By: Somnath Kolgiri, Pranit Suryawanshi, Viraj Shelar, Sachin Nashti, and Prashant Shelake
1. Assistant Professor, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitibai Phule Pune University, Pune, Maharashtra, India
2–5. Student, Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering, Savitibai Phule Pune University, Pune, Maharashtra, India
Abstract
This paper presents the design, analysis, and optimization of a multi-spindle drilling machine head
aimed at enhancing productivity and efficiency in manufacturing processes. Engineered to drill multiple
holes simultaneously, the multi-spindle head significantly reduces machining time and increases
operational throughput, making it ideal for high-volume production environments where speed and
accuracy are essential. The design process begins with a thorough requirements analysis and material
selection to ensure the machine head can endure operational stresses while remaining lightweight. A
detailed 3D model is created using CATIA software, followed by finite element analysis (FEA) with
ANSYS software to simulate various load conditions and assess stress distribution and structural
integrity. The FEA results inform the optimization process, revealing ways to minimize material usage
without sacrificing performance. A key outcome of this research is the 18% reduction in the overall
weight of the multi-spindle head, achieved through the strategic removal of material from non-critical
regions. Despite this weight reduction, the structural strength and performance of the machine head
remain unchanged, ensuring that it meets all necessary operational requirements. This lightweight
design not only reduces manufacturing costs but also improves the energy efficiency of the drilling
process. The paper also compares traditional calculation methods with the FEA results from ANSYS,
demonstrating that the optimized design falls well within the acceptable limits of both approaches. The
comparison validates the accuracy and reliability of the simulation results, further highlighting the
importance of using modern design and analysis tools in the optimization process. In conclusion, this
study shows how advanced design techniques, including 3D modeling and FEA, can be used to optimize
the performance of a multi-spindle drilling machine head. The results of the analysis provide clear
evidence that weight can be significantly reduced without affecting strength or durability, leading to a
more efficient, cost-effective, and high-performance drilling solution for modern manufacturing
environments.
Keywords: Multi-spindle drilling, ANSYS, finite element analysis, productivity, manufacturing
REFERENCES
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6. Bhaskar R, Mahesh V. Optimization of spindle head for high-speed machining through FEA. Int J Adv Eng Res Sci. 2015;2(6):94–98.
7. Groover MP. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems. 4th edition. Hoboken, NJ: John Wiley & Sons; 2010.
8. Khurmi RS, Gupta JK. A Textbook of Machine Design. New Delhi: S. Chand Publishing; 2005.
9. Kumar SA, Kumar RA, Josheph J, Tony CP, Badrinath R. Design and deformation analysis of multi-spindle drilling head parts. AIP Conf Proc. 2022;2446(1):180035. doi:10.1063/5.0110488.
10. Chandrasekaran T, Nagarajan R. Optimizing the performance of multi-spindle drilling using FEA and CAD tools. J Manuf Sci Eng. 2017;139(10):104502–104510.
11. Zhu JZ. The Finite Element Method: Its Basis and Fundamentals. 7th edition. Oxford: Elsevier; 2013.
12. Jain VK. Advanced Machining Processes. 1st edition. New Delhi: Allied Publishers; 2014.
13. CATIA User Guide. Dassault Systèmes [Online]. 2021. Available from: https://www.3ds.com.
14. Lawrence K. ANSYS Tutorial Release 2020. Mission, KS: SDC Publications; 2020.
15. Gupta K, Kumar S. Case studies on optimizing machining parameters using FEA for multi-spindle drills. Int J Eng Res Technol. 2019;8(5):541–549.
16. Uddin MS, Gupta AK. Design considerations for multi-spindle drilling heads. J Manuf Process. 2018;32:215–225.
17. Zhao Y, Li H, Wang J. Material selection for high-performance multi-spindle drilling heads. Mater Sci Forum. 2020;987:134–140.
18. Patel SR, Mehta NK, Joshi PH. Finite element analysis and optimization of multi-spindle drilling heads. Int J Mech Eng Robot Res. 2019;8(3):215–221.
19. Aamir M, Tolouei-Rad M, Vafadar A, Raja MN, Giasin K. Performance analysis of multi-spindle drilling of Al2024 with TiN and TiCN coated drills using experimental and artificial neural networks technique. Appl Sci. 2020;10(23):8633.
20. Lee J, Park S, Kim Y. Efficiency improvements in automotive manufacturing using multi-spindle drilling heads. J Autom Eng. 2021;48(4):655–662.
21. Vafadar A, Raja MNA, Giasin K. Effect of tool coating on performance of multi-spindle drilling in aluminum alloys. Appl Sci. 2020;10(23):8633.
Citation:
Refrences:
1. Chern TS, Wang J, Lin B. Multi-spindle drilling machine design for increased efficiency in machining operations. Int J Mach Tools Manuf. 2006;46(7-8):842–849.
2. Kalpakjian S, Schmid S. Manufacturing Engineering and Technology. 7th edition. Upper Saddle River, NJ: Pearson; 2014.
3. Norton RL. Machine Design: An Integrated Approach. 4th edition. Upper Saddle River, NJ: Pearson Education; 2011.
4. Balasubramanian R, Srinivas S. Application of finite element analysis in mechanical design. Int J Mech Prod Eng Res Dev. 2012;2(3):45–53.
5. Deng Y, Gao F. Finite element analysis of multi-spindle machining systems using ANSYS. J Manuf Process. 2010;12(3):122–129.
6. Bhaskar R, Mahesh V. Optimization of spindle head for high-speed machining through FEA. Int J Adv Eng Res Sci. 2015;2(6):94–98.
7. Groover MP. Fundamentals of Modern Manufacturing: Materials, Processes, and Systems. 4th edition. Hoboken, NJ: John Wiley & Sons; 2010.
8. Khurmi RS, Gupta JK. A Textbook of Machine Design. New Delhi: S. Chand Publishing; 2005.
9. Kumar SA, Kumar RA, Josheph J, Tony CP, Badrinath R. Design and deformation analysis of multi-spindle drilling head parts. AIP Conf Proc. 2022;2446(1):180035. doi:10.1063/5.0110488.
10. Chandrasekaran T, Nagarajan R. Optimizing the performance of multi-spindle drilling using FEA and CAD tools. J Manuf Sci Eng. 2017;139(10):104502–104510.
11. Zhu JZ. The Finite Element Method: Its Basis and Fundamentals. 7th edition. Oxford: Elsevier; 2013.
12. Jain VK. Advanced Machining Processes. 1st edition. New Delhi: Allied Publishers; 2014.
13. CATIA User Guide. Dassault Systèmes [Online]. 2021. Available from: https://www.3ds.com.
14. Lawrence K. ANSYS Tutorial Release 2020. Mission, KS: SDC Publications; 2020.
15. Gupta K, Kumar S. Case studies on optimizing machining parameters using FEA for multi-spindle drills. Int J Eng Res Technol. 2019;8(5):541–549.
16. Uddin MS, Gupta AK. Design considerations for multi-spindle drilling heads. J Manuf Process. 2018;32:215–225.
17. Zhao Y, Li H, Wang J. Material selection for high-performance multi-spindle drilling heads. Mater Sci Forum. 2020;987:134–140.
18. Patel SR, Mehta NK, Joshi PH. Finite element analysis and optimization of multi-spindle drilling heads. Int J Mech Eng Robot Res. 2019;8(3):215–221.
19. Aamir M, Tolouei-Rad M, Vafadar A, Raja MN, Giasin K. Performance analysis of multi-spindle drilling of Al2024 with TiN and TiCN coated drills using experimental and artificial neural networks technique. Appl Sci. 2020;10(23):8633.
20. Lee J, Park S, Kim Y. Efficiency improvements in automotive manufacturing using multi-spindle drilling heads. J Autom Eng. 2021;48(4):655–662.
21. Vafadar A, Raja MNA, Giasin K. Effect of tool coating on performance of multi-spindle drilling in aluminum alloys. Appl Sci. 2020;10(23):8633.
