1.

COVER PAGE
Design and Analysis of SPINDLE using
Solidworks and ANSYS Workbench
Submitted in fulfillment of the requirements of
course project of

Bachelor of Engineering
(Course Project)
By
NAMAN VORA: 60005170072
NIRAV SAMPAT: 60005170076
NISARG PAIDA: 60005170077
PRINCE JAIN: 60005170087
------------------------------------------------------------
Under project guide:

PROF. VINAYAK KHATAWATE

Dwarkadas J. Sanghvi College of Engineering

Mechanical Engineering Department

1
 2. CERTIFICATE

This is to certify that the project entitled “Design and

Analysis of SPINDLE using Solidworks and ANSYS
Workbench” is a bonafide work of
NAMAN VORA: 60005170072
NIRAV SAMPAT: 60005170076
NISARG PAIDA: 60005170077
PRINCE JAIN: 60005170087

Submitted to the University of Mumbai in partial

fulfillment of the requirement for the award of the project
course in “Bachelor of Engineering” in “Mechanical
Engineering”.

Project Guide

(Vinayak Khatawate)
2
 3. ABSTRACT

This project presents the Design and analysis of

SPINDLE. The following abstract using the two software
mainly Solidworks and Ansys Workbench.
This project report consists of the design of the
SPINDLE followed by design analysis of the same in
ANSYS software and verifying from the results obtained
by the software that the design is safe and verified for
practical applications considering the mechanical and
structural stresses and fatigue.

3
 4. INDEX
TITLE PAGE NO.
Chapter 1 - Cover Page 1
Chapter 2 – Certificate 2
Chapter 3 – Abstract 3
Chapter 4 – Index
Chapter 5 - Problem Statement 6
Chapter 6 – About
6.1. Introduction 6
6.2. Significance
6.3. Structure
6.4. Modes of Failure
6.5. Applications
Chapter 7 – Summary
Chapter 8 – Calculation 7
Chapter 9 – Modeling 9
Chapter 10 – Meshing 10
Chapter 11 - Material Data 11
Chapter 12 - Boundary Condition 12

Chapter 13 – Forces

Chapter 14 - Structural Analysis Of Spindle 14

14.1 Total Deformation

14.2 Equivalent Stress

Chapter 15 - Fatigue Analysis Of Spindle 16

15.1 Equivalent Stress

15.2 Safety Factors

Chapter 16 – Conclusion 18

Chapter 17 – Bibliography 19

4
FIGURE NO. FIGURE NAME PAGE NO.

1 Dimensions of Spindle 9

2 Meshing 10

3 Boundary Conditions 12

4 Structural Analysis Of Spindle 14

5 Fatigue Analysis Of Spindle 16

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 5. PROBLEM STATEMENT
To calculate the FOS for a shaft with two bearing for structural and fatigue
loading. The bearing forces are calculated with the help of 5ft force value of
4200N acting at the wheel center of the hub. The hub and bearing are
connected via the spindle. The fixed support is provided at the end of the
spindle. Bearing of ID 25mm to be used with 30 mm diameter to restrict the
bearings. A shaft also has to be fixed.

6. ABOUT
6.1. INTRODUCTION

A spindle is either one of two front axles in a rear wheel drive vehicle, or one
of the two rear axles in a front wheel drive vehicle. In a front wheel drive
vehicle this axle is capable of angular movement about the kingpin for
steering the vehicle.
Spindle is a type of Mechanical Joint. It has an ubiquitous presence in our
daily lives. It is a shaft which can be used to support the bearings. Evidently
the spindle is a crucial part of myriad of mechanical devices and thus it is
important for us as mechanical engineers to develop a greater
understanding of it. Also, its applications are as greatly varied in type as the
loads they bear.

6.2. SIGNIFICANCE

The spindle extending from the upright about which the wheel and hub
rotate. The structure is a solid shaft. A step has been provided to restrict the
bearing. The shaft was locked on the upright with 4 rectangular mating
surfaces and a circular mating surface and fastened with the help of a
washer and nut (M20x1.5) to eliminate compliance. The outer side of the
shaft was secured with a washer and a nut (M20x1.5) resting of the inner
face of the bearing.

6.3. STRUCTURE

The wheel hub rotates around the spindle, hence vertical force acting on
spindle, because of dynamic weight transfer at the time of loading of car
after jump. Therefore, the spindle has a capacity to sustain all forces, which
experience during dynamic condition.

The front stub axle length was set as per the axial clearance provided by the
brake caliper and was minimized to keep the wheel assembly as compact as
possible.

The dimensions of the spindle were set as per the calculations.

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 6.4. MODES OF FAILURE

1. Bending Failure.
2. Fatigue Failure

6.5. APPLICATION

1. Used as a Shaft in wheel assemblies.

2. To support bearings and restrict the movement of bearings.

7. SUMMARY

Spindle is a type of Mechanical Joint. It has a ubiquitous presence in

our daily lives. It is a shaft which can be used to support the bearings.
Evidently the spindle is a crucial part of myriad of mechanical devices
and thus it is important for us as mechanical engineers to develop a
greater understanding of it. Also, its applications are as greatly varied
in type as the loads they bear.

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 8. CALCULATIONS
Ra
5mm 5mm 20mm

4200KN Rb

FBD of HUB
∑Ma = 0
4200*5-Rb*20 = 0
Rb = 1050N

∑Fy = 0
Ra = Rb + 4200
Ra = 1050 + 4200
Ra = 5250 N
Rb
10mm 20mm 32mm

(fixed support)
A B C

Ra
FBD of SPINDLE

Bending Calculation
∑Mc =?
Ra × 52 – Rb × 32 = Mc
5250 × 52 – 1050 × 32 = Mc
Mc = 239400 Nmm

At bearing support,
(Бy ÷ y) = (M÷I)
Бb = (Syt ÷ FOS)

For Aluminum 7075-T6

Syt = 503 N/mm2

Y = Πd4/64

A = 256200 Nmm

For D = 25 mm

FOS = 3.217

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Fatigue Calculation

For Aluminium 7075,

Sut =575 MPa
S’ut = 0.3 Sut (For Cast Aluminium Alloys)
Se = Ra * Kb * Kc * Kd * S’ut
Ka = Surface Finishing Factor = 0.75 for machined surfaces
Kb = size factor = 0.85 for 700MS
Kc = Reliability Factor = 0.814 for 90% reliability
Kd = Stress concentration factor = 1/Kf
For D/d = 1.1 and r/d = 0.06 , Kf = 1.65

Se = 0.75 x 0.85 x 0.814 x 0.7 x 0.3 x 575

Se = 62.66

Mmax = 256200 N.mm

Mmin = 0

σ max = [256200/(D/2)] / [(π/64) x D4]

σ max = (2438508.378/D3)

σ min =0

Considering,
σ m = σ a = (σ max + σ max )/2 = (2438508.378/2D3)

By Soderberg Equation,
(1/FOS) = (σ m/Sy) + (σ a/Se) = σ m [(1/Sy) + (1/Se)]

(1/FOS) = (2438508.376/2D3)[(1/502) + (1/62.66)]

FOS = D3/ [2438508.376/2 {(1/502) + (1/62.66)}]

For D=25mm
FOS = 0.7

9. MODELLING
Diameter of spindle (OD) = 25 mm
Diameter to restrict bearings = 30 mm

Square dimensions = 32 mm x 32 mm

Nut to be used = M20 x 1.5

9
 +

Figure 1: Isometric View

Figure 2: Front View

The above part (spindle) has been

modeled in Solidworks.

Dimensions of Spindle
10
 10. MESHING OF SPINDLE

Figure 3: Meshing

 We meshed the imported geometry from Solidworks

in Ansys Workbench.
 We increased number of elements upto 88,231.
 Node numbers went upto 1,29,096.
 The above average meshing was needed to solve the
analysis problem to give a much accurate result of the two
forces 5250N and 1050N applied at different locations.
 Tetrahedron shaped elements were chosen for the meshing
using Ansys Workbench.

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 11. MATERIAL DATA

 The material data is as shown from the figure.

 The material selected is Aluminium 7075-T6 so that it can
withstand the forces applied on the spindle.
 The element size we selected is 2mm. We didn’t go for a
much smaller size or else our system would take a lot of
time for solving the mathematical model and also to avoid
the burden on the system (8GB RAM)

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 12. BOUNDARY CONDITIONS



Figure 4: Boundary Conditions (Fixed Support)



 The blue shaded region showed in the figure is fixed.


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 13. FORCES

Figure 5: Bearing Force 1

Figure 6: Bearing Force 2



 The two bearing reaction forces acting on the spindle are
shown in the above 2 figures.

14
 14. STRUCTURAL ANALYSIS OF SPINDLE
 

Figure 7: Equivalent Stress 


 The above figure shows the equivalent stress on the spindle.
 Maximum stress of 134.37 MPa occurs at fixed support
 Minimum stress of 1.937e-6 occurs at 2 ends
 The stress can be made less by keep the same cross section
along the length of the spindle.



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 Figure 8: Total Deformation

 The above figure shows the Total Deformation of the

component
 Maximum deformation of 0.19274 mm occurs at the end
outer end
 No deformation takes place at the inner side of the spindle

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 Figure 9: Equivalent Elastic Strain

 The above figure shows the Equivalent Elastic Strain Analysis of

the component
 Maximum elastic strain of 0.0019392 occurs at fixed support
 Minimum elastic strain of 2.9511e-11 occurs at 2 ends

Figure 10: Safety Factor


 The above figure shows the Safety factor of the component
 Maximum factor of safety of the component is 15
 Minimum factor of safety of the component is 3.73.

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15. FATIGUE ANALYSIS OF SPINDLE

Figure 11: Equivalent Stress in Fatigue

 The above figure shows the equivalent stress for fatigue

analysis.
 Maximum stress of the component is 134.37.
Minimum stress of the component is 1.937e-6.

Figure 12: Safety Factor 

 Fatigue Analysis using Soderberg’s Equation is done.
 Maximum factor of safety of the component is 15.
Minimum factor of safety of the component is 0.6
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

16. CONCLUSION
 As per the objective of the project, first spindle was
designed manually using empiricals and designing
procedures and selecting the materials according to
standard use. It was then verified doing manual
calculations that the design was indeed safe.

 The design was then recreated in Solidworks and from

there imported to Ansys for further analysis. It was found
that on applying all the loads the design turned out to be
safe as per the software too. Also it became easy to identify
the regions of maximum stress and minimum stress and
simultaneously maximum and minimum deformation of
individual components and overall assembly from the
results obtained from Ansys analysis so that if needed
further design changes can be made to reduce stress
concentration.

 During the course of this project we learned the principles

of designing and mainly to analyse components using
Ansys software. Also we learned qualities of team work,
punctuality and hard work.

 The value of FOS calculated and obtained in the software are
almost similar with an error of 10%.

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 17. Bibliography
 R.S. KHURMI, A Textbook MACHINE DESIGN

 Finite Element Procedures in Engineering Analysis by

K.J. Bathe, Prentice Hall.

 Finite Element Analysis-Theory and practice by Fagan

M.J. Prentice Hall.

 https://www.youtube.com/channel/UCEBb1b_L6zDS3
xTUrIALZOw ( lectures by Klaus-Jürgen Bathe)

 https://www.youtube.com/watch?v=vnpq5zzOS48&t=6
2s

 https://www.youtube.com/watch?v=c3yM5fT5Ztc



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