Fatigue Life Prediction of a CNC Machine Spindle Support Shaft under Realistic Loading Using RecurDyn Simulation

Abstract:

The current paper presents a comprehensive fatigue analysis of the steel column shaft spindle in a model CNC machine tool under prototypical cyclic loading conditions. The study integrates multi-body dynamic simulation with RecurDyn and stress-based as well as strain-based fatigue life prediction procedures. The geometry of the shaft, achieved through CAD and meshed as a deformable body using the RFlex interface, was loaded with eight-point force-controlled cyclic loading mimicking operation machining forces. Stress-based analysis made use of Manson-Coffin life criterion along with Gerber and Goodman mean stress correction models, whereas strain-based analysis made use of the Brown-Miller and Morrow criteria along with corresponding mean stress corrections. Material characterization was enabled by developing an S-N curve for the shaft steel, enabling accurate estimation of life. Fatigue damage accumulation was evaluated using Miner's Rule, and damage contour plots to find critical locations. Results indicated maximum damage values of the order 10⁻⁹ for stress-based and 10⁻¹⁰- 10⁻⁸ for strain-based models, which correspond to predicted fatigue lives in excess of 10¹³ cycles under the applied boundary conditions. Gerber and Goodman criteria-based safety factor analysis also provided minimum values of 6.12 and 4.93, respectively, which indicate a substantial margin against fatigue failure. The approach provides an experimentally validated framework for the evaluation of machine tool structural elements' durability, enabling optimal support schemes and longer life of operation.

• Periodical: Defect and Diffusion Forum (Volume 453)
• Pages: 23-32
• DOI: https://doi.org/10.4028/p-E1dQnW
• Online since: July 2026
• Authors: Yunn Lin Hwang*, Arslan Munir
• Keywords: Fatigue Analysis, Miner’s Rule, Safety Factor, S-N Curve, Spindle-Column Shaft, Strain-Based Method, Stress-Based Method

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