Research, Design and Develop a prototype of Multi-Spindle Drilling Head

Journal of Science & Technology 127 (2018) 029-034 29 Research, Design and Develop a prototype of Multi-Spindle Drilling Head Bui Ngoc Tam*, Tran Van Dich Hanoi University of Science and Technology, No. 1, Dai Co Viet, Hai Ba Trung, Hanoi, Viet Nam Received: August 25, 2017; Accepted: June 25, 2018 Abstract In recent years, the study of machine tool technology has got strong attention to expand development in universities, research institute and also in industry. However, there are a few publications/papers related a design and application of the multi-spindle drilling which flexibly adjusts parameters such as the number and the position of holes. In this research, the author will present a new design of a multi-spindle drilling head that uses Cardan universal joint for driving in order to increase productivity, decrease product expenses. To check the principle of working after simulation we developed a prototype of Multi-Spindle drilling head in this research. Keywords: Tool machine, multi-spindle drilling, drill systems, Cardan universal joint 1. Introduction* Multi-spindle Drilling machines are used in mechanical industry in order to increase the productivity of machining systems. Such machines are equipped with spindle heads that carry multiple tools for performing machining operations. The most noteworthy aspect when using multi-spindle machines is the cycle time, due to parallel machining, the total operating time is dramatically decreased. Added benefits include less chance for error, less accumulated tolerance error, and eliminate tools changes. In such a multi-spindle machine, a part to be machined is fixed on the table. It is not possible neither to fix two or more parts on the table or use two or more tables on the same machine. Thus, in every moment only one part can be present on such a machine. Throughout the survey in some mechanical factories of the mechanical flange machining which contains many holes arranged in a circle which is able to change the dimension shown in Fig. 1. Most of them have the low productivity because of using only one drill each time. Furthermore, the mechanical flange joint has a variety of dimensions, therefore it is very difficult to create the specialized attachment of each one because of cost. It is required to design the flexible drilling technology system which is able to drill multiple positions in one technological step while adjusting for the different diameters number of holes. Nowadays, more and more countries in the world are applying the technical achievements to manufacturing practice. This significantly decreases * Corresponding author: Tel.: (+84) 987.824.828 Email: tam.buingoc@hust.edu.vn the labor expenses, quickly responds to the demands of society, and competes on price and labor productivity. Fig.1. Illustration of the part Literature has been studied regarding the Multi- spindle drilling operation as follows: [1] Studied on Design & development of multi-spindle drilling head. In this case study, they developed SPM for drilling two holes simultaneously. Fixed Multi-spindle Drilling Head can be of fixed center construction for mass and large batch production and for batch production, adjustable center type design is offered. Planetary gear train type adjustable multi-spindle drilling head is used [2-4]. Twin-spindle drilling machines are used for mass production, a great time saver where many pieces of jobs having two holes are to be drilled [5]. The multi-spindle drilling attachment three spindles is driven simultaneously which carry three dill chunks [6]. A. M. Takale, V. R.Naik [7] studied about design and manufacturing of multi- spindle drilling head and cycle time optimization, the machine used for multi-spindle drilling head is same Journal of Science & Technology 127 (2018) 029-034 30 (Radial drilling machine) which presently uses to produce the part, so machine hour rate remains unchanged. Olga Guschinskaya, Alexandre Dolgui, Nikolai Guschinsky, and Genrikh Levin [8] studied about Scheduling for multi-spindle head machines with a mobile table. Most of previous studies on multi-spindle drill focus on the specific of part production which fixes the position of multi-holes (as shown in Fig. 2 the dimension 1=2=constant). It means that if there is a new part with the different dimension that drill system can’t be used, we have to design the new one. To overcome this limitation, in this paper, we will design a new drill system that is able to drill multiple positions in one technological step while flexibly adjusting the different diameters number of holes shown in Fig. 2. The paper is organized as follows: Section 2 proposes the principle of multi-spindle drill head; Section 3 will present the calculation and software simulation; Section 5 introduces the prototype and results; Section 6 gives conclusions and future work. Ø1 Ø 2 Fig. 2. Flange machining contains many holes 2. Proposed methodology This section, we will propose the principle of the multi-spindle drilling that can solve mission drill multiple positions in one technological step while flexibly adjusting for the different diameters number of holes. The main new idea follows: To propose the mechanical project ideas, then calculate, simulate, and optimize the mechanism of the simultaneous multi-position drilling system. To export the design drawings, manufacturer, plans to prepare for the process of manufacture and test. To transfer technology to the local mechanical factories. To serve teaching and research for the mechanical engineering student. There are some ways to drill multiple locations at once, for example, use gear systems multiple drills at the same time or the cardan joints (Universal Joint) systems. Cardan joints are common devices for transmitting motion between misaligned intersecting axes. Their capability of easy mounting, resisting high loads, and commercial availability makes them an attractive problem [9-15]. This research, we use Cardan joints (Universal Joint) systems shown in Fig. 3 combine with gear systems to design the Multi-Spindle drilling head. The Fig. 4 shows how we can drill multiple locations at once and flexibly adjust for the different diameters. The double cardan joint: The double cardan joint includes two objects: the cardan joint K1 and K2 shown in Fig. 4. We will compute kinematics of the double cardan joint. Fig. 3. Cardan shaft (Universal Joint) Fig. 4. double cardan joint. The cardan joint K1: ( ) ( ) ( )1 3 1tan tan .cos  = (1) The cardan joint K2: ( )3 3 1tan tan .cos 2 2          + = +        (2) ( ) ( ) ( )2 3 2tan tan .cos   = (3) ( ) ( )1 2 2 cos tan tan . cos a    = (4) Journal of Science & Technology 127 (2018) 029-034 31 In this case, the rotational speed of Cardan shaft is constant. 3. Simulation and Calculation 3.1. Design and simulate the mechanism of the simultaneous multi-position drilling system We use Inventor software to build a simulation of Multi-Spindle drill systems shown in Fig. 5 and Fig. 6. In the Fig. 5, the spindle position can be adjusted to center or far from the center of the main gear. The Fig. 6 shows the connection between gear systems and cardan joints for the principle of working. The overall of multi-spindle drill head was presented in Fig. 7. Fig. 5. The principle of multi-position drilling Fig. 6. Simulation of multi-position drilling Fig. 7. Modal of multi-position drilling 3.2. Compute the durability and power of the drilling system We will check the durability for cardan shaft [15]. The parameters of our proposed Cardan joint (see Fig. 8) are given values in Table 1. Input dynamic parameters: cutting drill hole with the diameter D=11 mm, material carbon steel C45 (HB = 170), feed rate: S = 0.12-0.20 mm/Rev [16]. From [16], we cutting speed for mild steel (workpiece material) 20-23 m/min. Cutting Speed: 1000 D n v    = (5) 655.557 650n =  ( )rpm Journal of Science & Technology 127 (2018) 029-034 32 Feed Rate=0.2(mm/rev)*650(rev/min)=130(mm/min) Power at one spindle (kW) ( ) 2 5 1.25 (0.056 1.55) 10 0.43 D k n P kW    + = = (6) Where Material Factor (K=1.22) with material carbon steel C45 (HB = 170). Power for 5 Spindles P=5*0.43=2.13 (kW)2.42 (hp) ✓ Assumed efficiency for gear drive and cacdarn shaft 90%, thus power available at gear shaft will be 2.69 (hp) ✓ Assumed efficiency for Belt drive 70% thus the power available at belt drive will be 4.76 (hp) Tormomem on each cardan joint [16]: 10* * * * *x MM C D q S y= (7) Where: CM = 0.0345; y = 0.8; q = 2 Mx = 10*0.0345*152*0.31*0.8 = 30,41 (N.m) Table 1. The main components value Parameter Value D 11 mm d1 12 mm L2 56 mm C 13 mm B 50 mm X 128 mm d2 12 mm D1 25 mm Lmin/Lmax 290/350 Durability under torque: Twisted bending stress of cardan shaft is calculated [15] The proposed cardan shaft is firstly theory based evaluated using the standard twisted bending stress of maximum allowed   172 = (MN/m2) [16].  max 12max . . .cos e hi p x x M i iM W W    = =  (8) Where: Memax the maximum torque on cardan shaft, ih1 maximum transmission ratio. max h1 brht dc n i .i n = (9) ip1 minimum transmission ratio. Wx : torque moment resistance 2 2 D Wx   = (10) And min max 290 cos 0.83 350 L L  = = = (11) With parameters given on Table 1, using the following equation 1 to equation 11 [16], the twisted bending stress can be calculated as =22 (MN/m2). Finally, we have    therefor it is satisfied durability under torque. Check the twist angle of cardan joint: The proposed cardan shaft is secondly theory based evaluated using the standard twist angle of cardan joint condition of the maximum allowed   03 = [16]. max 1 1. . .180 . . .cos e h p x M i i l G J    = (12) Where: Jx - moment of inertia of cross section, G modulus of elasticity when twisted G=8.5*104 (MN/m2) And ( )4 4 32 xJ D d  = − (13) max 1 1. . .180 . . .cos e h p x M i i l G J    = (14) With parameters given in Table 1, using the following equation (12) to equation (14) [ref (16)], the twist angle of cardan joint allowed can be calculated as =0.380. Finally, we have    it satisfied the twist angle of cardan joint condition. 4. Prototype and Result The prototype was produced and shown as in the Fig. 9, Fig. 10. The Bottom view of Prototype shown in Fig. 9, the cardan joint is adjusted to change the position of drill spindle. The Overall view of multi-spindle drill head shown in Fig. 10, we use 5 spindles in this prototype. - To check the principle of the driving system we used DC motor 24v/30w to drive main gear, it showed that the drive system worked as the simulation on software. - The Multi-Spindle drill system can drill 5 holes 5 on the wood sheet 5 mm thin. - The system worked smoothly without vibration. Journal of Science & Technology 127 (2018) 029-034 33 Fig. 8. Parameters of Cardan joint 5. Conclusion The obtained main results as follows: A new system of the multi-Spindle drill which uses Cardan universal joint and gear system for driving was designed. With the new drill system, we can drill multi-hole in one step for saving time, In addition, we can also flexibly adjust the position of the spindle to work a variety of different machine part. The system was simulated by inventor software and calculated durable. The demo prototype was produced to check the principle of new drill system. The experiment shown that the new system works stability. The next step, author plan transfers this research to the real application and extend to factories in order to directly compete with the international commodities. It is also an incentive, a driving force for the individuals, organization and companies to continuously cooperate in technical innovation and in the manufacturing process to create favorable conditions for maintaining and developing the domestic production stable in the period of international integration such as ASEAN, WTO, and so on. Fig. 9. Bottom view of Prototype Fig. 10. Overall view of multi-spindle drill head Acknowledgments This research is funded by the Hanoi University of Science and Technology (HUST) under project number T2016-PC-055. References [1] A.S.Udgave and Prof.V.J.Khot, “Design & development of multi-spindle drilling head (msdh)”, IOSR Journal of mechanical and civil engineering, ISSN: 2278-1684, PP: 60-69. [2] Bajirao H. NangarePatil, and P. R. Sawant, “Design and Development of Gearbox for Multi-Spindle Drilling Machine (SPM)”, International Journal of engineering research & Technology (IJERT) Volume 2, Issue 5, ISSN: 2278-0181, May-2013. [3] Prof. Ms.A.A.Shingavi, Dr.A.D.Dongare, and Prof. S.N.Nimbalkar, “Design of multiple spindle drilling machine”, International Journal of research in advent technology (E-ISSN: 2321-9637) Special Issue 1st International conference on advent trends in engineering, science, and technology (ICATEST 2015), 08 March 2015. [4] M.B. Bankar, P.B. Kadam, M.R.Todkar, “Improvement in design & manufacturing process of multiple spindle drilling attachment”, IOSR Journal Journal of Science & Technology 127 (2018) 029-034 34 of Engineering, Volume 3, Issue 1, Jan 2013, page 38-43. [5] Shinde Nikhil, “Design & Development of Twin Drill Head Machine and Drilling Depth Control”, International Journal of Innovative Research in Science, Engineering, and Technology, ISSN (Print): 2347 – 6710, Vol. 4, Issue 5, May 2015. [6] U. Deepak, C.Tharun Prabhakar, P.M.Prasanth, S.Manikandan, “Multi Spindle Drilling Machine”, International Conference on Latest Innovations in Applied Science, Engineering and Technology (ICLIASET 2017), March 2017, page 143-149. [7] A.M.Takale, V.R.Naik, “Design & Manufacturing of Multi spindle drilling head for its cycle time optimization”, International Journal of Mechanical Engineering applications Research – IJMEAR, Vol 03, Issue 01, January-April 2012. 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