20%
Weight Reduced
25%
Improvement in Structural
BACKGROUND
Design and development of a Vertical Honing Machine (SPM) capable of achieving extremely high machining accuracy with spindle/tool runout limited to 2 microns.
CHALLENGE
- Achieving ≤ 2 µm spindle runout under operating conditions.
- Maintaining high structural rigidity of spindle, column, and base assemblies.
- Minimizing vibration and resonance affecting machining accuracy.
- Reducing machine weight without compromising strength.
- Using standard components wherever possible to improve manufacturability and accuracy.
- Meeting customer-defined cycle time and functional requirements.
APPROACH
- Studied customer inputs, functional parameters, and runout requirements.
- Developed optimized machine arrangement and spindle architecture.
- Designed Base, Column, Spindle, Expansion, Fixture, and Guard Assemblies.
- Performed FEA for structural strength validation.
- Conducted weld strength and modal analysis to eliminate resonance issues.
- Incorporated customer feedback through iterative design improvements.
- Generated manufacturing drawings, BOM, and machine documentation.