taylan Altan[6]presented paper titled Process

simulation using finite element method prediction of cutting
forces, tool stresses and temperatures in high speed flat end
milling. End milling of die mold steels is a highly demanding
operation because of stresses and temperatures generated on
the cutting tool due to high hardness of work piece. Modeling
and simulation of cutting processes have ability for selecting
optimum conditions and improving cutting tool designs,
especially in an application such as high-speed milling. The
main objective of this study was to develop a methodology for
simulating and predicting chip flow, cutting process in flat end Fig. 5: Influence of cutting parameters (f, Vc) on the
milling, operation cutting forces, temperatures and tool cutting force[9].
stresses using finite element analysis (FEA). It was used in the
application for machining of P-20 mold steel with 30 HRC Haci Saglam, Suleyman Yaldizet.al [10] presented paper on
hardness by using the commercially available software the effect of tool geometry and cutting speed on main cutting
DEFORM-2D. force and tool tip temperature. In this paper, the effects of rake
angle and entering angle in the tool geometry and cutting
Mr. Sahil, Mr. Jiten Saini[7]has written a paper on Static, speed on cutting force components and the temperature
fatigue and modal analysis of connecting rod under different generated on the tool tip in turning operation were
loading conditions. Connecting rod is an important link investigated. The data used for the investigation were derived
between crankshaft and piston, and its primary function is to from experiments conducted on a CNC lathe. During the tests,
convert reciprocating motion into rotary motion of crankshaft. the depth of cut and feed rate were kept constant. They found
Connecting rod is subjected to many stresses than any other that rake angle was effective on all the cutting force

Journal of Material Science and Mechanical Engineering (JMSME)

Print ISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 2; January-March, 2015
156 Shivaraj S. Vadgeri and S.R. Patil

components, while cutting speed was effective on the tool tip  The configuration of the spindle is based on the
temperature. They got average deviation between specification of the work piece material, required cutting
experimental measured and calculated force results were conditions and commonly used tools on the machine tool.
found as 0.26%.  A motorized spindle will soften at high speed because of
the centrifugal effect on the machine tool spindle shaft.
 It was found out that the optimum bearing span to support
the spindle is having length 240 mm and has got
minimum deflection.
 During the cutting force measurement, it was found that
rake angle was effective on all the cutting force
components, while cutting speed was effective on the tool
tip temperature.
 It was observed that all cutting forces were increased
when the feed rates were increased. Optimum machining
Fig. 6: Experimental setup to determine cutting forces condition was obtained at rake angle = 00, approaching
and tool tip temperature[10]. angle = 750.
 Cutting forces during turning operation can be measured
Haci Saglam, Faruk Unsacaret.al [11] presented a paper titled experimentally and analytically by using empirical
investigation of the effect of rake angle and approaching angle relations, at this cutting force condition analysis of
on main cutting force and tool tip temperature. This author machine tool spindle can be done.
also done the same work as [10] and same experiment setup
was used, this paper differs in selection of parameters during REFERENCES
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that:

Journal of Material Science and Mechanical Engineering (JMSME)

Print ISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 2; January-March, 2015
A Review on Design and Analysis of Machine Tool Spindle 157

[10] Haci Saglam, Suleyman Yaldiz, “The effect of tool geometry

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Japan, August 2003.

Journal of Material Science and Mechanical Engineering (JMSME)

Print ISSN: 2393-9095; Online ISSN: 2393-9109; Volume 2, Number 2; January-March, 2015