Design, analytical and computational analysis, and development of a high-precision CNC spindle for a vertical machining center

Abstract This research focuses on design, simulation and development of a high precision Computer Numerically Controlled (CNC) spindle for vertical machining center. High speed spindle is designed and analyzed under the varying load conditions. SolidWorks 2020 is used for designing of CNC spindle (based on ISO BT40 standards) and ANSYS Workbench 2020 is used for analysis. Moreover, analytical calculations for deformation are also done. Three different materials i.e. AISI 4340 steel, Grey cast iron, and Ti6Al4V alloy are chosen for the analysis. Effect of varying load on deformation and stress on CNC spindle is discussed. AISI 4340 steel showed better mechanical characteristics as compared to other materials. Moreover, the results showed that steel gives lesser values of deformation as compared to other materials, when applied under different load conditions. Although Grey cast iron can be economical and weight of the spindle can also be reduced but Grey Cast iron has greater value of deformation when load is applied. On the other hand, Ti6Al4V alloy specimen exhibited less stress as compared to other materials but mechanical properties in terms of modulus of elasticity are not that good as AISI 4340 steel. So, AISI 4340 steel could be a good option for spindle materials that require desired properties such as strong corrosion resistance, tensile strength, yield strength, and propagation. This will boost the accuracy and efficiency of spindle. Based on these results, high-precision CNC spindle was developed.