Selection of Lathe Spindle Material Based on Static and Dynamic Analyses Using Finite Element Method

Lathe spindle is considered as an essential component that makes material removal possible during the machining operation. The stiffness of spindle has an important role on productivity and surface finish of the work piece. Lathe tool spindle leads to unbalanced vibration and uneven tension in pulleys and belts. In the present study, three dimensional model of the spindle is prepared. Four different materials like AISI 1045 carbon steel, AISI 4140 alloy steel, AISI 304 stainless steel and grey cast iron are considered. Based on FEM, the static and dynamic analyses are done separately under cutting forces and during rotation. From dynamic analysis, modal shapes are obtained. Computational simulation is done in ANSYS 15.0 workbench and static structural analysis is performed with varied cutting force and speed. Total deformation, equivalent stresses and strains have been used in identifying the suitable material. AISI 1045 carbon steel is showing the minimum values of total deformation and equivalent stress in all the cases. Similar stress pattern is observed in all the materials with the position of the maximum stress also being same with varied magnitude. The value of maximum total deformation is observed at spindle face area and minimum at the spindle bearing part for all materials. In spindle, the maximum equivalent stress is induced in spindle housing area and minimum at tail end. Also, the maximum equivalent strain is observed at the spindle housing area and minimum at tail end region. The rotational speed has less effect on the development of stresses and strains in the spindle. With the help of Campbell diagram, critical velocity is also found for choosing the best material applicable. Thus, the present work discusses the static and dynamic analyses on lathe spindle for different materials. (C) 2019 Elsevier Ltd. All rights reserved.