APPENDIX I

DESIGN OF MULTI-SPINDLE
DRAG FINISHER

A PROJECT REPORT

Submitted by

DEEPIKA R
SUNANDA S
VICKNESHVARI R M

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING GUINDY

ANNA UNIVERSITY, CHENNAI
JANUARY 2022

i
 APPENDIX 2

ANNA UNIVERSITY, CHENNAI

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN OF MULTI-SPINDLE

DRAG FINISHER” is the bonafide work of “DEEPIKA R (2019111019),

SUNANDA S (2019111093) and VICKNESHVARI R M (2019111106)” who

carried out the project work under my supervision.

Dr. D. SAMUEL RAJ

Guide and Associate Professor,

Department of Mechanical Engg.,

College of Engineering, Guindy,

Anna University,

Chennai – 600 025.

ii
 ANNA UNIVERSITY

CHENNAI – 600 025

ABSTRACT

Degree and Branch : BACHELOR OF ENGINEERING

(MECHANICAL ENGINEERING)

Month and Year of submission : January 2022

Title of the project : DESIGN OF MULTI-SPINDLE

DRAG FINISHER

Name of the students : DEEPIKA R (2019111019)

SUNANDA S (2019111093)
VICKNESHVARI R M (2019111106)

Name and Designation of the guide : Dr. D. SAMUEL RAJ,

Guide and Associate Professor,
Department of Mechanical Engg.,
College of Engineering, Guindy,
Anna University,
Chennai -600 025

iii
 Drag finishing is a developing manufacturing process that can increase

the life of the cutting tool. The primary aim of this project is to design a

compact and economical Drag finisher with special arrangement of workpiece

holders, that can finish multiple drill bits simultaneously. The epicyclic gear

system is adapted for the power transmission. Furthermore, an adjustable

vertical arrangement is provided to vary immersion depth of the cutting tool.

The individual components are designed in a CAD software. Depending on the

working conditions and the purpose required, the materials for the components

are selected. Static structural analysis of the design is carried out. Based on the

calculations, the boundary conditions for the Static analysis are known. The

results from the analysis are analyzed for optimizing the structure.

Signature of the students,

DEEPIKA R

SUNANDA S

Place: Chennai

Date: 22.01.2022 VICKNESHVARI R M

iv
 ACKNOWLEDGEMENT

The success and final outcome of this project required a lot of guidance
and assistance from many people and we are extremely fortunate to have got
this all along the completion of our mini project work. Whatever we have done
is only due to such guidance and assistance.

We respect and thank Dr. D Samuel Raj, Associate Professor,

Department of Mechanical Engineering, College of Engineering Guindy, Anna
University, Chennai, for giving us an opportunity to do the mini project work,
for invigorating the spirit in us, guiding and channelling all the efforts and
energy in right direction for completing this mini project.

We would like to express our special thanks to Mr. S. Joyson

Selvakumar, Teaching Fellow, Department of Manufacturing Engineering,
College of Engineering Guindy, Anna University, Chennai, for his support and
encouragement for our mini project.

We would like to express our profound gratitude to Mr. C.

Balamurugan, Associate Professor, College of Engineering Guindy, Anna
University, Chennai, for his valuable suggestions.

We convey our sincere thanks to all the staff members, friends,

department seniors and well-wishers for their continued support and suggestions
in all aspects of the project work. We submit our gratitude to our parents
without whom nothing would have been possible.

v
 APPENDIX 3
TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO.

ABSTRACT iii

LIST OF TABLES xvi

LIST OF FIGURES xviii

LIST OF SYMBOLS, ABBREVIATIONS xxvii

1 INTRODUCTION 1

1.1 SCOPE 1

1.2 IMPORTANCE 1

1.3 BASIC CONCEPT 2

2 LITERATURE REVIEW 3

2.1 GENERAL 3

2.2 LITERATURE SUMMARY 5

2.3 NEED AND OBJECTIVE OF PRESENT WORK 5

3 METHODOLOGY 6

3.1 GENERAL 6

3.2 DESIGN ABSTRACT 6

3.3 PRELIMINARY DESIGN CALCULATIONS 7

3.3.1 SPEED CALCULATIONS 7

3.3.2 TORQUE CALCULATION 9
3.3.3 BEARING SELECTION 9

3.4 STATIC STRUCTURAL ANALYSIS 11

vi
4 MODELING 12

4.1 2D SKETCH 12

4.2 3D MODELING 12

4.2.1 SUPPORTS 12
4.2.2 SPUR GEARS 13
4.3.2.1 SUN GEAR 14
4.3.2.2 PLANET GEAR 14
4.2.3 CARRIAGE 15
4.2.4 GEAR OUTPUT SHAFT 15
4.2.5 LOWER SHAFT 16
4.2.6 SHAFT KEY 16
4.2.7 DRUM 17

4.3 OEM COMPONENTS 17

4.3.1 DRILL CHUCKS 17

4.3.2 DC MOTOR 18
4.3.3 MOTOR CONTROLLER 19
4.3.4 FASTENERS 19
4.3.5 BEARING 20

5 ASSEMBLY 21

5.1 ASSEMBLY FLOWCHART 21

5.2 ASSEMBLY IN SOLIDWORKS 22

5.3 MOTION STUDY 22

6 MATERIAL SELECTION 24

6.1 GENERAL 24
6.2 MATERIAL SELECTION 24

vii
 6.3 MATERIAL PROPERTIES 25

7 ANALYSIS 26

7.1 GENERAL 26

7.2 ASSIGNING MATERIAL 26

7.3 BOUNDARY CONDITIONS 27

7.4 EXTERNAL LOADS 28

7.5 CREATING MESH 28

7.6 SIMULATION RESULTS 29

7.6.1 STRESS 29
7.6.2 STRAIN 30
7.6.3 DISPLACEMENT 30

7.7 RESULT AND DISCUSSION 31

8 CONCLUSION 32

REFERENCES 33

viii
 LIST OF TABLES

TABLE NO TITLE PAGE NO

1 Table of motions 8

2 Dimensions of SKF 6201 Ball Bearing 20

3 Material properties 25

4 Results of Static Structural Analysis 31

ix
 LIST OF FIGURES

FIGURE NO TITLE PAGE NO.

1 Surface structure before and after polishing 1

2 Dependence of Drag finishing on the size of the 3

cutting radius

3 2D Sketch 12

4 Supports 13

5 2D Sketch of spur gears 13

6 Sun gear 14

7 Planet gear 14

8 Carriage 15

9 Gear output shaft 15

10 Lower shaft 16

11 Shaft key 16

12 Drum 17

13 Drill chuck with key 18

14 24V DC Motor 18

15 Motor controller 19

16 Fasteners 19

17 Ball Bearing dimensions 20

x
18 SKF 6201 Bearing 20

19 Assembly in SOLIDWORKS 22

20 Motion analysis 23

21 Path tracer 23

22 Material assignment 26

23 Fixed support 27

24 Hinged support 27

25 External load 28

26 Creating mesh 28

27 Stress results 29

28 Strain results 30

29 Displacement results 30

xi
 LIST OF ABBREVIATIONS

AISI - American Iron and Steel Institute

CAD - Computer Aided Design

CAE - Computer Aided Engineering

DC - Direct Current

DLC - Diamond Like Carbon

EN - European Norms

GI - Galvanized Iron

MS - Mild Steel

OEM - Original Equipment Manufacturer

RPM - Revolutions Per Minute

PCD - Pitch Circle Diameter

PU - Polyurethane

PVD - Physical Vapour Deposition

PWM - Pulse Width Modulation

xii
 CHAPTER 1
INTRODUCTION

1.1 SCOPE
Today's rapid industrialization aims at increasing productivity and
reducing machining costs. For high productivity, tools are modified
technologically to achieve longer durability. In order to achieve that, it is
important to use cutting edge preparation methods to modify the cutting edge.
One of the methods for modification of the radius of the cutting edge is the drag
finishing process. The primary objective of this mini project is to build a setup
that can modify the cutting edge of drills.

1.2 IMPORTANCE

Drag finishing of cutting tools offers higher processing parameters i.e.,

feed rates, chipping volume. It provides better surface finish to the workpiece
after processing due to reduced surface roughness.

Figure 1 : Surface structure before and after polishing

1
 With brittle materials such as carbide, the sharp edge tends to flake and
wear quickly, especially when under a heavy load. From researches, it is found
that rounding the cutting edge of drill bits considerably stabilizes the edge and
increases tool life and reliability significantly.

1.3 BASIC CONCEPT

In Drag finishing, the workpieces (drills, in this project) are fixed in a
special arrangement of workpiece holders. Holders are then dragged in circular
motion through the container that is filled with the loose abrasive or polishing
media. This high-speed motion generates high contact pressure between the
drills and the media, which in a very short time produces good results in the
form of high-precision edge rounding and smooth finish.

2
 CHAPTER 2

LITERATURE REVIEW

2.1 GENERAL

Jozef Peterka (2020) investigated the dependence of the drag finishing

time on the size of the cutting-edge radius. During the first ten minutes of the
drag finishing, the cutting-edge radius was increasing steadily in an almost
linear fashion. After passing this first phase, increase of the cutting-edge radius
stabilized and became considerably slower. After 10 minutes the size of cutting-
edge radius was approximately 15 μm and when the drag finishing time was 100
minutes the size of cutting-edge radius increased only to size 30 μm.

Figure 2 : Dependence of drag finishing on the size of the cutting radius

Zone from 0 to 10 min - sharp increase of cutting-edge radius.

Zone from 10 to 90 min - a relatively linear increase of cutting-edge radius.
Zone from 90 to 100 min - sharp increase of cutting-edge radius

3
 Jaroslava Fulemova and Zdeněk Janda (2014) analyzed the influence
of cutting-edge preparation and cutting-edge radius on tool life and cutting
forces. The tool which was treated by drag finishing has almost 60% better tool
life than grinded tool. After removing the volume 6 cm3 the tool wear of the tool
with edge radius 5 μm is almost 0.085 mm and the tool wear on the tool with
edge radius 15 μm is around 0.035 mm. The cutting forces are increasing with
the volume of removed material (with increasing tool wear)

The tool with the edge radius 15 μm reached the highest tool life, the
lowest roughness of machined surface and the lowest force load in comparison
to the tools with edge radius 5 and 10 μm.

V.K. Jain (2001) investigated the influence of circumferential speed of

workpiece on material removal and change in surface roughness value (Ra).
Change in Surface finish and material removal increases as the circumferential
speed of the workpiece (or cutting velocity) increases. It is so because the
number of the grains in contact with the workpiece increases which results in
increased surface finish.

Marek Vozár (2019) gave an overview on methods of Cutting-edge

preparation. Wet finishing is important for operations with certain sort of
workpieces to prevent clogging of the media and maintaining efficiency of the
finishing process. The main use of dry finishing process is for surface polishing.
Movement of the workpieces in the abrasive creates friction that causes material
removal and achieving high surface quality. The type and size of the abrasive
media used for drag finishing cutting tools are some of the key factors
influencing the size of achievable cutting-edge radius, as well as the process
time needed to achieve desired cutting-edge radius.

4
2.2 LITERATURE SUMMARY

From the literature review, we could infer that increasing the drag
finishing time increases the cutting-edge radius. The increase in the cutting
radius increases tool life, decreases roughness of machined surface and the
cutting force. Increasing the cutting velocity increases change in surface finish
and material removal. The type and size of the abrasive media influences the
time taken to achieve the required cutting radius.

2.3 NEED AND OBJECTIVE OF PRESENT WORK

Drag finishing is done on the coated drills achieving higher surface

quality resulting in longer durability of the coating which allows for higher tool
life. The ultimate aim of the mini project is to design a compact Multi Spindle
Drag Finisher that can drag finish five drills simultaneously, with adjustable
vertical arrangements that affect the performance due to variable immersion
depth.

5
 CHAPTER 3

METHODOLOGY

3.1 GENERAL

This chapter discusses the methodology adopted for addressing various

tasks involved in design of multi spindle drag finisher, static load analysis of
spur gears and optimization of process parameters. The following flowchart
shows the steps involved in the proposed work.

Calculating design parameters

Designing the components in SOLIDWORKS

Static analysis in SOLIDWORKS simulation

Optimising the design and iterating

Results and discussion

3.2 DESIGN ABSTRACT

Designing a multi spindle drag finisher primarily requires designing a

motion transmission mechanism that can transfer rotational motion from a

6
single shaft to multiple drills. The required motion can be obtained by using
epicyclic gear transmission system.

The drill chuck is connected to a shaft. The shaft is connected to a spur

gear that acts as planet gear in the motion transmission. Five such shafts are
held by a planet carriage. To allow the rotation of the shaft, a bearing is fitted
between each shaft and the carriage. The five planet gears are made to mesh
with a larger gear that act as the sun gear. The sun gear is held stationary. The
output shaft from the motor is connected to carriage.

The rotational motion of the motor is transmitted to the carriage. The

rotation of the carriage forces the shaft to move. The planet gears which are in
mesh with the sun gear rotate about their own axes. Thus, the rotation of the
planet gear rotates the drill connected to the shaft.

3.3 PRELIMINARY DESIGN CALCULATIONS

Designing the components of Drag finisher require several design

parameters. The calculations of which are discussed here. After experimenting
with dimensions, the calculations are repeated according to the required design
changes.

3.3.1 SPEED CALCULATIONS

Module of the Spur gears are taken as 1.5

PCD of Sun gear, DS = 150 mm

Number of teeth on the Sun gear, TS = 150 / 1.5 = 100

PCD Of Planet gears, DP = 30 mm

Number of teeth on the Planet gear, TP = 30 / 1.5 = 20

7
 Table 1 : Table of motions

Step Revolution of elements

Condition of motion
No Arm A Sun gear S Planet gear P
Arm A fixed; Sun gear S
𝑇𝑠
1 rotates through +1 revolution 0 +1 -
𝑇𝑝
(i.e., 1 rev anticlockwise)
Arm A fixed, Sun gear S 𝑇𝑠
2 0 +𝑥 -x ×
𝑇𝑝
rotates through +x revolutions
Add +y revolutions to all
3 +y +y +y
elements
𝑇𝑠
4 Total motion +y x+y +y - x ×
𝑇𝑝

Speed of Arm is the output speed of the DC motor

 NA = 80 rpm
 y = 80
Sun gear remains stationary

 x+y=0
 x = -80
Speed of Planet gears = y – x (TS/TP)

= 80 – (-80) (100/20)

= 480

The drills connected to the planet gears revolve at a speed of 480 rpm when the
output speed of the DC motor is 80 rpm

8
3.3.2 TORQUE CALCULATIONS

To torque acting on the carriage is calculated,

Output speed of motor, N = 80 rpm

Power, P = 250 W

Angular velocity, ω = 2× π × N / 60

= 2× π × 80 / 60

= 8.37 rad / sec

Output Torque = P / ω

= 250 / 8.37

= 29.86 Nm

3.3.3 BEARING SELECTION

Axial load, Fa = 4.78 N

Radial load, Fr = 66.35 N

Speed, n = 480 rpm

Life, Lh10 = 36500 hrs.

Rated life L10 = 1051.2 million revolutions

The minimum diameter of the shaft is taken to be 12mm

The Bearing SKF 6201 with inner diameter 12mm is considered for selection

9
Dynamic capacity, C = 7280 N

Static capacity, C0 = 3100 N

Fa / C0 = 0.001542

e = 0.1887

Fa / Fr = 0.072

Fa / Fr < e

X =1

Y =0

Service factor, S = 1.8

Equivalent load, P = (XFr + YFa) S

= (1×66.35 + 0×4.78) 1.8

= 119.43 N

Required basic dynamic capacity, Cr = (L10)0.33 P

= (1051.2)0.33 × 119.43

= 1214.31 N

Cr < C

Hence, the Deep Groove Ball Bearing SKF 6201 is safe to use

10
3.4 STATIC STRUCTURAL ANALYSIS

Static load analysis is carried out in SOLIDWORKS. The spur gears are
assembled and the materials are assigned. Appropriate boundary conditions are
given. Fine mesh is given for the regions where the gears mesh together. Then
the static study is solved. The stress, strain and deformation values are obtained.
The steps involved are shown in the following flowchart.

Import the model

Assign the material properties

Choose Static load analysis

Set Boundary conditions

Mesh the model

Apply safety load

Solve and obtain results

11
 CHAPTER 4

MODELING

4.1 2D SKETCH

A 2D sketch is drawn initially which helps in determining the dimensions

of the components to be designed, considering all the constraints involved.

Figure 3 : 2D Sketch

4.2 3D MODELING

The components of the Drag finisher are designed in the SOLIDWORKS

software in such a way they facilitate the manufacturing process.

4.2.1 SUPPORTS

The supports are structural members that provide stability to the entire setup.
The work bowl is placed over the flat metal base. The multi spindle
arrangement is supported by the topmost parallel metal tube. The dimensions of

12
the rectangular pipes are chosen in such a way that the motor along with the
motor controller can be accommodated over it.

Figure 4 : Supports

4.2.2 SPUR GEARS

For the best results the drills are required to operate at an optimal speed
range of 300-500 rpm. The speed of the carriage is restricted to a maximum of
80 rpm. Thus, the gears are designed considering these constraints.

With a pre-installed rotating drum of fixed dimension, the PCD of the

gears are chosen in such a manner that the drills always remain in the annulus
region of the drum.

Figure 5 : 2D Sketch of Spur gears

13
4.3.2.1 SUN GEAR

The sun gear is bolted to the metal tube. The motor output shaft passes
through the hole which is drilled through the axis of the spur gear. The sun gear
remains stationary throughout the process.

Figure 6 : Sun gear

4.3.2.2 PLANET GEARS

The planet gears are meshed with the sun gear and are attached to the
carriage with the help of a shaft. As a result of which the planet gears rotate
about their own axis and revolve about the axis of the sun gear when the
carriage is rotates.

Figure 7 : Planet gear

14
4.2.3 CARRIAGE

The Carriage acts as the primary rotating component. The shaft from the
motor is welded to centre of the carriage. The carriage supports the majority of
the weight.

Figure 8 : Carriage

4.2.4 GEAR OUTPUT SHAFT

Upper end of the gear output shaft is locked with the planet gear and the
lower end is bolted to the lower shaft. Three slots are provided for the purpose
of adjusting the depth in which the drills are immersed in the abrasive media.

Figure 9 : Gear output shaft

15
4.2.5 LOWER SHAFT

The lower shaft acts as a connector between the gear output shaft and
drill chuck. The lower shaft is provided with external thread that mates with the
drill chuck.

Figure 10 : Lower shaft

4.2.6 SHAFT KEY

The shaft key acts as an integral part in connecting the planet gear and the
gear output shaft. The key ensures that the shaft transmits the rotation without
slipping.

Figure 11 : Shaft key

16
4.2.7 DRUM

The drum consists of the powdered abrasive particles which are confined
to the annulus region. The drum rotates about its own axis, thus increasing the
relative motion between the abrasive particles and the drills. The rotation of the
drum considerably extends the life of the process medium ensuring constant
process quality.

Figure 12 : Drum

4.3 OEM COMPONENTS

Apart from the components that are designed and fabricated, there are
several components that are procured from OEM manufacturers. They are listed
below.

4.3.1 DRILL CHUCK

Drill chuck is a device used to hold the drill bit. The jaws can be
conveniently tightened and loosened with the help of a key. This also helps in
accommodating drills of different sizes.

17
 Figure 13 : Drill Chuck with key

4.3.2 DC MOTOR

Figure 14 : 24V DC Motor

A Brushed DC motor is used to provide rotatory motion and power to the

arrangement. The specifications of the motor are listed below:

• Voltage: 24 Volt DC.

• Output: 250 Watt.
• RPM (after Reduction) – 300.
• Full load current – 13.4A.
• No load Current – 2.2A.

18
 • Torque Constant – 8 Nm (80 kg-cm).
• Torque stall – 40 Nm (400 kg-cm).

4.3.3 MOTOR CONTROLLER

Figure 15 : Motor controller

The 20A PWM DC Motor Speed Regulator Module (9V, 12V, 24V, 36V,
48V, 60V) is used for the brushed DC motor. The potentiometer in the motor
controller can adjust the speed, torque and direction of the rotation in the motor
output. It has an adjustable speed range ranging from 0% to 100%

4.3.4 FASTENERS
M6 Hex bolts and nuts are used to connect the upper and lower shafts as
well as to connect the sun gear with the supports

Figure 16 : Fasteners

19
4.3.5 BEARINGS

Based on the calculation under given load conditions and design

constraints, SKF 6201 Deep Groove Ball Bearing is chosen.

Figure 17 : Ball bearing dimensions Figure 18 : SKF 6201 Bearing

Table 2 : Dimensions of SKF 6201 Ball Bearing

d 12 mm Bore diameter

D 32 mm Outer diameter

B 10 mm Width

d1 18.45 mm Shoulder diameter

D2 27.34 mm Recess diameter

r1,2 Min 0.6 mm Chamfer dimension

20
 CHAPTER 5

ASSEMBLY

5.1 ASSEMBLY FLOWCHART

The Multi spindle drag finisher consists of many components that are assembled
together. The flowchart drawn below shows the sequential order in which the
components are assembled from the beginning to the end.

Carriage

Bearings

Supports

Gear output shaft

Sun gear

Planet gear
Bolts

Shaft key

Lower shaft

Bolts

Drill chuck

21
Drill bit
5.2 ASSEMBLY IN SOLIDWORKS

The CAD models of the components are assembled in SOLIDWORKS.

The sun gear is bolted to the supports. The planet gears are attached to the gear
output shafts through a keyway connection. The bearings are fitted into the
carriage and the gear output shafts are inserted into the bearings. Five planet
gears are meshed with the sun gear, which then undergoes rotation as well as
revolution. The lower shafts are bolted with the gear output shafts. The drill
chuck is attached to the lower shaft.

Figure 19 : Assembly in SOLIDWORKS

5.3 MOTION STUDY

Motion of the entire assembly model is graphically simulated in

SOLIDWORKS Animation. Mates given in the assembly allow the motion of
components during simulation. Motion studies simulate and animate the motion
that is prescribed for a model.

22
 Figure 20 : Motion analysis

The path traced by the edge of the cutting tool is traced in

SOLIDWORKS Motion study. The drills rotate about their own axis and
revolve about the mean centre of all the drills. The combined motion makes the
tip of the cutting tool trace the path of a curve. The curved path traced by the
tool edge is shown in the figure 21.

Figure 21 : Path tracer

23
 CHAPTER 6

MATERIAL SELECTION

6.1 GENERAL

The materials to the designed components are assigned with the idea of
minimizing the cost while meeting the performance goals at the same time.
Other criteria including availability and manufacturing efficiency are also taken
into account.

6.2 MATERIAL SELECTION

For the spur gears, the material 16MnCr5 is chosen, owing to its strength,
ductility and wear resistance. With relatively good impact properties at low
temperatures, 16MnCr5 is suitable for gears.

For the carriage, the material EN 24 (equivalent to AISI 4340) is chosen

for its high tensile steel strength. Even as the carriage carries most of the
weight, EN 24 prevents bending of the carriage flanges due to the load it carries.

For the gear output and lower shafts, EN8 (equivalent to AISI 1040) is
used. EN 8 has good tensile strength and can be surface-hardened to produce
components with enhanced wear resistance. Also, EN 8 is readily machinable in
any condition.

As the drum carries the powdered abrasives and rotates at a high speed, it
is required that the material must be wear resistant. Galvanised Iron has high
hardness making it wear resistant and is used for the drum.

24
 Mild steel rectangular pipes are used for the supports. MS is ideal for
welding and fabrication of the supports

6.3 MATERIAL PROPERTIES

The physical and mechanical properties of the materials selected are

given in the table 3.

Table 3 : Material properties

MATERIAL 16MnCr5 EN 24 EN 8 GI MS
Components Spur gears Carriage Shafts Drum Supports
Mass Density
7800 7830 7850 7850 7750
(Kg/m3)
Ultimate Tensile
1230 1000 560 560 400
Strength (N/mm2)
Yield Strength
950 680 460 470 320
(N/mm2)
Poisson’s ratio 0.284 0.33 0.285 0.29 0.31

25
 CHAPTER 7

ANALYSIS

7.1 GENERAL

Design of the components can be validated only if it can withstand the

external forces it experiences under working conditions. CAE analysis is carried
out in SOLIDWORKS. The behavior of the parts under the given conditions is
simulated and the results are observed.

7.2 ASSIGNING MATERIAL

The gears are assembled by giving appropriate mating conditions and

checked for interference. The assembled model is imported in SOLIDWORKS
Simulation. The static structural analysis is chosen. The material 16MnCr5 is
assigned for all the components.

Figure 22 : Material assignment

26
7.3 BOUNDARY CONDITIONS

The center of the Sun gear is selected for the fixed geometry. It can resist
horizontal and vertical forces as well as the moment.

Figure 23 : Fixed support

The inner cylindrical faces of the planet gears are given hinged supports
so that they can only rotate about its own axes.

Figure 24 : Hinged Support

27
7.4 EXTERNAL LOADS

A calculated torque of 29.86 Nm is applied on the cylindrical surfaces of

the planet gears. The torque acts about the axis of the Sun gear.

Figure 25 : External load

7.5 CREATING MESH

Figure 26 : Creating mesh

28
 Coarse mesh is created for the entire components and using mesh control
fine mesh of size 0.2 mm is created for the faces of the gear that mesh with each
other. Fine mesh provides more accurate results.

7.6 SIMULATION RESULTS

The required outputs are displayed in the form of contours. The design is
validated by analyzing the stress, strain and displacement the component
underwent during the given conditions.

7.6.1 STRESS

The simulation result from the Von Mises stress analysis displays the
maximum and minimum stress experienced by the gears when external load is
applied.

Figure 27 : Stress results

29
7.6.2 STRAIN

The maximum magnitude of strain experienced by the gears is displayed

in the figure 20.

Figure 28 : Strain results

7.6.3 DISPLACEMENT

The result from the displacement analysis shows the region undergoing
maximum displacement under the given conditions.

Figure 29 : Displacement results

30
7.7 RESULTS AND DISCUSSION

The results from the Static structural analysis of the Spur gears are
presented in the table 4.

Table 4 : Results of Static Structural Analysis

Maximum stress 3 MPa

Maximum strain 7.2 × 106
Maximum deformation 0.2 mm

The maximum stress the components experience is less than their yield
strength. Thus, the components will not encounter failure. Also, the maximum
deformation is negligible which suggests that the external forces cannot affect
the working of the system. It is inferred from the table that the components can
withstand the conditions.

31
 CHAPTER 8

CONCLUSION

In this project, a Multi-Spindle Drag Finisher is designed by using

computer aided design software package. The materials for the components are
chosen considering their mechanical properties. After the static load test, which
was carried out in SOLIDWORKS software, the best design was achieved after
several design changes. Depending on the output required, the immersion depth
and the speed of rotation of the cutting tool can be varied. Based on the need,
the number of drills that can be accommodated can be altered. The final design
is satisfactory in functional, economical and load carrying aspects

32
REFERENCES

[1] Lummus, J. (1970), 'The journal of Canadian Petroleum’, Factors to be

Considered in Drilling Optimization, pp. 1379-1389

[2] Malkorra, I. and Souli, H. (2021) 'Surface Integrity in Machining and

Post-processing', Modelling of Drag Finishing—Influence of Abrasive
Media Shape, 5(2), pp. 41

[3] Monkova, K. (2018) Manufacturing Technology, Tool life investigation

of the thread making tools, Vol.18, No.5., pp 787-792. ISSN 1213-2489

[4] Patel, D. and Verma, R. (2015) 'International Journal of Mechanical

Engineering and Robotics Research', Analysis of Drilling Tool Life,
Vol.4, No.1, pp. 523-539

[5] Peterka, J., Pokorny, P., Vaclav, S., Patoprsty, B. and Vozar, M. (2020)
'Development of effective methods for correction and optimization of
coupled mechanical systems', Modification of cutting tools by Drag
Finishing, pp. 3822-3825

[6] Rounding of cutting edges, OTEC Präzisionsfinish GmbH (2019)

Germany, [online]
https://www.otec.de/en/finishing-processes/rounding/

[7] Span, J. (2017) Free Abrasive Finishing Non-Newtonian Shear

Jamming, McMaster University, Hamilton, Ontario, pp. 1-39

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