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Vol 03, Issue 01; January-April 2012 International Journal of Mechanical Engineering applications Research IJMEAR
http://technicaljournals.org ISSN: 2249- 6564
Design & manufacturing of multi spindle drilling head (msdh) for

its cycle time optimisation
1
A. M. TAKALE, 2V. R. NAIK
1
M.E. (Mech) P.D.D.student, Textile and Engg. Institute, Ichalkaranji, Kolhapur.
2
Head of Mechanical Department, Textile and Engg. Institute, Ichalkaranji, Kolhapur.
1
adik1617@rediffmail.com, 2vrnaik66@gmail.com
ABSTRACT
The growth of Indian manufacturing sector depends largely on its productivity & quality. Productivity depends
upon many factors, one of the major factors being manufacturing efficiency with which the operation /activities
are carried out in the organization. Productivity can be improved by reducing the total machining time,
combining the operations etc. In case of mass production where variety of jobs is less and quantity to be
produced is huge, it is very essential to produce the job at a faster rate. This is not possible if we carry out the
production by using general purpose machines. The best way to improve the production rate (productivity)
alongwith quality is by use of special purpose machine. Usefulness and performance of the existing radial
drilling machine will be increased by designing and manufacturing of multispindle drilling head attachment.
This paper deals with design and development of multispindle drilling head for cycle time optimisation of the
component.
Keywords- Design, Analysis, Manufacturing, Statistical process control (Process capability)
INTRODUCTION
Multi-spindle head machines are used in mechanical industry in order to increase the productivity of machining
systems. Such machines are equipped by 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 nor use two or more
tables at the same machine. Thus, in every moment only one part can be present on such a machine. No part can
[1]
be loaded before the previous part is not finished .
In todays market the customer demands the product of right quality, right quantity, right cost, & at right time.
Therefore it is necessary to improve productivity as well as quality. One way to achieve this is by using multi
spindle drilling head. On the other hand, in order to meet quality requirements of final product. Another way of
achieving good quality during production is to use the statistical quality control techniques at every stage of
production. If the production is statistically under control the process can continue and there is no need for a
change in the process. However, if it is not statistically under control, the assignable causes should be
[2]
discovered and removed from the process .
1. VARIOUS METHODS OF MULTISPINDLE
Fig.1 Adjustable multispindle drilling head Fig.2. Fixed multispindle drilling head
The various methods of multispindle drilling head are
a) Adjustable multispindle drilling head-
Can be used in many components, where change the centre distance to some range. It will increase drilling
capacity in single special purpose machine. These are the gear adjustable centre drilling head, in which drill
Spindle is fitted on slotted plate (slotted plate is fixed in position in the gear box) and the gear is mounted on the
drill spindle. By changing the gears as per required pitch circle diameter the drill spindle is adjusted in the
slotted plate.
b) Fixed Multispindle drilling head-
Where cannot change the centre distance to some range. Is planetary gear train, compound gear train.
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134
Features of both the type multispindle drilling head are

1) By using these multispindle drilling heads, increase the productivity is substantial.
2) Time for one hole drilling is the time for multiple no. of holes drilling.
3) Multispindle drilling ensures the positional accuracy.
Multispindle heads can be of fixed centre construction for mass and large batch production and for batch
[3]
production, adjustable centre type design is offered . Here planetary gear train type fixed multispindle drilling
head is selected, because component P.C.D. is fixed (120mm) and having large batch production of the
component it is easy to design & manufacture, quiet & efficient gearing. The design for the same is shown in
annexure 1.
2. DESIGN
The Component drawing for which multispindle drilling head is designed is as shown.
Fig.3.Component drawing CAD model of component.

2.1 SPINDLE HEAD ACTUATION SYSTEM DESIGN
By using automation studio software the head actuation results are as follows:
Fig.4 hydraulic circuit fig.5 Rapid forward
stroke
Fig.6 Feed forward stroke fig.7 Retraction stroke
The basic hydraulic circuit is as shown in fig.4 during the rapid forward stroke the oil enters in to the actuator
directly through solenoid operated direction control valve and oil returns in to the tank through flow control
135
valve and cam operated direction control valve. During feed forward stroke (cutting operation) oil returns in to
the tank through flow control valve only and cam operated direction control valve is blocked with the help of
cam. During retraction stroke oil enters in to the actuator through in to the tank through throttle check valve and
cam operated direction control vale and oil returns in to the tank directly through solenoid operated direction
control valve.
Using parametric inputs of the design the cutting force obtained through software is 8500 N and by using
[4]
imirical design it is 8197 N which is closely matching . By putting technical data in the automation studio
software the results are shown as above, from the above simulation results it is clear that head actuation
successful takes place forward and retraction.
LAYOUT OF MULTISPINDLE DRILLING HEAD IS AS SHOWN
Fig.8. Multispindle drilling head

By using this multispindle drilling head 5 holes of diameter 15.24/15.31mm and one hole diameter 5.0 mm
(for M6x1 tapping) drill at a time. Drive is given by motion to main spindle, which drives planetary gear train
fitted in the housing, then drill shafts rotates as per the gear ratio.
3. ANALYSIS
Stress analysis is carried out on major components of multispindle drilling head like main spindle gear and main
spindle. In the analysis shown below, tangential and radial force is considered. Analysis software ANSYS 12 is
[5]
used to verify the maximum stresses induced in the main spindle gear and main spindle .
4.1 The deflection and stress analysis of main spindle gear having material En24 (40Ni2Cr1Mo28) (Syt = 1300
[6]
N/mm2) . is as follows
Fig.9 Displacement analysis Fig.10 Stress analysis

From displacement analysis and stress analysis it is clear that design is safe. Because induced stress (682.069
N/mm2) is less than the yield stress (Syt = 1300 N/mm2) of the material
136
[7]
4.2 The deflection and stress analysis of main spindle having material SAE8620 (40Ni3) (Syt = 600 N/mm2)
[6]
. is as follows
Fig.11 Displacement analysis Fig.12 Stress analysis

From displacement analysis and stress analysis it is clear that design is safe. Because induced stress (279.843
N/mm2) is less than the yield stress (Syt = 600 N/mm2) of the material.
4. MANUFACTURING
The Multispindle drilling head requires various components, the major components are gear box, drilling
spindle, gear shafts, main spindle gear, drive gears, idler gears etc. It requires various machines to manufacture
them like band saw machine for cutting operation, lathe machine for rough machining, drilling machine, surface
grinding machine, cylindrical grinding machine, internal grinding machine, slotting machine, milling machine,
hobbing machine etc.
Case study:
Consider a component main spindle gear
Raw Material :- En24[8]
Component : - Main Spindle gear
Raw matl. Size :- 110x 25
The process sheet for the component main spindle gear is as shown below, which shows the stepwise
[9]
manufacturing process & machine require to manufacture the part .
Op. No. Operation Details Machine Used
1 Cut the bar to the raw material size Power hacksaw machine
2 Hold in the chuck, facing to remove 2mm material Lathe machine
3 Turning 106x12mm length Lathe machine
4 Boring 24.8 through Lathe machine
5 Chamfering Lathe machine
6 Reverse the component, hold in chuck to control length 21.5mm Lathe machine
7 Turning 106 to remaining length Lathe machine
8 Chamfering Lathe machine
9 Internal key way 6x3 through Slotting machine
137
10 Teeth cutting Gear hobbing machine

11 Hardening hardness 45-50 HRC -
12 Internal grinding 25 Internal grinding m/c
[10]
13 Teeth grinding Gear grinding m/c
14 Remove burr & sharp corners -
5. STATISTICAL PROCESS CONTROL (PROCESS CAPABILITY)

The process capability (or machine accuracy study) of a machine or manufacturing process can be defined as the
minimum tolerance to which machine can possibly be expected to work and produce no defectives under the
specified conditions. If the product is fully within tolerance limits, it can be said that the system is capable.
The tolerance limits are determined by customers, engineers and management and they are classified as
requirements, aims, specifications and standards. There should be lower and upper limits of specification .
Machine tool capability (Cp) and process capability (Cpk) are used to determine the capability. Cp is used to
determine the systems location in tolerance limits. If the system is not at the center of specification values, the
trend of Cp is progressing faulty. Cpk is used to determine the average so that the system will work better in the
specification limits. If the value of Cpk is 1 it shows that the manufacturing is going on in the system
specification limits staying at 99.73% level (3 sigma limits). When the value of Cp and Cpk is 1, this is
considered, as the minimum requirement of the system for some companies. Alongside this, larger Cp and Cpk
[11]
values, for instance 2, are accepted by many companies .
Approach
The process capability of P.C.D. 120mm of component shown in fig. 3 is as follows
138
Here number of observations in sub-group (n) are 5 & for n=5,

d2 = Factor of estimating sigma from R bar = 2.33
A2 = Factor for determining limits for X bar chart from R bar = 0.58
D4 = Factor for determining limits for R chart = 2.11
USL = Upper specification limit = 120.2 mm
LSL = Lower specification limit = 119.8 mm
Cpk-1 = Process capability used to determine the average so that the system will works better in the upper
specification limit.
Cpk-2 = Process capability used to determine the average so that the system will works better in the lower
specification limit.
Since in the production, for P.C.D. 120 mm, Cp = 1.83 > 1 and Cpk = 1.69 > 1 the machine tool and process is
[12]
sufficient .
6. CONCLUSION
1) By using multispindle drilling head productivity will increase. Because with the present process one hole
produces at a time requires 4 minutes for each component (because tool change takes place for drilling 5mm
hole (for M6x1 tap)). i.e. 12-15 parts are produced during one hour, but by using multispindle drilling head
cycle time approximately takes place 1 minutes. i.e. 55-60 parts may produce during one hour.
2) Possibility of hole missing is eliminated, because six holes drilled at a time.
3) The cost per piece is reduced. As seen in conclusion no.1 the production rate is approximately double by
using multispindle drilling head. The machine used for multispindle drilling head is same (Radial drilling
machine) which present uses to produce the part, so machine hour rate remains unchanged.
4) Statistical quality control is applying statistical rules and techniques to each phase of design, manufacturing
and service. One of the techniques for assuring the quality during production is to apply the statistical period
control techniques to each phase of production during or after manufacturing. Statistical quality control has had
great deal of improvements in companies using mass production. Capability analysis helps to determine the
ability for manufacturing between tolerance limits and engineering specifications. Capability analysis can be
applied not only to production period but also to a machine or machine tool. Capability analysis gives the
information about changes and tendencies of the system during production. It is used to determine the system
tendencies between tolerance limits. Deviations and faults of the average of process dimensions can be seen. Cp
and Cpk are used to determine capability.
ACKNOWLEDGMENT
Authors are thankful to M/s Sanmati CNC Engineering Works for sponsoring the project & providing
manufacturing and metrological facilities.
REFERENCES
1) Olga Guschinskaya, Alexandre Dolgui, Nikolai Guschinsky, and Genrikh Levin Scheduling for multi-
spindle head machines with a mobile table. January 2007 (Research report 2007 500 002)
2) Ali Riza Motorcu, Abdulkadir Gullu - Statistical process control in machining, a case study for machine tool
capability and process capability. Materials and Design 27 (2006) 364372
3) Dolgui, N. Guschinsky & G. Levin A design of decision support tool (DSS) or mass production machining
systems vol. 57, No. 3, 2009.
4) T. Lakshmi Narayanan, S. Madhavan, Ankur Sinha Investigation of Thrust, Torque and Delamination on
drilling of Glass fabric/Polypropylene matrix composite. 2010 International Conference on Mechanical &
Electrical Technology (ICMET 2010)
5) Nirav P. Maniar, D. P. Vakharia, Chetan M. Patel - Design & manufacturing with modeling, dynamic
balancing & finite element analysis of rotary fixture for CNC turning centre to function as HMC. ASME early
career technical journal 2009 ASME Early Career Technical Conference, ASME ECTC October 2-3, 2009.
6) Yan-fang Yin Digital tools for material selection, 2010 International Conference on Educational and
Network Technology (ICENT 2010).
7) C. Brecher, G. Spachtholz, F. Paepenmller - Developments for High Performance Machine Tool Spindles.
Laboratory for Machine Tools and Production Engineering
8) Kalpesh Maniya, M. G. Bhatt - A selection of material using a novel type decision-making method.
Preference selection index method. Materials and Design 31 (2010) 17851789.
9) C. Brecher, M. Esser, S. Witt - Interaction of manufacturing process and machine tool. CIRP Annals -
Manufacturing Technology 58 (2009) 588607
139
10) B. Karpuschewski , H.-J. Knoche, M. Hipke - Gear finishing by abrasive processes. CIRP Annals -
Manufacturing Technology 57 (2008) 621640.
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underlying theory, Journal of Operations Management 26 (2008) 536554.
12) S. Segonds_, C. Bes, G. Cohen, Y. Landon - Statistical study of the spindle dilatation phenomena
Application to a NC lathe. International Journal of Machine Tools & Manufacture 47 (2007) 23072311.
ANNEXURE 1
a) Calculation of spindle speed
1) Vc = (DN/1000)
2) N = (Vc*1000)/(D)
Where,
N=Spindle speed in rpm
b) Calculation of Power required for 1 spindle
P1 = (1.25*D*K*N*Fr)/105
Where,
D = Drill diameter (mm)
N = Spindle RPM
Fr = Feed (mm / revn)
K=Material factor
c) Power required for six spindles = 6 x P1
d) Thrust calculation
Th = 1.16*K*D*(100*Fr)0.85
e) Gear pair design
Design Gear Pair 1 & 2
1) Speed of pinion = Np
2) Speed of Gear = Ng
f) Sut material ultimate strength
g) PCD of pinion = dp
h) PCD of gear = dg
i) Pitch line velocity (V),
V = (*dp*Np)/60
j) Velocity factor (Cv) = 3/(3+V)
k) Estimation of module based on beam strength m= [(60*106*P*Cs*fs)/(*Zp*Np*Cv*(b/m)*(Sut/3)*Y] (1/3)
Where,
P = Power at spindle
Cs = Service factor
F.S. = Factor of safety
Zp =No. of teeth on pinion
Np= rpm of pinion spindle
Cv= Velocity factor
Y Lewis factor
AUTHOR BIOGRAPHY
A. M. Takale.
M.E. (Mech.) Product design and development student department of mechanical engineering
Textile and Engg. Institute, Ichalkaranji, Kolhapur. Has two years of academic experience and
six years of industrial experience. To his credit there is one paper at national conference.
Author Prof. (Dr.) V. R. Naik.

Working presently as professor and HOD (Mech.) has 17 years of academic experience and six
years of industrial experience. He has around in various reputed organisations in the areas of
Design and Development. To his credit there are twenty two papers at national and
international conferences and five papers in the various journals of national and international
repute. He is also principal investigation to various funded project.

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133

Design & manufacturing of multi spindle drilling head (msdh) for

Features of both the type multispindle drilling head are

Fig.3.Component drawing CAD model of component.

Fig.4 hydraulic circuit fig.5 Rapid forward

Fig.8. Multispindle drilling head

Fig.9 Displacement analysis Fig.10 Stress analysis

Fig.11 Displacement analysis Fig.12 Stress analysis

10 Teeth cutting Gear hobbing machine

5. STATISTICAL PROCESS CONTROL (PROCESS CAPABILITY)

Here number of observations in sub-group (n) are 5 & for n=5,

Author Prof. (Dr.) V. R. Naik.

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