Structural Design Of The Horizontal Deep Hole Internal Grinding Machine

Cylindrical parts with deep holes and thin-wall structures are the backbone of aerospace,such as sleeves,actuators,and landing gears of aircraft.However,in precise,the precision machining of inner holes of cylindrical parts with small bores,large depth to diameter ratios(>7-8)is more problematic,which realized the significance of the grinding of such deep holes.In this article,a structure of the deep hole internal grinding machine was developed and the structural behavior against two different materials cast iron and artificial granite material machine base studied.Furthermore,the key components of the machine are selected and designed.However,there are several fundamental factors that could affect the grinding process quality,especially for the deep holes,the structural stiffness is one of them.In the study,the design is divided into two stages;the first is the design and analysis of the DHIG shaft structure because its stiffness makes a major influence on the surface quality of the final product and the second is for the machine design structure,particularly,about the enhancement of dynamic response.Both are crucial factors and need to be addressed.The vital structure of this grinding machine is the internal grinding shaft tool structure and one of the decisive factors distressing the surface grinding quality because of the long overhanging length and complexity of the structure with a limited exterior dimension.Initially,the model of the grinding shaft tool structure is designed in CREO-Parametric software.Then the designed model is carried through the static and dynamic analyses by employing ANSYS FEA software to authenticate and assure the structural stiffness and behavior to attain high precision machining of deep holes.While analysis,various parameters such as materials of the internal grinding shaft and various structural designs of the shaft took under research consideration and calculated the maximum deformation for the most optimized design.However,the deformation was found at 10.42 μm and 63.16 μm in gravity and cutting force direction at the maximum grinding force of 98.05 N and 90.22 N in radial and tangential directions,respectively.Afterward,the complete machine structure was analyzed against distinct materials with an optimized design of the DHIG shaft.Subsequently,being a most crucial part of the machine,shaft design is verified through the comparative study of theoretical,simulation analyses,and experimental work.The final results for shaft deformation verification gathered through FEM and modified mathematical principle deflection equation and have the error of less than 7 %.