4. Cylindrical Grinding Machine
Workhead
Carriage
Tailstock
Bed
Table
(Courtesy: Micromatic Grinding Technologies Ltd.)

5. 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

6. SPECIFICATIONS AND MATERIAL PROPERTIES1.
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.)

7. CUTTING FORCES USED S.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

8. Analysis of Cylindrical Grinding Machine

9. Analysis of Cylindrical Grinding Machine

10. Analysis of Cylindrical Grinding Machine
Deformation contour of entire machine tool

11. Analysis of Cylindrical Grinding Machine

12. Analysis of Bed
Deformation (in m) contour of bed

13. Analysis of Bed

14. Components/Sub-assemblies
S.No
Components/Sub-assemblies
Total
Deformation in μm
(max.)
X-axis*
Y-axis*
Z-axis*
VonMises stress in MPa 1.
Bed
0.139
0.0218
0.0266
0.0863
0.192 2.
Carriage
0.0129
5.848e-3
3.91e-5
2.326e-3
0.022 3.
Workhead assembly
6.45
1.86
5.21
7.84 4.
Tailstock
9.14
0.238
2.11
7.99
11.36 5.
Workhead+Workpiece+
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 = 70N
Y-axis*- Vertical axis Fy = 350N
Z-axis*- Radial axis Fz = 800N

15. Parametric Optimization
Pre-optimization sensitivity analysis
Design Variables

16. 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

17. Topology Optimization
Preliminary results of possible topology modifications in bed
Topology Optimization Results

18. Topology Optimization
Feature based representation of bed for feature sensitivity analysis
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

19. 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

20. Machine Tool Design

21. Machine Tool Design

22. Machine Tool Design Initial (12:40pm) 12:40pm to 3:45 pm (running)
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