Modeling and Design Analysis of a Deep Hole Internal Grinding Machine

Abstract

Cylindrical parts with deep holes and thin-wall structures are the backbone in the field of aerospace, such as sleeves, actuators, and landing gears of aircraft. In precise, the machining process of inner holes with small bores, large depth to diameter ratios (${>} {7}{-}{8}$), and intricate interiors such as multi-stepped surfaces and arc surfaces is more problematic, which realized the significance of the grinding of such deep holes.

In this research, a structure of a deep hole internal grinding machine is introduced. The modal of the machine structure is designed in CREO-Parametric software, and afterward, the designed modal is carried out through the static and dynamic analyses using ANSYS FEA software to access structural behavior and authenticate the structural stiffness to acquire a high level of precision machining. The maximum directional deformation we got is about 0.036266 mm across the machine structure along X-axis, and the overall deformation of the structure is 0.065515 mm. The vital structure, concerned with the excellence of machining for this grinding machine, is of the internal grinding tool because of the length of more than 900 mm and the complicated design of the structure with a restricted outer dimension. The tool structure is constructed and also carried out through a separate stiffness analysis. After analysis, quite a few enhancements have been made to reduce deformation by heighten the structural stiffness of the tool shaft and machine structure, and also provide the replacement of a motorized spindle with a belt and motor drive system of a tool to segregate the effects of vibrations and forces on machining quality due to driving mechanism. The deformation of shaft structure happened in the gravity direction is 0.042381 mm and in the cutting force direction 0.036707 mm.