workhead
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Workhead
Bed
Table
Carriage
Tailstock
(Courtesy: Micromatic Grinding Technologies Ltd.)
Cylindrical Grinding Machine
Validation of Geometric and FE Models
Workhead Tailstock
Force (F)
150 mm
75 mm
Applied
force Deflection in µm
(N) Experimental FEA
50 0.5 0.41
100 0.7 0.82
150 1.2 1.23
200 1.6 1.64
250 2.0 2.06
300 2.4 2.47
Frequency in Hz
Mode Experimental Computational
1 55.12 62.67
2 110.13 108.16
Static & Dynamic Tests
SPECIFICATIONS AND MATERIAL PROPERTIES
1.Grinding Wheel specifications
Wheel Peripheral speed
Max. Diameter
45 m/sec
660 mm
2.Rapid feed rate
Feed during rough grinding
Feed during finish grinding
10 m/min (max)
3.75 mm/min (max)
1.5 mm/min
3. Spindle diameter 80mm
4. Max RPM 700 (max)
5. Spindle power 11KW
(Courtesy: Micromatic Grinding Technologies Ltd.)
CUTTING FORCES USEDS.No. Component of
force
Direction of
Application
Values in N
(CMTI
handbook)
Values in
N (Given
by
Industry)
1. Tangential
cutting force
Vertically
downwards
244.3 350
2. Axial force Towards the
workhead
48.86 70
3. Radial force Inwards,
towards the
operator
732.9 800
Analysis of Cylindrical Grinding Machine
Analysis of Cylindrical Grinding Machine
Deformation contour of entire machine tool
Analysis of Cylindrical Grinding Machine
Analysis of Cylindrical Grinding Machine
Deformation (in m) contour of bed
Analysis of Bed
Analysis of Bed
S.No Components/Sub-
assemblies
Total Deformation in μm
(max.)
X-axis* Y-axis* Z-axis* VonMises stress in
MPa(max.)
Deformation in μm
(max.)
Deformation in μm
(max.)
Deformation in μm
(max.)
1. Bed 0.139 0.0218 0.0266 0.0863 0.1922. Carriage 0.0129 5.848e-3 3.91e-5 2.326e-3 0.0223. Workhead
assembly 6.45 1.86 1.86 5.21 7.84
4. Tailstock 9.14 0.238 2.11 7.99 11.365. Workhead
+Workpiece+
Tailstock
7.22 1.64 2.09 5.92 10.88
6. Entire assembly
4.57 0.585 1.39 4.51 9.99
X-axis*- Axial axis Fx = 70NY-axis*- Vertical axis Fy = 350NZ-axis*- Radial axis Fz = 800N
Parametric Optimization
Design Variables
Pre-optimization sensitivity analysis
Topology Optimization
Topology Optimization
provides with optimum distribution of material within a specified design space satisfying functional requirements of a part/product.
(a) (b) (c)
Topology optimization on various components of a cylindrical grinding machine tool (a) Bed (b) Frame of workhead (c) A
component of wheel head subassembly
Preliminary results of possible topology
modifications in bed
Topology Optimization
Topology Optimization Results
Feature based representation of bed for feature
sensitivity analysis
Topology Optimization
Feature 1 Feature 2 Feature 3
% Decrease in mass 6.56 4.02 8.38
% Increase in static deflection 2.13 3.28 7.25
% Increase in 1st Natural Frequency 4.73 0.10 8.37
Feature Sensitivity Analysis Results
Design Case of Bed of Cylindrical Grinding Machine
475 Kgs of bed weight can be reduced by increasing maximum permissible deflection
from 3.6 µm to 3.9 µm
Machine Tool Design
Machine Tool Design
Machine Tool Design
Initial
(12:40pm)
12:40pm to
3:45 pm
(running)
3:45pm to
5:00pm
(rest)
Axial 0 µm 40 µm 10 µm
Radial -3 µm 12µm 8µm
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