The Imitation Study of Taper Connections

Stiffness of Face Milling Cutter Shank

Using Machine Spindle in the SolidWorks
Simulation Environment

Oleksandr Melnyk(&) , Larysa Hlembotska , Nataliia Balytska ,

Viacheslav Holovnia , and Mykola Plysak

Zhytomyr State Technological University, 103 Chudnivska St.,

Zhytomyr 10005, Ukraine
o.l.melnyk@ukr.net

Abstract. The article deals with the radial stiffness increase of face milling
cutter taper with a shank 7:24 using a machine spindle. The preliminary
investigations prove that stiffness increase of such connections is possible by
means of a face milling cutter shank with two-contact centering faces design. In
this case, a smaller centering face is proposed to design hollow with reduced
radial stiffness. In the paper, we have carried out the stiffness imitation study and
considered a face-milling cutter taper connection stress-strain state with an
improved shank under loading with a machine spindle using SolidWorks.
To perform simulation modeling, we have used a parametric 3D model of taper
connections static behavior in which external and internal tapers dimensions are
associated with certain deviation limit through the SolidWorks equation tool.
The parameters of the computational process of nonlinear static analysis in the
simulation module have been determined. The parametric model boundary and
kinematic conditions have been considered. It has been determined that standard
simulation tools use for carving force simulation leads to stiffness system arti-
ficial increase. Therefore, in the paper, to simulate the impact carving, we
propose to use specially created orthotropic material thermosetting forces. The
imitation study shows that face milling cutter shank with two centering faces of
all deviation limits leads to higher stiffness connection (smaller radial
displacements).

Keywords: Hollow taper shank
Radial displacement
Nonlinear analysis

1 Introduction

One of the main conditions of face milling cutters (FMC) stable operation is high
precision and rigid of FMC connection with a machine (hereinafter–connection) [1, 2].
The rigidness of such connection may be increased in two ways: increasing
the precision of the production base surfaces of the cutter, the ancillary tool and the
machine spindle; a constructive improvement of the quality and precision of the
connections between the FMC shank and the machine spindle.

© Springer Nature Switzerland AG 2020

V. Ivanov et al. (Eds.): DSMIE 2019, LNME, pp. 602–612, 2020.
https://doi.org/10.1007/978-3-030-22365-6_60
 The Imitation Study of Taper Connections … 603

The first way, related to the direct increase in the requirements for the precision of
the elements (for example, to the 4th qualification), requires the improvement of
manufacturing technology, and processing cost increase. In addition, it may turn out to
be technically impossible.
Therefore, the constructive improvement of the connection stiffness is relevant.
To do this, it is proposed to apply a modified shank.

2 Literature Review

The general problem of increasing the uniformity of the knives FMC load and the
entire technological system of processing during milling is advisable to solve by two
counter ways. Firstly, we may reduce the magnitudes of the systematic and random
components of the cutting edges beating of knife blades. Secondly, it is also possible to
reduce the impact of the very phenomenon of beating on the uniformity of the milling
process [1, 3]. It is known that the beating causes a significant change in loading of the
cutting edges of the face-milling cutter due to the difference in the actual values of the
cutoff parameters from the theoretical ones, nevertheless, it is not always taken into
account in calculations [4].
Due to existing manufacturing errors in conic surfaces of the shank and machine
spindle, there is a disconformity of their fitting in the connection and moreover even the
absence of actual contact on the length part of this connection. The main errors of the
form are: non-circularity in cross-sections; deviation of generators from straightfor-
wardness, deviation of the cone angle from the nominal value [1].
Recently there has been an increase of interest in hollow taper shanks designs
[5, 6], which allows improving the precision and stiffness of the connection of the
shank with the spindle. Hollow taper shanks have a number of advantages, including:
– providing approximately twice bigger the clamping force;
– increase of permissible speeds of rotation (more than 8000 rpm.);
– high static and dynamic rigidness of the FMC connection with machine spindle
hole;
– ability to compress deformation to match the surface profile of the machine spindle
opening;
– transmittance of high torque;
– high precision of the position repetition when installing the shank of FMC into the
machine spindle;
– short time to replace the tool;
– reduction of radial beating.
Therefore, in order to improve the conical connections of FMC with taper shank
(7:24) with a machine spindle hole [1], it is proposed to use a connection for two
centering faces, with the hollow lower centering face with reduced radial stiffness. In
order to avoid the manufacturing errors in conical creature taper shanks [1], it is
recommended to perform a mid-cavity with the abandonment of two centering faces.
However, it may be possible to contact one of them. For this purpose, the thread
604 O. Melnyk et al.

connection of the shank with an arbor draw-in rod of the machine is moved towards the
big centering face. Consequently, the small centering face is created with a reduced
contact area (see Fig. 1b).

Fig. 1. General view of a solid-state model of a standard shank (a) and an improved shank (b),
where 1 is a lower centering face; 2—big centering face.

The stiffness of the taper connection greatly depends on the deviation of angles of
the conics shank and machine spindle [1, 3]. The schematic formation of a clearance in
connections of cones is depicted in Fig. 2 (the deviation of the cones angles is greatly
magnified for better visualization).

Fig. 2. Schematic formation of a clearance in the taper connection: a angle element of cone
shank smaller angle of a machine spindle element; b cone angle element of machine spindle
smaller angle of element of conic shank.
 The Imitation Study of Taper Connections … 605

The most unfavorable case to ensure stiffness is depicted in Fig. 2a.

Therefore, in order to determine the influence of the structural parameters of the
shank on connection stiffness at the design stage, it is important to use computer
modeling for static behavior of the taper shank of FMC with gradual load.

3 Research Methodology
3.1 Approved Method of Accuracy Rationing of the Taper Connection
Due to a number of reasons, which will be discussed below, the simulation model of
the face milling cutter-machine spindle connection can not fully reflect all actual design
characteristics. Consequently, we have applied some simplifications in evaluation of
conical parts of the FMC and the machine spindle accuracy.
Standards establish two ways of cone tolerances rate:
General evaluation of all kinds of tolerances with TD tolerance of the cone diameter in any
section. Separate normalization of each type of tolerance: TDS tolerance of the cone diameter in
a given section, AT angle tolerance of the cone, tolerance of TFR roundness, tolerance of the
TFL straightness of the cone element [7].

In this study cone shaped tolerances (TFR, TFL) have not been taken into account,
because the first method of accuracy rationing of the cone [7] is chosen—the general
evaluation of all tolerances by the admission of TD. Tapered connection of FMC—
machine spindle is fixed according to the given force of pressing (realized by tightening
of an arbor draw-in rod).
Since TD is tolerance of the cone diameter of in any section, we confine ourselves to
the cross sections of the cut-out cones bases of the machine spindle and shank. As for
tool tapers, the 6th grade of accuracy is chosen. Thus, the combination of tolerance
fields for cones in the indicated sections will be the following: ∅39.6H6/p6 


and, respectively, ∅69.8H6/p6, where: £39:6H6 þ 0:013 0 , £39:6p6 þ 0:035
þ 0:022 ; and

 
£69:8H6 þ 0:0160 , £69:8p6 þ þ 0:026 :
0:042

As a result, using the basis of marginal variation dimensions we form limit devi-
ation combinations, which have been used in the calculations.

3.2 Developing Simulation Technique for Tightening of an Arbor Draw-

in Rod of Face Milling Cutter in SolidWorks Simulation
In order to adequately formulate the simulation model and carry out static analysis in
the SolidWorks Simulation environment, before the radial load is applied, the balance
of structure for the deformed form should be established from the effect of the pulling
force of tightening of the arbor draw-in rod.
In our opinion, the tightening effort of the arbor draw-in rod can be realized in the
following ways: connector “Screw”, which does not require the formation of a geo-
metric model; the application of an axial force that will simulate the effect of the arbor
606 O. Melnyk et al.

draw-in rod when it is tightened, and at the same time forming a radial force application
curve imitating the load on the FMC by applying the force of tightening the an arbor
draw-in rod; the formation of preliminary effort from the tightening of an arbor draw-in
rod by means of the thermo-elastic insert into the arbor draw-in rod.
Using connector “Screw” simulation program introduces a completely rigid kine-
matic connection between the grid (for faces with specified connector) [8]. Although,
the mechanical compliance of such connector occurs only in the axial direction or
during rotation.
The use of virtual screw connections Simulation artificially increases system
stiffness. Moreover, there are contradictory views on how Simulation imitates screw
connections: in [8] it is indicated that the core of a virtual screw is replaced by a beam
that can work for bending and stretching, the ends of the beam are connected by
absolutely rigid rods with all finite nodes elements belonging to the conditional head of
the screw; in [9] it is indicated that the system creates a virtual pin by introduction of
absolutely rigid kinematic relationship between the user-selected faces, thereafter
interconnections that control mechanical compliance in the axial direction and during
rotation are formed (i.e., such system cannot work in bend).
Since in the task, one of two external force factors are the effort of tightening the
arbor draw-in rod (thread connection of the arbor draw-in rod and shank). Conse-
quently, simulation of this power factor with a virtual bolt will increase system
stiffness.
Due to the opposition of axial force to the change of the application curves, as the
axial force (simulates of tightening the arbor draw-in rod), the radial force requires the
use of significant computer resources and time.
Therefore, in the paper, it is proposed to form a preliminary effort from the
tightening the arbor draw-in rod by means of thermo-elastic insert into the arbor draw-
in rod. Thermosetting insert parameters have been selected according to the recom-
mendations of [8, 9], as well as the results of an iterative procedure.
In SolidWorks database, a new material with orthotropic properties has been
formed, including thermal coefficients of linear expansion (TCLE) in the radial
direction (relative to the axis of the arbor draw-in rod), which in the transverse section
of the used cylindrical insert (see Fig. 4) deformation would actually be absent at the
change temperature. The TCLE in the radial direction is 1.7  10−9 K−1, in the axial
0.0001 K−1. The rest of the properties are similar to the properties of the arbor draw-in
rod material (steel 40X). The reference geometry of the orthotropic material Top of the
details assembly has been selected, which is the orthogonal to the axis of symmetry of
the “real” screw.
When cooled (apposition of the appropriate thermal load), the insert made of the
orthotropic material (see Fig. 3, position 1) will reduce its dimensions in the direction
of the axis of the arbor draw-in rod and, thus, will simulate tightening the arbor draw-in
rod load.
 The Imitation Study of Taper Connections … 607

Fig. 3. Placement of the thermo-elastic orthotropic insert and application of the radial force:
1—thermoelastic insert, 2—radial force 2000 N.

To determine the required value of the thermal load (cooling temperature), of the
insert (Fig. 3, position 1) an iterative procedure for determining the load with a virtual
screw, for which the axial force is known, has been performed. The radial central force
(the direction of force acts through the symmetry axis of milling cutter) of 2000 N
(Fig. 3, position 2) has been applied to the milling cutter.
The essence of the iteration procedure for determining orthotropic material prop-
erties, geometric parameters of the orthotropic part of the screw, and thermal load
parameters is to achieve the equality of the axial force of the virtual screw (Fig. 4a) and
the value screw of the contact force of the “real” screw head (Fig. 4b).

Fig. 4. Selection of the parameters of orthotropic material: a axial force of the virtual connector;
b the value of the contact/frictional force under the “real” screw head.
608 O. Melnyk et al.

3.3 Parameters of the Computational Process of Nonlinear Static

Analysis
To simulate the taper connection of the face mill shank and the machine spindle to
investigate its stiffness, a nonlinear static analysis is required. In our opinion, in this
case nonlinearity is, caused by two aspects: contact nonlinearity and geometric non-
linearity. The geometric nonlinearity lies in the fact that the deformation of parts during
the tightening the arbor draw-in rod can significantly (30–50%) change the stiffness of
the system. Additionally, stiffness increase will be significant even with a small change
of the contact area. The contact nonlinearity is to change the contact area with
increasing axial force from the tightening the arbor draw-in rod.
In the nonlinear study, the choice of computational process parameters is signifi-
cant, the main of which are period of time for which the research is conducted (the time
in this case is pseudo-variable); increment of step and action; assignment of tolerances
of iterative process convergence; control method (tab “Advanced”); iterative algorithm
(tab “Advanced”).
Physical nonlinearity of materials is displayed depending on the characteristics of
elasticity from the loading history—the nonlinearity of the “stress-deformation” curve
or the dependence of deformation on time (viscoelasticity, creep).
The nonlinearity contact most often arises at the boundary of the body contact when
the initial load is transmitted through a small area, which can lead to significant
deformations in this zone. In addition, contact friction, in particular, is also a source of
nonlinearity. Moreover, the increase in stiffness will be significant with a small increase
in the contact area. In such places the finite-element mesh parameters will be deter-
minant. The process of generation of a finite-element mesh in the nonlinear analysis is
similar to the process of generation in the linear, but, as it has already been stated, the
sensitivity to the quality of the mesh is much higher.
Materials of the investigated assembly are linear-elastic isotropic.
Due to a common known fact [8, 9], interference is permissible only in interference
fit, which, in turn, makes it necessary to use the mate “Tangent” for the conical contact
surfaces between the machine spindle and the face mill shank and the use of the
“Analysis” tool to check for interference absence.
It is necessary to assign kinematic conditions that exclude the possibility of
assembly movements as a rigid continuous body or the movement of any part (or
aggregate of details) without deformation [8, 9].
The SolidWorks Simulation toolkit allows to view contact tasks and small and large
displacements in a linear setting. For linear and nonlinear analysis, the option “Large
displacement” is available, which allows the task solution by the method of successive
loads with the analysis of the surface paired position and the orientation of the normal
to them at each step.
Although the use of the “Large displacement” option is accompanied by a number
of limitations, unlike non-linear studies, the results will only be available at the last
step; if there is a non-linearity that is not caused by a contact, the linear analysis is
inapplicable.
 The Imitation Study of Taper Connections … 609

Consequently, it has been found that the formation of contact conditions with the
help of a contacts set (“No Penetration”) in the variant “Node to Surface” is optimal.
The “Node to Node” type contact can not be implemented in the event of clearance,
because it requires the creation of a compatible mesh. This type of contact requires less
PC resources for the calculation in the case of no significant component slip, so this
type of contact is not suitable for studying shank stiffness. On the other hand, the mesh
generator on the basis of curvature does not support contact type “Node to Node”.
Therefore, this type of contact can not be used in this case.
In general, the type of “Surface to Surface” contact is more precise than “Node to
Surface”, if the parameter “No Penetration” is used (prevents interference, but allows
clearance and accounts for friction). However, tasks solution with “surface-to-surface”
contact requires a lot of PC resources.

4 Results
4.1 Imitation Study of Stiffness of Taper Connection of Face Milling
Cutter Shank with Machine Spindle
The stiffness of the developed simulation model will be higher than the actual node due
to the following factors: in imitation solid-state models tolerance of cone form devi-
ations (TFR, TFL) are not taken into account; in the imitation model, no backlash is
taken into account in the machine spindle node.
For the research of connection of the face mill with standard and modified shanks
and the machine spindle several combinations of dimensions limit deviation (Table 1)
have been assigned. They have been introduced into the parametric model via the use
tool “Equations”. This study is clearly nonlinear; consequently, the static nonlinear
study in the Simulation module has been used. Computational process of nonlinear
study parameters, and boundary and kinematic conditions are shown in Fig. 5.

Table 1. Combination of limits dimensions of cones and radial stiffness simulation results.
Combinations of limit Standard shank Modified shank
deviations (mm) Radial Coefficient of Radial Coefficient of
displacement stiffness (N/µm) displacement stiffness
(mm) (mm) (N/µm)
Set 1 DSpindle ðmmÞ 39:6
39:644;
0.0808998 24.721 0.0081659 244.920
dShank ðmmÞ 69:8
69:852
Set 2 DSpindle ðmmÞ 39:626; 0.0621107 32.200 0.0089895 222.482
dShank ðmmÞ 39:644
69:8
69:884
Set 3 DSpindle ðmmÞ 39:6 0.04914 40.700 0.0118237 169.151
40 ;
dShank ðmmÞ 69:84
70:00
Set 4 DSpindle ðmmÞ 39:6 ; 0.0899449 22.235 0.0073461 272.255
dShank ðmmÞ 39:67
69:8
69:884
610 O. Melnyk et al.

Fig. 5. Static nonlinear study in the Simulation module: a parameters of the computational
process; b contact conditions.

As it is shown in Table 1, the modified shank of FMC provides an increase in

connection coefficient of stiffness with the machine spindle to 12.24 times compared
with standard shank.
The results of tapered shank connection of FMC with the machine spindle simu-
lation agree with the results of experimental studies [1].
Thus, the values of radial displacements (Table 1, Fig. 6) confirm the assumption
that the hollow shank with two contact bands and a reduced radial stiffness in the area
of a smaller contact band can increase connection stiffness of FMC with the machine
spindle. The latter, in its turn, is one of the important factors of prerequisite in stabi-
lizing the work of FMC.
To show the displacement components of the milling cutter in the model 2 the
sensors have been formed. Their values are given in Table 1.
 The Imitation Study of Taper Connections … 611

Fig. 6. Plot of displacement along Z axis: a standard shank; b modified shank.

5 Conclusions
(1) The rationing reasonable use of all tolerances types, with TD tolerance of a cone
diameter in any section has been grounded as a way of rationing the accuracy of
the conic connection of FMC with machine spindle and combinations of marginal
deviations sizes of external and internal cones for the editing of the parametric 3D
model are determined.
(2) The technique of tightening force simulation of the arbor draw-in rod for study
stiffness shank taper connection of FMC with the machine spindle in the Solid-
Works Simulation software environment has been developed. This technique
allowes to avoid artificial stiffness increase, which significantly increases the
accuracy of simulation displacements shank under the influence of cutting forces
components.
(3) Computing process parameters of the nonlinear static analysis have been
appointed, boundary and kinematic conditions have been assigned. The adequacy
of boundary and kinematic conditions formation for contact nonlinear problems is
the key factor in obtaining the result with acceptable accuracy. Therefore, a “real”
screw has been introduced into the model and an insert has been used for sim-
ulation of mechanical compliance threaded connection, which allows obtaining
more accurate results.
(4) The imitation study of the simulation of stiffness tapered shank connection of
FMC with machine spindle has confirmed that the use of a hollow shank of
modified design with two contact bands provides an increase in the stiffness
connection compared with the standard shank in the range from 4.15 to 12.24
times for boundary deviations combinations.
612 O. Melnyk et al.

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