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