Chapter (5)

D i
Design of Spindles and Spindle Supports 
f S i dl d S i dl S t
5.1 Functions of Spindle Unit and Requirements
The spindle unit of a machine tool performs the following important functions:
1. centering the workpiece, e.g., in lathes, turrets, boring machines, etc., or the cutting
tool, as in drilling and milling machines,
2. clamping the workpiece or cutting tool, as the case may be, such that the workpiece
or cutting tool is reliably held in position during the machining operation, and
3. imparting rotary motion (e.g., in lathes) or rotary cum translatory motion
(e.g., in drilling machines) to the cutting tool or workpiece.

Requirements
1. The spindle should rotate with a high degree of accuracy. The accuracy of rotation
i determined
is d t i d by
b the
th radial
di l andd axial
i l run outt off the
th spindle
i dl nose, andd these
th mustt nott
exceed certain permissible values which are specified depending upon the required
machining accuracy. The rotational accuracy is influenced maximum by the stiffness
and accuracy of spindle bearings, particularly the one located at the front end.
2. The spindle unit must have high static stiffness. The stiffness of the unit is made up of the
stiffness of the spindle unit proper and the spindle bearings. Machining accuracy is
influenced by bending, axial as well as torsional stiffness.
3. The spindle unit must have high dynamic stiffness and damping. Poor dynamic stability of
the spindle
p unit adversely
y affects the dynamic
y behavior of the machine tool as a whole,,
resulting in poor surface finish and loss of productivity due to restriction on the limiting
undeformed width of cut.
4. The matingg surfaces that are liable to wear restrict the life of the spindle
p unit. These
surfaces, such as journals, quills (in drilling machines), etc., must be hardened to improve
their wear resistance. The spindle bearings must also be selected or designed to retain the
initial accuracy during the service life of the machine tool.
5. The deformation of the spindle due to heat transmitted to it by the bearings, cutting tool,
workpiece, etc., should not be large, as this has an adverse effect on the machining
accuracy.y In case of spindles
p runningg at high
g rotational speeds,
p , particular
p care should be
taken in selecting ,or designing the front bearing as it is the major source of heat
transmission to the spindle.
6. The spindle
p unit must have a fixture which pprovides qquick and reliable centering g and
clamping of the cutting tool or workpiece. The centering is achieved by means of an
external or internal taper at the front end of the spindle. The spindle ends, including the
p have been standardized for the common ggroups
taper p of machine tools and are shown in
Table 5.1.
Table 5.1: Spindle ends
Application Figure Remark

Lathes, turrets, single External taper 7°7'30" is used only in heavy-duty

spindle automatic and semi- machine tools for centering chuck or face plate
automatic
i lathes,
l h etc. Generally,
ll chucks
h k or face
f plates
l are centeredd by
b a
cylindrical surface

Milling machines Steep taper 7 : 24 is necessary so that the milling arbor

and cutter once located and damped should be able to
hold their position under the pulsating milling force

Taper 7:24

Drilling and boring

machines

Grinding machines In grinding machines the concentricity of location is

extremely important. There-fore, the grinding wheel is
mounted on an adaptor which is press-fitted on the
Taper 1:3 spindle taper
5.2 Materials of Spindles
The blank for a machine tool spindle may be:
1. rolled stock in the case of spindles having diameter < 150 mm, and
2. casting (preferably obtained by centrifugal casting method) in the case of spindles
having diameter > 150 mm.
In machine tool spindle design the critical design parameter is not strength but stiffness. If we
compare the mechanical properties of various steels, we find that their modulus of elasticity is
more or less equal, although the strength of alloyed steels can be considerably greater than that of
mild
ild steel.
l Since
i stiffness
iff (the
( h main
i design
d i parameter)) is
i primarily
i il determined
d i d by
b the
h
modulus of elasticity of the material, it may be concluded that no particular benefit accrues from
using costly alloyed steels for making spindles.
I the
In th light
li ht off the
th preceding
di discussion
di i andd the
th requirements
i t laid
l id down
d in
i Sec.
S 5.1,
5 1 the
th following
f ll i
recommendations for selecting the spindle material may be formulated:
1. for normal accuracy spindles, plain carbon steels C45 and C59 (AISI C1045 and C1050)
hardened and tempered to Rc = 30. 30
2. for above normal accuracy spindles-low alloy steel 40 Cr 1 Mn 60 Si 27 Ni25 (AISI 5140)
induction hardened to Rc= 50-56; if induction hardening of above normal accuracy spindles is
difficult due to complex profile then low alloy steel 50 Cr 1 Mn 60 Si 27 Ni 25 (AISI 5147) is
used with hardening to Rc = 55 - 60.
3. for spindles of precision machine tools, particularly those with sliding bearings-low alloyed
steel 20 Cr 1 Mn 60 Si 27 Ni 25 (AISI 5120) case hardened to Rc = 56 - 60 or
38 Cr 1 A1 90 Mn 45 Si 27 Ni 25 Mo 20 (EN 41) nitride to Rc = 63 - 68, and
4. for hollow, heavy-duty spindles-gray cast iron or, spheroid graphite iron.
5.3 Effect of Machine Tool Compliance on Machining Accuracy
Consider a uniform shaft being machined between centers on a lathe (Fig. 5.1).
L t KA be
Let b the
th stiffness
tiff off centre
t A andd KB that
th t off centre
t B.B Due
D tot radial
di l componentt Py
of the cutting force, centre A will be displaced by a distance
yA = PA / KA (5.1)
and centre B by yB = PB / KB (5.2)
Here PA and PB are the forces of reaction at ends A and B respectively. They can be
determined from the following equations of static equilibrium:
1. Moment of forces about point B = 0, i.e.
PA . l = Py(l- x)
wherefrom,, PA = Py(1-x/l) ((5.3))
2. Moment of forces about point A = 0, i.e.
PB. l = Py . x
wherefrom
wherefrom, PB = Py . x/l (5.4)

Fig. 5.1 Schematic diagram of a simple turning operation

Substituting the values of PA and PB in Eqs (5.1) and (5.2) respectively, we obtain
yA = Py (1 – x/l)/ KA (5.5)
yB = Py . x/l(1/KB ) (5 6)
(5.6)
Owing to the compliance of centers A and B, the workpiece occupies position A'B"
(assuming KA>KB) and its displacement at the cutting point can be found as
yx = yA + CC' C
C'‘
from similar triangles A'C'C" and A'B'B", we have
C' C''/ B' B''= x/l
Therefore
Therefore, A'
A C'
C B'
B
yx = yA + (yB - yA ) x/l (5.7)
Substituting the values of yA and yB from Eqs (5.5) and (5.6), Eq. (5.7) yields

Or (5.8)

if it is assumed that KA/KB = α, Eq. (5.8) can be modified as follows:

(5.9)

from where, keeping in mind that Py /KA = yAmax we get

(5.10)
From the variation of yx/yAmax as a function of x/l for different values of α may be
concluded that:
1. when α < 1, i.e., stiffness of the headstock centre is less than the stiffness of the
tailstock centre, maximum displacement of the workpiece occurs at the headstock; and
2. when α > l,, i.e.,, the stiffness of the tailstock centre is less than that of the headstock,,
maximum displacement of the workpiece occurs at the tailstock.

The deviation of the profile of a turned job from a true cylinder depends upon the
difference of maximum and minimum displacements of the workpiece axis. As already
stated, maximum displacement occurs at the headstock or tailstock depending upon the
value of α.
α
The deflection is minimum where compliance yx/Py is minimum. Therefore, the location
of the point of minimum deflection may be determined from the condition:

From Eq. (5.9),

which upon
p equating
q g to zero yyields
(5.11)
That the deflection at xO is minimum (and not maximum) is confirmed from the fact that

Substituting the value of xo in Eq. (5.10), we obtain

Or (5.12)

For α<1: The maximum displacement occurs at the headstock centre, i.e.,
ymax = yAmax. Therefore

From where, (5.13)

For α >1:
1: The maximum displacement occurs at the tailstock centre, i.e.,
ymax = yBmax Therefore

α yBmax α
max min yBmax yAmax yAmax
1 α yAmax 1 α

y α2
Since      Bmax yAmax , we get max min
5 14
5.14
y Amax 1 α
It should be noted that the profile accuracy is governed by Eq. (5.13) for α < 1 and by
Eq. (5.14) for α > 1.
The relationships represented by Eqs (5.13) (5 13) and (5.14)
(5 14) have been plotted as a function
of α and shown in Fig. 5.3. The dotted portions of the curve represent the range in which
the curves are not valid. It is evident from Fig. 5.3 that the difference ymax -ymin is
minimum
i i att α = 1 and
d iis equall tto hhalf
lf the
th headstock
h d t k centret displacement,
di l t i.e.,
i

It may thus be concluded that the maximum profile accuracy is achieved when the
stiffnesses of headstock and tailstock centers are equal.

If the stiffness of the saddle is given by KS, the displacement of the cutting edge due to
saddle compliance can be found as

The total compliance of the machine tool can be found as

the sum of compliances of the workpiece and saddle, i.e.,

or

Fig. 5.3 Variation of (ymax-ymin)/yAmax as a function of α

5.4 Design Calculations of Spindles
Figure 5.4 shows the schematic diagram of a spindle. As is evident from the diagram,
th spindle
the i dl represents t a shaft
h ft with:
ith
1. supported length l acted upon by driving force P2, and
2. cantilever of length c acted upon by external force Pl.
The spindle is basically designed for bending stiffness deflection of the spindle nose
should not exceed a certain pre-specified value, i.e.,
ymax < [y]
y ((5.17))
The total deflection of the spindle nose consists of:
1. deflection y1 of the spindle axis due to bending forces P1 and P2, and
2. deflection y2 of the spindle axis due to compliance of the spindle supports.
When the spindle has a tapered hole in which a centre or cutting tool is mounted,
the too deflection of the centre or cutting tool consists of deflections (1) and (2) above
in addition to
3. deflection y3 of the centre or cutting tool due to compliance of the tapered joint.

Fig. 5.4 Schematic diagram of a spindle

5.4.1 Deflection of Spindle Axis due to Bending
For determining the deflection of the spindle nose due to bending, we must first
E t bli h a proper design
Establish d i diagram.
di In
I this
thi context
t t the
th following
f ll i guidelines
id li may be
b
employed with success
1. if the spindle is supported on a single anti-friction bearing at each end, it may be
represented as a simply supported beam, and
2. if the spindle is supported in a sleeve bearing, the supported journal is analyzed as
beam on an elastic foundation; for purposes of the design diagram the sleeve bearing is
replaced by a simple hinged support and a reactive moment Mr acting at the middle of
the sleeve bearing.
The reactive moment is given as: Mr=k.M
k.M
Mr = bending moment at the support,
k = coefficient which varies from k= 0 at small loads to k= 0.3-0.35

Consider, for example, the spindle shown schematically at (Fig. 5.5a).

By replacing the rear ball bearing by a hinge, and the front sleeve bearing by a hinge
and reacti
reactivee moment Mr, the spindle can be red
reduced
ced to the design diagram of Fig.
Fig 5.5b.
5 5b
The deflection at the free end of the beam (spindle nose) can be determined by
Macaulay's method and is found to be
where E=modulus of elasticity of the spindle material
I=average moment of inertia of the spindle section
The deflected beam is shown at Fig.
Fig 5.5c.
5 5c

Fig.5.6 Deflection of spindle due to compliance

Fig 5.5
Fig. 5 5 (a) Schematic diagram of the spindle,
spindle
(b) Design diagram of the spindle, of the supports
(c) Deflected axis of the spindle

5.4.2 Deflection of Spindle Axis due to Compliance of Spindle Supports

Let δA and δB represent the displacement of the rear and front supports respectively.
Owingg to its compliance
p of supports,
pp the spindle
p deflects as shown in Fig.
g 5.6 ((for design
g
purposes we are considering the most unfavorable case when bearing displacements are
oppositely directed). From similar triangles OCC' and OBB',

wherefrom, (5.19)
Again, from similar triangles OAA' and OBB',

wherefrom
wherefrom, ٥ ( 5.20)
5 20)

Substituting this value of x in Eq. (5.19), we get

(5.21)
It is evident from Eq. (5.21) that displacement δB of the front bearing has greater
influence upon deflection y2 of spindle nose than displacement δA of the rear bearing.
Displacements δA and δB can be determined from the following expressions

(5.22) (5.23)
where RA and RB are reactions at supports A and B respectively, while KA and KB are
their stiffness. Reactions RA and RB can be found from the following equilibrium
conditions applied to the design diagram of Fig. 5.5b:
1. moment of all forces about point A = 0, i.e.,
 MA=0 0, or RB. ll-P
P2. a+Mr-P
P1(c+ l) 0
l)=0
wherefrom, (5.24)

2 momentt off all

2. ll forces
f about
b t point
i t B = 0,
0 i.e.,
i
 MB=0 or RA. l-P2. b-Mr+P1c=0
wherefrom,

Keeping in mind Eq. (5.22-25), the final expression for deflection y2 maybe written as
follows:

The total deflection of the spindle nose can be determined as the sum of y1 (Eq.
(5 18)) and
(5.18)) d y2
2 Eq.
E (5.26)),
(5 26)) ii.e.,
y = y1 +y2 (5.26a)
The resultant deflected axis of the spindle is shown in Fig. 5.7.

Fig. 5.7 Total deflection of the spindle axis

5.4.3 Optimum Spacing between Spindle Supports
An important parameter in spindle design is the ratio λ= l/c. The optimum value of
this ratio is that ensures minimum total deflection y it can be determined from the
condition dy/dλ = 0. The qualitative variations of y1, y2 and y1 + y2, for constant
values of forces P1 and P2 are depicted Fig. 5.8 as functions of ratio l/c.
The point of minimum of the y1 + y2 curve yields the
optimum value of ratio l/c which generally lies between
3 and 5. The value of λ optt depends upon:
1. Ratio of stiffnesses of the front and rear bearings,
α = KB / KA and
2 Factor
2.
Fig. 5.8 Effect of l/c ratio on yl, y2 and y1+y2
Where Kc = 3EIc/C3 = bending stiffness of the cantilever, and
Ic = average momentt off inertia
i ti off the
th spindle
i dl over the
th cantilever,
til andd
Il = average moment of inertia of the spindle over the supported length.
The variation of λopt as a function of F has been depicted
in Fig. 5.9 for α = 1 and 10, When the spindle is mounted
on anti-friction bearings, an additional check is necessary
to ensure that the constraint λopt > λmin = 2.5 is not violated
because for λ< 2.5 the bearing play leads to considerable
radial run out of the spindle nose.
Fig. 5.9 Effect of spindle and supports stiffness on λopt
An opposite constraint on maximum span stems from the requirement that for normal
functioning of the spindle driving gear, the stiffness of the span should not be less than
250 500 N/micron.
250-500 N/micron This constraint is expressed through the following relationship:

where
h Dl = average diameter
di t off the
th supported
t d length
l th off the
th spindle
i dl
k = 0.05 in the case of normal accuracy machine tools
= 0.1 in the case of precision machine tools

When the spindle is supported on hydrostatic journal bearings, the maximum

deflection at middle of the span should satisfy the condition:
ylmax < 10-4l =0.0001 l
and the maximum span length lmax should be limited by the above constraint.
p the requirement
This constraint based upon q that the maximum misalignment
g due to
deflection of the journal should not exceed one-third of the bearing gap.