COMPARATIVE ENGINEERING AND FINITE ELEMENT ANALYSIS (FEA) OF A CONICAL TAILSTOCK DESIGN UNDER DIFFERENT MATERIAL CONDITIONS
10th INTERNATIONAL CONGRESS ON ENGINEERING AND SCIENCES, İstanbul, Türkiye, 17 - 18 Ekim 2026, ss.1-11, (Tam Metin Bildiri)
- Yayın Türü: Bildiri / Tam Metin Bildiri
- Basıldığı Şehir: İstanbul
- Basıldığı Ülke: Türkiye
- Sayfa Sayıları: ss.1-11
- Dokuz Eylül Üniversitesi Adresli: Evet
Özet
This study presents a comprehensive comparative Finite Element Analysis (FEA) of a custom conical tailstock assembly subjected to a standardized 2000 N axial working load, commonly encountered in precision machining operations. Ensuring the structural integrity and rigidity of this critical component is paramount to maintaining high dimensional accuracy and preventing premature mechanical failure. To evaluate structural performance, stiffness, and safety margins, three distinct engineering materials—Alloy Steel, Nodular/Gray Cast Iron, and Aluminium 7075-T6—were investigated under identical static boundary conditions, featuring a fixed rear cylindrical geometry and uniform tip loading. The numerical simulations were evaluated by focusing on key mechanical parameters, specifically von Mises stress distribution, total displacement (elastic deformation), and the Factor of Safety (FOS). The findings reveal that because the geometry and applied loading conditions remained constant, the maximum von Mises stress values were nearly identical across all three material configurations, peaking at approximately 1.42 MPa, which is well below their respective yield strengths. Consequently, exceptionally high safety factors (FOS > 100) were achieved in all cases. However, noticeable variations were observed in structural rigidity and deformation behavior, directly correlating with the elastic modulus of each material. Alloy Steel exhibited the lowest maximum displacement (0.55 µm), providing optimal rigidity, whereas Cast Iron and Aluminium 7075-T6 displayed slightly higher micro-level deformations of 1.74 µm and 1.58 µm, respectively. These sub-micron and low-micron displacement results confirm that all tested materials maintain robust structural stability under the specified operating load. Ultimately, this comparative investigation provides valuable guidelines for material selection, suggesting Alloy Steel for maximum stiffness, Cast Iron for superior vibration damping, and Aluminium 7075-T6 for lightweight design considerations in machining fixtures.