Combining Material Characterization to Computer Modeling Helps Optimize a Spindle System for Machining Shafts

To date, Federal Mogul Tri-Way Ltd. has relied on past experience to design machinery, a system of belts or gears providing torsion and thrust to cutting tools. If a shaft within a spindle system is not properly sized, it can deflect under the action of the tangential cutting effort resulting in a poor finish of the machined component. Of even more importance, if rotation of the tool approaches a natural frequency of the shaft, deflections of the spindle under load amplify. In fact, Tri-Way has at instances replaced shafts during trials, causing delays in delivering machinery. On the other hand, over-designing spindles cost money. A literature search by the Canadian Institute for System Technologies Information did not locate tools to help Tri-Way optimize spindles. The company has turned to Windsor Industrial Development Laboratory to develop and validate a computer model to simulate the static and dynamic behavior of spindle systems. This paper summarizes the findings of such research to date.