Computer Aided Engineering Performance Analysis of Lathe Machine Spindle using Field Generated Data

Abstract

This research investigated the computer aided engineering performance analysis
of a lathe machine spindle using field generated data. The Excel 360x1000 lathe in
the FUPRE workshop has been used for numerous students training and project
experiments using non-optimal settings, without evaluation of the spindle
performance, productivity, and product surface finishing. This study analyzed the
interaction between input [spindle speed, depth of cut and feed] and response
[material removal rate and surface roughness of machined part] parameters, as
well as evaluates the integrity of the lathe spindle during turning of AISI 1085
work-piece using carbide inserts. RSM was used for the design of the experiment
and optimization of the process to obtain maximum material removal rate and
minimal surface roughness. The turning process was also to modeled, utilizing
maximum generated cutting forces acting on the spindle during machining to
ascertain its resilience. Optimization of the dependent and independent variables
proffered the best solution based on set constraints with a desirability of 0.788. The
conducted Finite element analysis [static, dynamic, and fatigue] yielded spindle
maximum deflection of 0.01432mm, maximum von mises stress of
18840000N/m^2, least natural frequency of 898.64Hz, and spindle remaining
fatigue life of 100 million cycles. These findings infer that the lathe spindle is robust
and optimal responses were achieved at a specific input configuration.