342 Machine Tools Handbook

Another method of reversing rotation direction uses a swiveling quadrant, incorporating

an additional idler gear [Fig. 4.18c]. The swiveling quadrant enables engaging gears ‘B’ or
‘C’ with the driving gear ‘A’. When gear ‘C’ is meshed with driver ‘A’, the gear ‘D’ and the
keyed shaft are driven in the same direction as the driver ‘A’. Swiveling the quadrant to mesh
gear ‘B’ with driver ‘A’ however, rotates the driven gear ‘D’ and its shaft in the opposite
direction.
As engagement of gear ‘B’ or ‘C’ with gear ‘A’ is radial, and driver ‘A’ is rotating during the
engaging motion, all the gears in this arrangement usually have helical teeth. Mating gears
have helix angles of the opposite hands.
Bevel gears reversal mechanism [Fig. 4.19a] comprises three gears. The driving shaft I is
square with the driven shaft II. The driven shaft is mounted with a cluster of two bevel gears
‘B’ and ‘C’. Splined internally, the cluster can be slid axially on the driven shaft. Engaging
bevel gear ‘B’ of the cluster with driving gear ‘A’, rotates the driven shaft in one direction.
Sliding the cluster towards the right meshes gears ‘A’ and ‘C’ to rotate the driven shaft in the
opposite direction.

Fig. 4.19: Reversal mechanisms with bevel gears

The cluster can be replaced by a special jaw clutch, similar to the one in [Fig. 4.18a]. In
this arrangement [Fig. 4.19b], the driving gear ‘A’ is permanently enmeshed with bevel gears
‘B’ and ‘C’, rotating freely in opposite directions on the driven shaft II. Moving the central
splined part of the jaw clutch towards the left meshes its teeth with the clutch half on gear ‘B’.
This rotates the driven shaft in one direction. Engaging the central half with the clutch half on
gear ‘C’, on the other hand, rotates the driven shaft in the opposite direction. It should be
remembered that neither driven gear ‘B’ nor ‘C’ are keyed [or splined] to the driven shaft II.
They rotate free of shaft II, in opposite directions.
 CHAPTER 5
MACHINE TOOL ELEMENTS
Machine tools comprise a variety of elements:
spindles, bearing supports, saddles (carriages)
and guideways for feed motions, workpiece
tables, and composite housings with columns,
arms, beds, etc.
5.1 SPINDLES
Rotating elements which mainly bear bending
loads, with little or no torsion, are called
axles. Elements which transmit considerable
torque are called shafts. They are usually
mounted with torque transmitters like gears,
belt pullies, and chain sprockets. Spindles
are end-output shafts which carry tools or
work-piece holders.
5.1.1 Functions of a spindle
1. Holding workpiece/cutting tool
2. Positioning (centering) workpiece/cutting
tool
3. Imparting rotary motion (torque) to
workpiece/cutting tool.
To fulfill these functions satisfactorily, a
spindle should fulfill the following requisites.
5.1.1.1 Requisites of a good spindle
1. Precise mounting with minimum rotary
and axial runout (for precision
machining)
2. Adequate static and dynamic stiffness, to
minimize distortions resulting from
cutting forces
3. Wear resistance through hardening, or
replaceable anti-friction bearings
4. Heat dissipation through selection of
adequate bearings
5. Precision mounting surfaces for locating
workpiece grippers (chucks, collets), or
cutting tools (drills, cutters)
6. Long life against fatigue, by limiting the
bending stresses.
5.1.2 Spindle materials
Distortion depends upon the modulus of
elasticity (E). As ‘E’ is not significantly higher
for costly high-tensile steels, they do not offer
any marked advantage above the moderately-
priced structural and alloy steels.
The choice of the material depends upon
the following considerations:
344 Machine Tools Handbook
5.1.2.1 Stress
This depends upon the power transmitted (kW/HP) and the bending stress, dependent upon
the forces on the mounted transmission elements. The resultant bending stress can be computed
from the following equation:
Resultant bending stress = fb

M 2 + 0.45T 2
fb = (Eqn. 5.1)
Z
M = Maximum bending moment (kgfmm) = M x 2 + M y2
Mx, My = Bending moments in planes x and y, square with each other
T = Torque (kgfmm)
6000 P
= , where P = Power transmitted (kW)
2p N
N = Spindle Revs/Min
Z = Modulus of spindle section (mm3)
= 0.0982 D3, where D = Spindle outside f (mm)
The permissible bending stress fb depends upon the type of loading, and the ultimate tensile
strength of the material used.

Table 5.1: Permissible bending stress for spindles

Sr. No. Type of load Permissible bending stress f b in kgf/mm 2 [7.0307 ¥ 10 – 4
¥ Lbs/ Inch 2 ]
C45/55 40Ni2 15Ni2 Spheroidal
En 8/9 Cr1/En 24 Cr1 Graphite
RC 30 RC 50 En 354 Cast
95 kg/mm2 160 kg/mm2 Case Hrd Iron
[135120 psi] [227570 psi] 65 kg/mm2 37 kg/mm2
[92450 psi] [52630]
1 Steady load light bending moment 8 [11378] 12 [17068] 5 [7112] 2.8 [3982]
2 Fluctuating load light bending moment 6 [8534] 9.2 [13085] 3.7 [5263] 2.1 [2990]
3 Fluctuating load considerable bending moment 4.5 [6400] 7 [9956] 2.85 [4054] 1.6 [2276]

The cast spindles are used only in applications requiring hollow cavities or odd shapes,
which usually take a lot of time for machining from bar-stock.

5.1.2.2 Stiffness or rigidity

Stiffness or rigidity is the ratio between the load (W ) and deflection (d ). The overall stiffness
of the spindle can be found from the following equation:
 Machine Tool Elements 345
W
S= (kgf/mm) (Eqn. 5.2)
d
The cutting load varies according to the workpiece material, cut, feed, etc. The resultant
(total) defection of the shaft [Fig. 5.1] comprises the deflection of the spindle at the overhanging
end (dR ), and the yield of the bearing, closer to the overhung end (dQ ).
Deflection of the machine spindle must be limited, by providing for adequate rigidity.
Max. deflection = dmax £ 0.0002 L, (Eqn. 5.3)
where L = Span between the bearings (mm)
Even the deflection at the drive gears must be limited.
Deflection at gear = dg £ 0.01 m (Eqn. 5.4)
m = module of the gear. [1 Diametral Pitch = 25.4 module]
The overall deflection (d ) can be computed from the following equation. Referring to [Fig.
5.1]:

Fig. 5.1: Spindle with single overhanging load

Ê A2 Ê L Aˆ Ê1 A ˆ
2
A2ˆ
d=WÁ Á + ˜ + d Á + ˜ + d P 2˜ (Eqn. 5.5)
Ë 3E Ë I L I A ¯
Q
Ë L¯ L ¯
IL = Moment of inertia of spindle, in the portion between bearings P and Q
IA = Moment of inertia of spindle in the overhanging length A.
dQ = Deflection/kg of Bearing Q
dP = Deflection/kg of Bearing P..
Deflection can be minimized by optimizing the span between the bearings. Differentiating
Eq. 5.5 for minimum deflection,

Ê Ê dQ . R ˆ ˆ
Optimum span (Lo) = 3 6EI Á d P + dQ + Á A ˜ ˜ (Eqn. 5.6)
L
Ë Ë ¯¯

The value of R can initially be taken to be 4 times overhang A. The computed value of Lo
can be substituted for R to find Lo by iteration.
346 Machine Tools Handbook
The actual span can be up to 20% higher than the calculated value of Lo.
The values of dP and dQ can be found from the size and the type of bearing chosen. Equations
5.44 and 5.45, Tables 5.13 to 5.16, and [Fig. 5.21] in the later section on Elastic Deformation,
give the details of the method for determining the deflection per kg, of various types of bearings.
p
Inertia of shaft = D4 = 0.0491 D4 [Inch4 = 41.623 ¥ 104 mm4]
64
Example 5.1: Find the spindle size and optimum span of bearings, and deflection, if the
spindle overhang (A) is 80. The cutting force at the overhung end is 110 kg. Powered by a
5 kW motor, the spindle runs in a 58-470 R.P.M. range. Use a roller bearing near the overhung
end, and a ball bearing at the farther end.
Solution: The bending moment on the overhanging portion is a multiple of the cutting force
and the overhang.
M = 110 ¥ 80 = 8800 kgmm.
6000 ¥ 5
T= = 82.32 kg m = 82320 kgmm. [Tmax when RPM [N] is
2p ¥ 58
minimum]

From Eqn 5.1, Combined moment = M 2 + 0.45 T 2

= 8800 2 + 0.45 (82320)2

= 55918.7 kgmm.
Referring to Table 5.1, for C 45 and fluctuating load fb = 6 kg/mm2.
From Eqn. 5.1,

M 2 + 0.45 T 2 55918.7
Z = 0.0982 D3 = = = 9319.8
fb 6

9319.8 3
D= 3 = 94906 = 45.63
0.0982
For a 45 f ¥ 100 f ¥ 36 roller bearing,
dr = 0.25 (100 - 45) = 13.75 ~ 14
Example 5.18a gives the details of the calculations for finding deflection of f 45 ¥ f100 ¥ 36
roller bearing, and the calculated value: dq = 0.000137.
A slightly smaller, say 40 f ball bearing, will be used at the farther end. Choosing f 40 ¥
f 68 ¥ 15 Brg. with Co = 980.
Example 5.17 computes the value of dP. It is 0.00045/kg.
IL = IA = 0.0491 ¥ 454 = 201340.7 mm4
 Machine Tool Elements 347
Ê Ê dQ . R ˆ ˆ
From Eqn. 5.6, Lo = 3 6EI L d
Á P + dQ + ÁË A ˜¯ ˜
Ë ¯

Taking R = 4A = 4 ¥ 80 = 320,

Lo = 3 6 ¥ 2.1 ¥ 104 ¥ 201340.7(0.00045 + 0.000137 + 0.000137 ¥ 4)

= 3 253.698 ¥ 10 8 (0.000587 + 0.000548)

= 3 28.79 ¥ 106 = 306.5

Substituting this value for R,

Ê 306.5 ˆ ˆ
Lo = 3 253.698 ¥ 10 8 Á 0.000587 + ÊÁ0.000137 ¥ ˜
Ë Ë 80 ¯ ˜¯

= 3 28.19 ¥ 106 = 304.326

Again substituting 304.4 for R,

Ê Ê 304.326 ˆ ˆ
Lo = 3 253.698 ¥ 10 8 Á0.000587 + Á0.000137 ¥ ˜
Ë Ë 80 ¯ ˜¯

= 3 28.11 ¥ 106 = 304.06

This figure is close enough to preceding figure stop the iteration. The span can be 20%
longer, i.e. between 304 and 365 say 335.
From Eqn. 5.5, deflection of the shaft can be found for a span of 305.
Ê A2 Ê L Aˆ Ê1 A ˆ
2
A2 ˆ
d=W Á Á + ˜ + dQ ÁË + ˜ + d P 2˜
Ë 3E Ë I L I A ¯ L¯ L ¯

Ê 802 Ê 335 + 80 ˆ ˆ Ê 80 ˆ 2 802

= 110 Á Á ˜ ˜ + 0.000137 Á 1 + ˜ + 0.00045
Ë 3 ¥ 2 .1 ¥ 10 Ë 201340.7 ¯ ¯
4 Ë 335 ¯ 3352
= 110 (00.000209 + 0.00021 + 0.0000257) = 0.05
From Eqn. 5.3,
Max. permissible deflection = dmax
dmax = 0.0002 L = 0.0002 ¥ 335 = 0.067.
This deflection is excessive. The overall deflection should not exceed half the value of the
permissible runout (usually 0.02). In fact, the preferable value is only one-third of the
permissible runout. Generally, the maximum deflection is limited to 0.006 mm, i.e. 6 microns.
348 Machine Tools Handbook
Even the slope at the edge of the bearing, closer to the load (Q in [Fig. 5.1]), must be limited
to 0.001 Radians. Actual slope can be found from Eqn. 5.6.

WAL
Q= (Eqn. 5.7)
3EI A
Maximum permissible slope (misalignment) depends upon the type of bearing used.

Table 5.2: Permissible slopes for machine spindles

Brg Ball Brgs Roller Brgs

type Single row Double Angular Thrust Cylindrical Spherical
row contact
q max 0.001 0.0002 0.003 0.0002 0.0003 0.009
Rad.

Self-aligning, double row ball bearings can have a misalignment of up to 0.04 radians.
Example 5.2: Find the slopes for the shafts from the following data:

Shaft f,, mm I a mm4 Lo mm A mm W kg

45 201340.7 305 80 110

60 636336 269 80 110
70 1178891 315 80 110

WAL
Solution: From Eqn. 5.7, q =
3EI A

110 ¥ 80 ¥ 305
q45 = = 0.000211 radians
3 ¥ 2.1 ¥ 104 ¥ 201340.7

8800 ¥ 269
q60 = = 0.00006 radians
6.3 ¥ 10 4 ¥ 636336

315
q70 = 0.1396 = 0.000037 radians.
1178891
All the slopes are within the permissible limits, specified in Table 5.2.
When there is a drive gear, on the part between the bearings, the overall deflection (d ) can
be found from the following equation [Fig. 5.2]:
 Machine Tool Elements 349
Ê B2 ˆ
WA 2 ( A + L ) – 0.5 W g ABL Á1 – 2 ˜ – M r AL
Ë L ¯
d= (Eqn. 5.8)
3E I
Wg = Load due to gear (kgf); B = Distance between gear & rear bearing
M r = Reactive bending moment (kgfmm) £ 0.35 WA
I = Average value of moment of inertia of the sections of the spindle. The
slope at the edge of the bearing at Q, can be found from the following
equation:

1 Ê Ê B2 ˆ ˆ
q= ÁWAL – 0.5 W g AL ÁË1 – 2˜
– MrL˜ (Eqn. 5.9)
3EIË L ¯ ¯
Forces due to gears can be found from formulae 2.89 to 2.92 given in Chapter 2.
Example 5.3: Find the spindle diameters for the overhanging part, and the part between the
anti-friction bearings, for the spindle in [Fig. 5.2]. The spindle is powered by a 2.5 kW
motor, running at an R.P.M., ranging from 400 to 2400. The spindle is mounted with a gear
at 60 mm from the rear bearing (P ). It has 80 teeth, of 1.5 module. The gear generates a
radial separating force of 101 kgf. The spindle is subjected to fluctuating load. Determine the
deflections at the gear, and the overhanging end. Check the slopes for the limit of 0.001
radians. The spindle runout should not exceed 0.02 TIR [Total Indicated Runout]. The reactive
bending moment can be taken as 10% of the bending moment, due to the overhanging load
(M Q).
Solution: Referring to [Fig. 5.2],
MQ = 70 ¥ 40 = 2800 kgfmm
6000P 6000 ¥ 2.5
Torque (T ) = = = 5.97 kgfm
2p N 2 p ¥ 400
= 5970 kgfmm
Combined (Equivalent) moment = Mc

Mc = 28002 + 0.45 ¥ 5970 2 = 4886.55

Fig. 5.2: Spindle for Example 5.3

350 Machine Tools Handbook
From Table 5.1, for fluctuating and considerable bending load, permissible bending stress
( f b) = 4.5 kgf/mm2.

4886.55
\ D= 3 = 22.28
4.5 ¥ 0.0982

~ 25 the next bigger std. bearing size.

Permissible deflection = dmax
dmax £ 0.0002 L £ 0.0002 ¥ 160
£ 0.032
But the permissible runout is only 0.02. So the maximum deflection should be 1/3 of 0.02,
i.e. 0.0067.
From Eqn. 5.8,

Ê B2 ˆ
WA 2 ( A + L ) – 0.5 Wg ABL Á1 – 2 ˜ – 0.01 WA 2 L
Ë L ¯
d=
3 EI

Ê 602 ˆ
= 70 ¥ 40 2 (40 + 160) - 0.5 ¥ 101 ¥ 40 ¥ 60 ¥ 160 Á1 –
Ë 160 2 ˜¯

– 0.1 ¥ 70 ¥ 40 2 ¥ 160
3 ¥ 2.1 ¥ 10 4 ¥ 0.0491 ¥ 25 4

2.24 ¥ 107 –1.666 ¥ 107 – 1.79 ¥10 6

= = 0.0033
1.208 ¥ 109

Slope at the edge of bearing Q = qQ

Ê B2 ˆ
WAL – 0.5 WgAL Á1 – 2 ˜ – 0.1WAL
Ë L ¯
qQ =
3 EI

70 ¥ 40 ¥ 160 - 05
FG
. ¥ 101 ¥ 40 ¥ 160 1 -
IJ
602
- 01
. ¥ 70 ¥ 40 ¥ 160
=
H 1602K
3 ¥ 21
. ¥ 104 ¥ 19179.7

= 1.063 ¥ 10-4 = 0.0001

Both the deflection (0.0033) and the slope (0.0001), are well within the permissible limits of
0.006 and 0.001, respectively. From Eqn. 5.4; dg = 0.01 Gear module
 Machine Tool Elements 351
\ dg = 0.01 ¥ 1.5 = 0.015
101 ¥ 60 ¥ 100
B.M. at gear (Mg) =
160
= 3787.5 kgfmm
Mg
dg = (2 ¥ 160(160 - 60) - 1002 - (160 - 60)2)
6EI

3787.5
= (12000) = 0.0376
6 ¥ 2.1 ¥ 104 ¥ 19179.7

As dg is more than the permissible deflection of 0.015, a further increase in the shaft diameter
is necessary.
For dg = 0.015
3787.5 ¥ 12000
I= = 0.0491 D g4
0.015 ¥ 6 ¥ 2.1 ¥ 104

\ Dg = 4 489768.2 = 26.4 ~ 30 (the next bigger standard bearing size).

Even the overhanging part of the spindle can be increased to f 30. This will further reduce
the deflection and slope. Readers can find the deflection and slope for a f 30 spindle, as an
exercise.
When a number of gears are mounted on the spindle, it is convenient to find their resultant,
force and maximum bending moment to determine the maximum deflection in the portion
between the bearings.
Example 5.4: Find the diameters in the overhanging part and between the bearings, for the
spindle in [Fig. 5.3]. The reactive bending moment for Brg at Q can be taken as 15% of the
moment, due to the overhanging load. The gears 1 and 2, mounted between the bearings, are
of 2 module. The runout of the spindle should be limited to 0.03 TIR. The spindle is running
in the range of 350 to 2500 R.P.M., and transmitting 1 kW. The load is fluctuating considerably.

Fig. 5.3: Figure for Example 5.4

352 Machine Tools Handbook
Solution:
M = 200 ¥ 30 = 6000 kgfmm
6000 ¥ 1
T= = 2.728 kgfm
2 p ¥ 350
= 2728 kgfmm

Mc = 60002 + 0.45 ¥ 2728 2 = 6272.87

From Table 5.1, for heavy bending moment and fluctuating load, permissible stress for C 45
[medium carbon steel] is 4.5 kgf/mm2.
6272.9
\ D= 3 = 24.21 ~ 25
4.5 ¥ 0.0982
As the bending moment (6000) is more than double the torsional moment (2728), the spindle
should be designed for bending strength. Refer to [Fig. 5.3]. Take moments about point P.
Wg ¥ B = Wg1 ¥ B1+Wg2 ¥ B2
Wg = Resultant of loads (Wg1 + Wg2) kgf.
Wg1 = Radial load due to Gear 1 (kgf)
Wg2 = Radial load due to Gear 2 (kgf)
B1 = Distance of gear Wg1 from left support P (mm)
B2 = Distance of gear Wg2 from left support P (mm)
B = Distance of load resulting from Wg1, Wg2
40 ¥ 50 + 65(150 - 70)
B= = 68. 57
40 + 65
Maximum permissible runout = 0.03 TIR
0.03
Maximum permissible deflection = = 0.01
3
From Eqn. 5.7,
Ê B2 ˆ
WA 2 ( A + L ) – 0.5 W g ABL Á1 – 2 ˜ – M r AL
Ë L ¯
d=
3 EI
Mr = 0.15 WA = 0.15 ¥ 200 ¥ 30 = 900 kgf.
FG
200 ¥ 302 ¥ 180 - 0.5 ¥ 105 ¥ 30 ¥ 68.57 ¥ 150 ¥ 1 -
68.572IJ
- 900 ¥ 30 ¥ 150
d=
H 150 2 K
3 ¥ 2.1 ¥ 104 ¥ 0.0491 D 4
= 0.01
 Machine Tool Elements 353
3.24 ¥ 107 - 0.338 ¥ 107 - 0.4 ¥ 10 7
\ D= 4
0.01 ¥ 0.309 ¥ 104
= 29.97 ~ 30 (The nearest bigger Std. Brg. Size.)
For the portion between the bearings, i.e. for resultant force Wg, at distance B ,
W g B[ L – B ] 105 ¥ 68.57 ¥ [150 - 67.57]
Mg = = = 3908.6
L 150
Mg
dg = {2L(L - B) - (L - B)2 - (L - B)2}
6EI
3908.6
= 4 4
{2 ¥ 150(150 - 68.57) - 2(150 - 68.57) 2 }
6 ¥ 2.1 ¥ 10 ¥ 0.0491 ¥ 30
= 7.8 ¥ 10-7(24429 - 2 ¥ 6647.14)
= 0.0087
The module of the gears is 2.
\ dg = 0.01 ¥ 2 maximum permissible.
As the deflection 0.0087 is less than permissible 0.02, a f 30 shaft would do.
Slope of the spindle at the outer edge of the bearing Q, can be checked from Eqn. 5.9,

Ê B2 ˆ
WAL – 0.5Wg AL Á1 – 2 ˜ – M r L
Ë L ¯
qQ =
3EI

Ê 68.57 2 ˆ
200 ¥ 30 ¥ 150 - 0.5 ¥ 105 ¥ 30 ¥ 150 Á1 - - 900 ¥ 150
Ë 150 2 ˜¯
=
3 ¥ 2.1 ¥ 104 ¥ 39771

= 0.00023, i.e. much lesser than the permissible maximum of 0.001 radians.
Deflections can also be found graphically, by the B.M. Area Moment method [Fig. 5.4].
It is necessary to draw a bending moment diagram first. Consider the length of the beam as
X axis. Then the difference in deflections at any two points, is equal to the moment of the
bending moment area, between the two points around the Y axis, through one of the two
points divided by EI. [1 Lb. Ft. = 0.1356 kgm]
354 Machine Tools Handbook

Fig. 5.4: Bending moment and deflection for Example 5.4

Referring to the B.M. diagram in [Fig. 5.4], the deflection at point R with respect to point
P, can be found as below:
Moment of B.M. area between P and R about Y axis, through P
R=
EI
D PRU Area × Distance of its centroid from P
=
2.1 ¥ 10 4 ¥ 0.0491 D 4
1
2RU ¥ PR ¥ 23 PR
=
2.1 ¥ 10 4 ¥ 0.0491 ¥ 30 4
1
2 ¥ 650 ¥ 50 ¥ 32 ¥ 50 541669.4
= 4
=
2.1 ¥ 10 ¥ 39771 83519 ¥10 4
= 0.00065
Similarly, for deflection at point ‘S ’,
541669.4 + Moment of Trapezoid RUSZ about P
ds =
83519 ×104
Ï 30 Ê 2 ¥ 650 + 160ˆ ¸
541669.4 + (12(650 +160) (150 -(70 + 50)) ) ¥ Ì50 + Á ˝
Ó 3 Ë 650 + 160 ˜¯ ˛
=
83519 ¥ 10 4
541669.4 + 826500
= = 0.0016
83519 ¥ 10 4
Deflection at T, with respect to Q
Moment of Area VQT around Y axis, through Q
dT =
83519 ×10 4
 Machine Tool Elements 355
( 12 ¥ 6000 ¥ 30 ) ¥ 23 ¥ 30 1,800,000
= 4 =
83519 ¥ 10 83519 ¥ 104
= 0.00216
It will be necessary to use a very high scale, i.e. 0.001 = 10 mm, or 10,000 : 1 for deflection
(Y axis), to make it perceptible in [Fig. 5.4].

Fig. 5.5(a): Centrifugal force due to deflection

Academicians in quest of subjects for post-graduate research, endeavor to find

mathematically-ideal conditions. It has been found that the runout of a spindle, due to play
L
between the anti-friction bearings, can be minimized, by keeping the ratio above 2.5.
A
L
≥ 2.5 (Eqn. 5.10)
A
The diameter of the spindle between the bearings (DL ), should have stiffness (SL ) exceeding
35 kgf/micron. This can be ensured by satisfying the following condition:
D1.333
L£ L (Eqn. 5.11)
l 0.333
l = 0.05 for average accuracy, and,
= 0.1 for high-precision machines.
For hydro-static bush bearings, the maximum deflection in the spindle portion between the
L
bearings, should be limited to 4 .
10
L
dL £ 4 (Eqn. 5.12)
10
Example 5.5: The spindle of a high-precision machine is subjected to 200 kgf overhung load at
60, from the nearest bearing. It is subjected to 50 kgf load at mid-span, between the anti-friction
bearings. Find the spindle diameters in the overhung portion (DA ), and between the bearings
(DL ), to optimize the span (L). The spindle is transmitting 5 kW at 110 R.P.M. It is subjected to
a fluctuating load. The deflection between the bearings should be limited to 0.03.
Solution:
M = WA = 200 ¥ 60 = 12000 kgfmm
356 Machine Tools Handbook
6000 P 6000 ¥ 5
T= = = 43.4 kgfm
2p N 2 p ¥ 110
= 43400 kgfmm
From Eqn 5.1, for a fluctuating load and light bending moment for a medium carbon steel
(C45) spindle,
f b = 6 kgf/mm2. From Eqn. 5.1,

12000 2 + 0.45 × 43400 2

fb = 6 =
0.0982 DA3

9.91832 ¥ 10 8
\ DA3 = = 53451
6 ¥ 0.0982

DA = 37.67 ~ 40 (Next bigger Std. Brg size).

For the portion supported between the bearings for central load,

WL3 50 L3 L3
dL = = = 0.001
48 EI 48 ¥ 2.1 ¥ 10 4 ¥ 0.0491 DL4 DL4
1.333
From Eqn. 5.11; L £ DL
l 0.333
For a precision machine, l = 0.1
\ For a borderline case,

D1.333
L= L
= 2.154 DL1.333
0.10.333
If DL = DA = 40, then L = 2.154 ¥ 40 1.333 = 294.3,

Ê 294.33 ˆ Ê 25490304 ˆ
And dL = 0.001 Á 4 ˜ = 0.001 Á
Ë 40 ¯ Ë 2560000 ˜¯

= 0.00996 ~ 0.01
L
From Eqn. 5.10; ≥ 2.5 or L ≥ 2.5 ¥ 60 ≥ 150. The optimum span of 294.3 satisfies Eqn.
A
5.10.
In actual practice, the span of the bearings is determined by practical considerations such as
ease in assembly, and ease in maintenance of drive and control elements. The diameters of various
portions of spindle are then determined, using various formulae cited for the design of the spindle,
since the spindle is usually provided with steps for clamping the inner races of the bearings.
 Machine Tool Elements 357
Usually, the span of the spindle bearings is made suitable for elements such as the gears
and pullies, mounted on it. After working out a tentative design, its strength (stiffness), deflection,
and slopes are checked for conformity with the permissible limits.
It is also advisable to check the twist (Angular deflection) angle (a). The angle depends
upon the spindle length, and the power transmitted (kW).

Table 5.3: Angular deflection (a ) per meter and spindle f for solid and hollow spindles

Shaft type Max. angular deflection a°/metre Spindle f mm

[Divide by 25.4 for Inch equivalent]

kW
Solid 0.25° D = 128 4
RPM

kW
0.35° D = 118 4
RPM

kW
Hollow 0.25° D 4 - d 4 ≥ 2.742 ¥ 108
RPM
kW
0.35° D 4- d 4 ≥ 1.959 ¥ 108
RPM

D = Outside f of shaft - (mm)

d = Inside f of shaft - (mm)
kW = Power in kilowatts; R.P.M. = Revs/min
Example 5.6: Find the diameters for:
1. Solid shafts for transmitting 5 kW at 200 R.P.M., with angular deflection of 0.25° and
0.35°.
2. Hollow shafts, if inside f = 30
Solution:
5
1. For 0.25°, D = 128 4 = 50.9 ~ 51
200
5
For 0.35°, D = 118 4 = 46.92 ~ 47
200
2. d 4 = 304 = 810000
5
For 0.35°, D 4 = 1.959 ¥ 108 ¥ + 810000
200
358 Machine Tools Handbook

D= 4 570.75 ¥ 10 4 = 48.90

5
For 0.25°, D 4 = 2.742 ¥ 108 ¥ + 810000
200

D= 4 766.5 ¥ 10 4 = 52.6

5.1.3 Critical speed

Deflections resulting from external loads and the weight of the spindle itself, generate centrifugal
forces. Their values depend upon the radius of rotation (deflection) and the angular velocity (w).
Centrifugal force = Weight ¥ w2d
= Area ¥ Density ¥ w2d
At very high speed, the centrifugal force momentarily causes very detrimental, high-
vibration resonance. This speed is called the critical speed for the particular spindle.
Usually, the spindle has a number of steps where the cross-sectional area is different. Under
such circumstances, each step of a uniform cross-section is converted to a concentrated,
weight-acting mid-length. Thus, theoretically it becomes a weightless shaft, with a number of
concentrated loads at various points. There will be a number of critical speeds. But we have
to consider only the first critical speed, to keep the highest spindle speed at less than 20% the
first critical speed. Figure 5.5b gives the formulae for finding critical speeds under various
load dispositions, and spindle supporting systems. If the length of the bearing (l ) is longer
than 0.3 of the bearing bore (d ), the bearing is considered long and stiff, i.e., a rigid fixed
point. Bearings, shorter in length, are considered simply-supported points. Self-aligning
bearings are also considered simply-supported points.
Brg. length < 0.3 d …. Simply supported beam (short length bearing)
Brg. length > 0.3 d …. Fixed beam (Stiff, rigid bearing)
Example 5.7: Find the critical speed for a 50 f spindle, carrying 100 kgf overhung load, at
40 mm from the nearest bearing. State the constraints posed by the critical speed, if the
spindle is supported by rigid bearings, which can be considered fixed points.
Solution:
Referring to [Fig. 5.5b],
d2
NC = 5.26 ¥ 104
1 W1
502
= 5.26 ¥ 104 ¥
40 100 ¥ 40
 Machine Tool Elements 359
2500
= 5.26 ¥ 104 ¥
2529.8
= 51980 Revs/min
Spindle speed should either be more than 62376 (1.2 ¥ 51980) or less than 41584
(0.8 ¥ 51980) RPM.

Fig. 5.5(b): Critical speeds

[1≤ = 25.4 mm] [1 Lb = 0.45 kg]