Third Edition Neh pee] e] a) SLE Sette eG Celie)Machine Tool Design and Numerical Control Third EditionAbout the Author Dr. N. K. Mehta retired as Professor from IIT Roorkee (former University of Roorkee) in 2010 after serving in the Department of Mechanical and Industrial Engineering for almost 40 years. He also served as Counselor (Science and Technology) at the Embassy of India in Moscow from 1995 to 1998. Dr. Mehta has done extensive research in the areas of Machine Tool Design, Machining Science and Computer aided Manufacturing. He has more than 120 research papers to his credit and has supervised 12 PhD Thesis and over 50 M Tech dissertations. In addition, Dr. Mehia was Translation Editor of the Soviet Journal of Structural Mechanies and Design of Structures for four years and has translated nine text books and monographs in English. He was also the Conve- nor of the First International and Twenty second AIMTDR Conference in 2006. Dr. Mehta’s contribution to teaching and research has been widely acknowledged and he has been the recipi- ent of numerous awards and honours such as G. C. Sen Memorial Prize for Best Research Paper at the Tenth AIMTDR conference in 1982, the A. N. Khosla Research Prize and silver medal in 1984, Member Program Advisory Committee of Mechanical Engineering and Robotics of the Department of Science and Technol- ogy, Govt. of India and Member Core Advisory Group of R&D in Machine Tool sector constituted by the Principal Scientific Advisor to the Govt. of India,NZ NZ) t= Tata McGraw-Hill Published by the Tata MeGraw Hill Edueation Private Limited, 7 West Patel Nagar, New Delhi 110 008. Machine Tool Design and Numerical Control (3e) Copyright © 2012, by Tata McGraw Hill Education Private Limited. ‘No part of this publication may be reproduced or distributed in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior written permission of the publishers. The program listings (if any) may be entered, stored and executed in a computer system, but they may not be reproduced for publication. This edition can be exported from India only by the publishers, ‘Tata MeGraw Hil] Education Private Limited. ISBN (13): 978-1-25-900457-5 ISBN (10): 1-25-900457-0 Vice President and Managing Director-—MHE: Ajay Shukla Head—Higher Education Publishing and Marketing: Vibha Mahajan Manager: Sponsoring—SEM & Tech Ed.: Shalini Jha Editorial Researcher: Harsha Singh Copy Editor: Prevoshi Kundu Sr Production Manager: Satinder $ Baveja Production Executive: Anuj K. Shriwastava Marketing Manager—Higher Ed.: Vijay Sarathi General Manager Production: Rajender P Ghansela Production Manager: Reji Kumar Information contained in this work has been obtained by Tata McGraw-Hill, from sources believed to be reliable, However, neither Tata McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein, and neither Tata McGraw-Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that Tata McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance ofan appropriate professional should be sought. ‘Typeset at Tej Composers, WZ-391, Madipur, New Delhi 110063, and printed at Cover Printer: Cl aes edIn Memory of My ParentsContents About the Author ii Preface xi 1, INTRODUCTION TO MACHINE TOOL DRIVES AND MECHANISMS— 1 GENERAL PRINCIPLES OF MACHINE TOOL DESIGN 1.1 Working and Auxiliary Motions in Machine Tools 7 1.2. Parameters Defining Working Motions of a Machine Tool 3 1.3 Machine Tool Drives 19 1.4. Hydraulic Transmission and Its Elements 23 1.5. Mechanical Transmission and Its Elements 34 es for Undertaking the Design of a New Machine Tool 52 1.7, General Requirements of Machine Tool Design 54 1.8 Engineering Design Process Applied to Machine Tools 57 1.9 Layout of Machine Tool 60 Review Questions 65 References 67 1.6 Technico-economical Prerequi: 2. REGULATION OF SPEED AND FEED RATES 68 2.1 Aim of Speed and Feed Rate Regulation 68 2.2. Stepped Regulation of Speed: Design of Speed Box 69 23 Design of Feed Box 90 24 Machine Tool Drives Using Multiple-speed Motors 95 25. Special Cases of Gear Box Design 98 2.6 General Recommendaitions for Developing the Gearing Diagram 105 2.7 Determining the Number of Teeth of Gears /08 2.8 Classification of Speed and Feed Boxes 1/8 2.9 Stepless Regulation of Speed and Feed Rates 124 2.10 Kinematics of Machine Tools 40 Review Questions 163 References 166 3. DESIGN OF MACHINE TOOL STRUCTURES 167 3.1 Functions of Machine Too! Structures and their Requirements 167 3.2 Design Criteria for Machine Tool Structures 167vill | Contents 3.3. Materials of Machine Tool Structures 170 3.4 Static and Dynamic Stiffness 175 3.5 Profiles of Machine Tool Structures 182 3.6 Basic Design Procedure of Machine Too! Structures 188 3.7 Design of Beds 197 3.8 Design of Columns 2/3 3.9 Design of Housings 2/6 3.10 Design of Bases and Tables 2/9 3.11 Design of Cross Rails, Arms, Saddles and Carriages 22/ 3.12 Designof Rams 222 3.13 Model Technique in Design of Machine Too! Structures 224 Review Questions 228 References 231 4. DESIGN OF GUIDEWAYS AND POWER SCREWS 233 4.1 Functions and Types of Guideways 233 4.2. Design of Slideways 234 4.3. Design Criteria and Calculations for Slideways 243 4.4 Guideways Operating under Liquid Friction Conditions 257 45S is 265 46 gn of Anti-friction Guideways 267 4.7 Combination Guideways 273 48 Protecting Devices for Sideways 274 4.9 Design of Power Screws 276 Review Questions 285 References 287 in of Acrostatic Slidews 5. DESIGN OF SPINDLES AND SPINDLE SUPPORTS 288 5.1 Funetions of Spindle Unit and Requirements 288 5.2 Materials of Spindles 289 5.3 Effect of Machine Tool Compliance on Machining Accuracy 290 54 Design Calculations of Spindles 294 5.5 Anti-friction Bearings 303 56 Sliding Bearings 310 Review Questions 332 References 333Contents ix 6. DYNAMICS OF MACHINE TOOLS 6.1 Machine Too! Elastic System-cutting Process Closed-loop System 335 6.2 General Procedure for Assessing Dynamic Stability of Ees—Cutting Process Closed-Loop System 336 6.3. Dynamic Characteristics of Elements and Systems 339 64 Dynamic Characteristic of the Equivalent Elastic System 340 6.5. Dynamic Characteristic of the Cutting Process 352 6.6 Stability Analysis 366 6.7 Forced Vibrations of Machine Tools 378 Review Questions 383 References 385 7. CONTROL SYSTEMS IN MACHINE TOOLS. 7.1 Funetions, Requirements and Classification 386 7.2. Control Systems for Changing Speeds and Feeds 386 7.3. Control Systems for Executing Forming and Auxiliary Motions 396 7.4 Manual Control Systems 397 7.5. Automatic Control Systems 410 7.6 Adaptive Control Systems 4/5 References 418 8. NUMERICAL CONTROL OF MACHINE TOOLS 8.1 Fundamental Concepts, Classification and Structure of Numerical Control Systems 4/9 8.2 Manual Part Programming 440 8.3 Computer Aided Part Programming 465 Review Questions 486 References 493 9. EXTENSIONS OF NUMERICAL CONTROL— CNC, DNC, MACHINING CENTRES: 9.1 Distributive Numerical Control (DNC-1) 495 9.2 Computer Numerical Control (CNC) 495 9.3 Machining Centres 498 9.4 Direct Numerical Control (DNC-2) 501 9.5 CNC Programming 504 Review Questions 538 Index 335 386 419 494 543Preface About the Book The first edition of the book was published in 1984 under the title, Machine Too! Design, when the subject was gaining popularity as a specialised course in engineering institutions in the country. The motivation for writing the book is to provide a basic text for undergraduate students that would also serve as a useful reference for postgraduate students and practicing engineers. The revision of the book for the second edition published in 1996 was undertaken with the limited objec- tive of incorporating the advances in numerical control in the intervening years. Therefore, the chapter on ‘Numerical Control of Machine Tools” was substantially modified and a new chapter on Extensions of Nu- merical Control — CNC, DNC, Machining Centers’ was added. To adequately, reflect the updated content, the title of the book was changed to Machine Tool Design and Numerical Control, In today’s ‘user-friendly age’, the revision for the third edition has been undertaken primarily to make the book more reader friendly and the changes are mostly based on the feedback from the reviewers and a survey carried out by the publisher. The important new features of this edition are summarised below: + A subsection on ‘Calculation of Machining Time’ has been added in Chapter 1. The highlight of this section is the inclusion of calculation of machining time of grinding operations which is usually not covered in text books. + A major section on ‘Kinematics of Machines Tools” has been added in Chapter 2, wherein the gearing diagrams of lathe, drilling machine and milling machine have been discussed to give the readera better understanding of the finer practical aspects of gear box design. A new attractive feature of this section is the discussion on thread cutting operation on lathe and operations using indexing head on milling machine based on fundamental principles, as distinct from the usual thumb rule type approach in most of the existing books. It is felt that this section will serve as useful base material for formulating design projects and independent assignments for final year students of mechanical and production engineering disciplines + In the second edition the design procedure of machine tool gear boxes was terminating with the calculation of gear teeth. This has been extended in the present edition, to its logical conclusion by adding a subsection on ‘Determination of Shaft and Gear Dimensions’ in Chapter 2. + A subsection on “Design of Lathe Bed’ has been added in Chapter 3 giving the detailed procedure supported with a solved example to provide practical illustration of the theoretical aspects for one specific case. This material will be helpful in formulating design projects and assignments not only for beds of various machine tools but also for other structural elements of machine tools such as bases, columns, tables etc. + A large number of solved examples have been added, especially in Chapters 1-3 in support of the elaboration of the new topics added in these chapters. In addition, new review questions have also been added in almost all the chapters.xil | Preface + A major curtailment has been undertaken in Chapter 8 on ‘Numerical Control of Machine Tools’ Previous edition contained a detailed description of the hardware of NC technology spread over seven subsections. Most of this technology has now become obsolete. It has, therefore, been thoroughly condensed and retained in one subsection only to the extent necessary for understanding the functioninglopcration of NC machine tools. + Enhanced pedagogy includes Solved Examples: 25 Review Questions: 130 Computer Programs for NC, CNC and DNC: 12 Structure of the Book The book is organised into 9 chapters. Chapter 1 is an introductory chapter that provides a review of the concepts of working and auxiliary motions in machine tools and calculation of machining time of various operations. It also gives an overview of the elements of hydraulic and mechanical transmissions employed in machine tools. A section on layout of machine tools is unique to this book and is extremely relevant in the context of increasing emphasis on modularity and reconfigurability in CNC machines. Chapter 2 deals with the description of the laws of stepped regulation of speed and feed in machine tools and goes on to provide in rigorous detail the procedures for the design of gear boxes for stepped control of speed and feed, covering the whole gamut of issues from selecting the optimum structural diagram and speed chart to the finalisation of gearing diagram and determination of shaft and gear dimensions. A separate sec- ion is devoted to design of gear boxes with multiple speed motors and special gear boxes with overlapping speeds, broken geometric progression, etc., which have been supported with multiple diagrams. Steeples regulation of speed and feed rates by electrical, hydraulic and mechanical methods is discussed in great detail. To strengthen the understanding of kinematics of machining operations, thread cutting on lathe and operations using indexing head on milling machine are described from first principles, as distinct from the thumb rule approach presented in most of the existing books. In Chapter 3, the functions and requirements of the machine tool structures are discussed along with the design criteria and their application to individual structural elements such as beds, bases, columns etc, As- pects of design related to selection of the shape of structural elements and their strengthening with ribs and stiffeners are discussed in detail with lot of supporting data. In view of the complexity of their configuration and force system, it is seldom possible to analytically arrive at an exact design solution for structural elements of machine tools. Model techniques are therefore an essential part of the validation of their design and the fundamentals of these techniques are discussed at the end of the chapter. The description of the functions and classification of guide ways are dealt in Chapter 4. The design cri- teria of slideways are discussed and the detailed procedure of slideways design for stiffiness and wear resis- tance based on average and maximum pressure is presented, Selection of slideway profiles and techniques of clearance adjustment and protection are presented and explained with the help of simple sketches. The design of hydrodynamic guideways, hydrostatic guideways, aerostatic guideways and anti-friction guideways is described in detail, supported with analysis as well as the relevant design data and curves. Design of sliding friction and rolling friction power screws is also included in this chapter. Chapter 5 discusses the functions and requirements of machine tool spindles and an analyses the effect of the compliance of spindles and their supports on machining accuracy. A major portion of this chapter is devoted to the design of sliding bearings, hydrodynamic and hydrostatic journal bearings and aerodynamicPreface xill and aerostatic bearings, supported with analysis and the relevant design data and curves. Issues specific to machine tools such as functional requirements, appropriate combinations of bearings for different machine tools and pre loading of bearing are discussed in detail The initial thrust of Chapter 6 is on establishing the study of the dynamic behaviour of a machine system. The latter can be looked upon as a closed loop system in which the machine tool elastic system (MTES) and cutting process (CP) are the interacting elements. The dynamic cutting force models of Tlusty, Tobias and Kudinov are discussed and compared. Stability analysis of single and multiple degree of freedom systems with and without mode coupling is described, Regenerative chatter and the response of MTES-CP system under forced vibrations are also discussed. Dynamics of machine tools is a difficult topic, but by adopting a logical approach based on fundamental principles of control theory, it has been made easy to understand. Chapter 7 discusses the functions, requirements and classification of machine tool controls and goes on to describe the speed and feed changing mechanisms with simple centralised control, preselective control and selective control, For manual control systems, anthropometric and functional anatomy data has been systematically compiled for ergonomic design of control members such as push buttons, knobs, toggles, cranks, levers, hand wheels, ete., and also for the location of displays and control members. The highlight of this chapter is the detailed compilation of data for ergonomics design of control members which is not only unique to this book but also sets it apart from any other text book on machine tool design. Chapter 8 elaborates on the fundamental concepts of numerical control and classification of numerically controlled machine tools. It provides an overview of the NC hardware technology to the extent necessary for understanding the functioning and operation of NC machine tools. A major portion of this chapter is devoted to manual part programming for point-to-point, positioning- cum-straight cut and continuous path systems. The concept of computer aided part programming has been discussed and the APT programming system has been covered in reasonable detail, Both the manual and APT part programming systems have been illustrated with sample problems with step-by-step explanation of the part programs. The concluding chapter, i., Chapter9 deals with the extensions of numerical control, namely computer numerically controlled (CNC) machine tools, machining centres and direct numerical control (DNC). A major portion of this chapter is devoted to CNC part programming for machining centres as well as turning centres. The programming concepts of tool diameter compensation, tool length off set, ete., are taken one at- a-time and illustrated with suitable programming examples. Advanced programming features sueh as mirror imaging and canned cycles are discussed and illustrated with complete programs for sample parts, In addition, the present edition also contains new and improved solved examples, computer programs and. chapter-end review questions to help students understand the concepts in a better way. Acknowledgements I would like to thank my M.Tech student Ganesh Jagdale and Ph.D. student Vikas Upadhyay for their as- sistance in collecting and collating the reference material and for agreeing to be the sounding boards who helped me to fine tune the new material for this edition from the viewpoint of a student, I would like to take this opportunity to express my deep gratitude to Shri Rajesh Kumar for typing the text and drawing the tech- nical figures for the new material of this edition and for always being by my side and providing technical and secretarial assistance to me over the years much beyond the call of duty. I would also like to thank the following reviewers for reviewing this book:xiv | Preface Dinesh Khanduja National Institute of Technology, Kurukshetra Haryana A. P. Harsha Institue of Technology, Banaras Hindu University, Varanasi Utiar Pradesh Ashish Banerjee Jadavpur University, Kolkata West Bengal L. Bhaskara Rao Vellore Institute of Technology Univers Vellore Tamil Nadu A. Venugopal National Institute of Technology, Warangal Andhra Pradesh T, Rangaswamy Malnad College of Engineering, Hassan Karnataka Lam especially thank ful to the editorial team of Tata McGraw Hill for their sincere help and guidance during the development of this book. I would like to personally thank Ms Harsha Singh, Ms Preyoshi Kundu and Mr Anuj Shriwastava who put so much energy and effort in bringing this book to its final stage. In the end, I must confess that the response received from the readers for the earlier editions is both hum- bling and gratifying. | am grateful to them for their continuous support of my modest contribution to the teaching and practise of machine tool design and numerical control. I sincerely hope that the changes incor- porated in the current edition will add more value to the book and will continue to provide useful service to students, teachers and practising engineers for many more years to come. NK MentaINTRODUCTION TO MACHINE 1 TOOL DRIVES AND MECHANISMS— GENERAL PRINCIPLES OF MACHINE TOOL DESIGN The machine tool is a machine that imparts the required shape to a workpiece with the desired accuracy by removing metal from the workpiece in the form of chips. In view of the extremely vast range of shapes that are in practise imparted to various industrial components, there exists a very large nomenclature of machine tools. Machine tools can be classified by different criteria as given below. 1. By the degree of automation into (machine tools with manual control, (i) semi-automatic machine tools, and (iii) automatic machine tools. By weight into (i) light-duty machine tools weighing up to It. (ii) medium-duty machine tools weighing up to 10t, and (ili) heavy-duty machine tools weighing greater than 10+. 3. By the degree of specialisation into (i)_general-purpose machine tools—which can perform various operations on workpieces of differ ent shapes and sizes, (ii) single-purpose machine tools—which can perform a single operation on workpieces of a par- ticular shape and different sizes, and (iii) special machine tools—which can perform a single operation on workpieces of a particular shape and size 1.1. WORKING AND AUXILIARY MOTIONS IN MACHINE TOOLS For obtaining the required shape on the workpiece, it is necessary that the cutting edge of the cutting tool should move in a particular manner with respect to the workpiece. The relative movement between the workpiece and cutting edge can be obtained either by the motion of the workpiece, the cutting tool, or by a combination of the motions of the workpiece and cutting tool. These motions which are essential to impart the required shape to the workpiece are known as working motions. Working motions are further classified into two categories: 1. Drive motion or primary cutting motion 2. Feed motion2 | Machine Too! Design and Numerical Control Working motions in machine tools are generally of two types: rotary and translatory. Working motions of some important groups of machine tools are shown in Fig. 1.1. Shaping —> Milling Grinding Fig. 1.1 Working motions for some machine tools 1. For lathes and boring machines drive motion—rotary motion of workpiece feed motion—translatory motion of cutting tool in the axial or radial direction 2. For drilling machines drive motion—rotary motion of drill feed motion—translatory motion of drill 3. For milling machines drive motion—rotary motion of the cutter feed motion—translatory motion of the workpiece 4. For shaping, planing, and sloting machines drive motion— reciprocating motion of cutting tool feed motion—intermittent translatory motion of workpiece 5. For grinding machines drive motion—rotary motion of the grinding wheel, feed motion—rotary as well as translatory motion of the workpiece. Besides the working motions, a machine tool also has provision for auxiliary motions. The auxiliary mo- tions do not participate in the process of formation of the required surface but are nonetheless necessary to make the working motions fulfil their assigned function. Examples of auxiliary motions in machine tools are clamping and unclamping of the workpiece, idle travel of the cutting tool to the position from where cutting is to proceed, changing the speed of drive and feed motions, engaging and disengaging of working motions, ete.Introduction to Machine Too! Drives and Mechanisms 3 | In machine tools, the working motions are powered by an external source of energy (electrical or hydraulic motor). The auxiliary motions may be carried out manually or may also be power-operated depending upon the degree of automation of the machine tool. In general-purpose machine tools, most of the auxiliary mo- tions are executed manually. On the other hand, in automatic machines, all auxiliary motions are automated and performed by the machine tool itself. In between these two extremes, there are machine tools in which the auxiliary motions are automated to various degrees, i.e., some auxiliary motions are automated while others are performed manually. PARAMETERS DEFINING WORKING MOTIONS OF 1.2 AMACHINE TOOL ‘The working motions of the machine tool are numerically defined by their velocity. The velocity of the pri- mary cutting motion or drive motion is known as cufting speed, while the velocity of feed motion is known as feed. ‘The cutting speed is denoted by v and measured in the units m/min. Feed is denoted by s and measured in the following units: mu/rev in machine tools with rotary-drive motion, e mmvtooth in machine tools using multiple-tooth cutters, e.g, milling machines, . lathes, boring machines, ete., 1. 2. 3. _mm/stroke in machine tools with reciprocating-drive motion, e.g., shaping and planing machines, and 4, mm/min in machine tools which have a separate power source for feed motion, e.g., milling machines, In machine tools with rotary primary cutting motion, the cutting speed is determined by the relationship, di y= eo min ay 1000, where d = diameter of workpiece (as in lathes) or cutter (as in milling machines), mm n= revolutions per minute (rpm) of the workpiece or cutter In machine tools with reciprocating primary cutting motion, the cutting speed is determined as m/min (12) 10007, where L =length of stroke, mm T, = time of cutting stroke, min If the time of the idle stroke in minutes is denoted by T,, the number of strokes per minute can be deter- mined as 1 T.+T; Generally, the time of idle stroke 7; is less than the time of cutting stroke; if the ratio 7./T; is denoted by K, the expression for number of strokes per minute may be rewritten as 1 K n= == __ (13) TA+T/T.) T+ K)Machine Too! Design and Numerical Contro! Now, combining Eqs (1.2) and (1.3), the relationship between cutting speed and number of strokes per minute may be written as follows: n-L(K +1) aa) 1000K ‘The feed per revolution and feed per stroke are related to the feed per minute by the relationship, Sy —sen as) where 5», = feed per minute s = feed per revolution or feed per stroke n = number of revolutions or sirokes per minute ‘The feed per tooth in multiple-tooth cutters is related to the feed per revolution as follows: Zz (16) wheres = feed per revolution feed per tooth of the cutter Z = number of teeth on the cutter ‘The machining time of any operation can be determined from the following basic expression: a eain (17) Sm where 7, = machining time, min L = length of machined surface, mm 5, = feed per minute 1.2.1 Calculation of Machining Time ‘As mentioned above, the machining time of various operations is determined using Eq. (1.7), wherein 5), is found from Eq. (1.5) for single point tools and Eq, (1.6) for multiple tooth cutters. Further, for a given work- tool pair, an optimum cutting speed is specified for which the corresponding rpm or strokes/min is calculated using Eq. (1.1) and Eq. (1.4), respectively. In may further be noted that for a given length | of'a workpiece, the actual tool travel is greater on account of the need to provide an approach of AI for safe entry of tool (on commencement of machining) and over travel of A2 for safe exit of tool (on completion of the machining cut). Generally, 41 and A2 are taken equal to 2-3 mm, The difference in the formulae of machining time calculation for various operations arises from the individual process geometry, which is reflected in the corresponding tool travel. Hence, the calculation of tool travel for various operations is described below. In the figures of all the operations discussed below | indicates the tool position at the commencement of cut and Tat the end of cut. Operations on Lathe (a) Turning operation on workpiece held between centres (Fig. 1.2) length of tool travel L =/-+ Al + A2 +43 where length of workpiece Al = approach; generally equal to 2-3 mm over travel; generally equal to 2-3 mm tcot ; where fis depth of cut and @ is principal or side cutting edge angle; for straight edged tools ¢ = 90°, hence A3 =0Introduction to Machine Too! Drives and Mechanisms 5 23 Fig. 1.2 Turning operation on workpiece supported between centres (b) Turning operation on workpiece clamped in chuck (Fig. 1.3) length of tool travel L =/+ Al + A3 where = length of machined surface Al and A3 are the same as in turning of workpiece held between centres Fig. 1.3. Turning operation on workpiece clamped in chuck6 | Machine Too! Design and Numerical Contro! (©) Facing operation (Fig. 1.4) length of tool travel L = D/2 + Al + A2 + A3 where D = diameter of workpiece Al = approach; generally equal to 2-3 mm 2 =over travel; generally equal to 1-2 mm is essential to ensure that a protruding stem is not left attached to the face of the machined workpiece A3 =rcot $; where fis depth of cut and @ is principal or side cutting edge angle; for straight edged tools @= 90°, hence A3 = 0 The length of tool travel for parting and grooving operations is determined ina similar manner. 43 yo > lat aay Fig. 1.4 Facing operation NID (d) Boring operation in partial length of workpiece; hole od to be enlarged to @D (Fig. 1.5) length of tool travel L =/+A1 + 03 where 1 = length of bore Al =approach; generally equal to 2-3 mm 43 =rcot g; where sis depth of cut and g is principal or side cutting edge angle; for straight edged tools $= 90°, hence A3 = 0Introduction to Machine Too! Drives and Mechanisms 7 Fig. 1.5. Boring operation in partial length of workpiece (c) Boring operation in full length of workpiece; hole od to be enlarged to @D (Fig. 1.6) length of tool travel L =/-+ Al + A2 +3 where 1 = length of bore A2 = over travel; generally equal to 2-3 mm Al and A3 are the same as in boring operation in partial length of workpiece a3. Ay Mt A3 L 4.8 Boring operation in full length of workpiece8 | Machine Too! Design and Numerical Contro! Example 1.1 Determine the machining time for turning a shaft from $70 mm to $64 mm over a length of 200 mm at n= 600 rpm ands = 0.4 mmv/rey. The turning tool has principal cutting edge angle $= 45°, Depth of eut = Length of travel L = 200 + reot @ + Al + A2 Assuming Al and A2 = 2 mmeach L =200+3x1+2+2=207 mm Machining Time - —207__ ~ 08625 mm. 00 x 0.4 Example 1.2 A ring has to be cut out from a pipe of outside diameter D 250 rpm and feed 0.14 mm/rev. Calculate the machining time. 100 mm and inside diameter d = 84 mm at Length of travel in a pipe cutting operation is =P=4 artnn Assuming Al = A2=2mm p= 100-84 1349-19 2 Machining time T,,, = a 12 = 0.342 mm, 2500.14 Operations on Drilling Machine Drilling operation (Fig. 1.7) length of tool travel L =/ + Al + A2 + A3 where 1 = height of the workpiece Al = approach; generally equal to 2-3 mm A2 = over travel; generally equal to 2-3 mm A3 = (di2) cot 6, where dis drill diameter and 2¢ is the lip angle of the drill ‘The length of tool travel for counter boring and reaming operations can be determined in a similar manner.Introduction to Machine Too! Drives and Mechanisms 9 | Sr, ° e 33 at a 4 2 or <*> 22 " 38 Fig. 1.7 Drilling operation Example 1.3 Calculate the machining time for drilling a 930 through hole in a 30 mm thick plate at a speed of 30 m/min and feed 0.1 mm/tooth. Length travel =30+ Al +A2+ $ cot Assuming Al =A2=2mm and @=60° (half of lip angle) L = 3042424 52 cot 60° = 42.66 mm The rpm of the drill is 1000 30 _ 1000 Feed per revolution of drill = 2 x feed per tooth because a drill has two cutting teeth Therefore, s,= 2% 0.1 = 0.2 mm/rev Hence, feed per minute s,, = 4° x02 = 2% mm/min 7 7 Machining time Ty, = 22.66 0.67 min.40 | Machine Too! Design and Numerical Contro! Operations on Milling Machine In all the milling operations described below. Al = approach; generally equal to 2-3 mm A2 = over travel; generally equal to 2-3 mm (a) Horizontal milling machine: Plain milling operation (Fig. 1.8) length of cutter travel L=/+ Al +A2+A3 where 1 = length of the workpiece 3 =BC= JOC? - OB? = JR? - OB? = {R?-(R-1)* = JR?- (R240 -2R0) = y2Rr—? = D-1 Fig. 1.8 Plain milling operation (b) Vertical milling machine: Symmetrical face milling operation (Fig. 1.9) length of cutter travel L= J+ Al +A2+ 3 where 1 = length of the workpiece A3 =AB= 0A -OB=R- JOC? = BC? = R- we -(2) 2 =05(D— D> - B?)Introduction to Machine Too! Drives and Mechanisms 14 Fig. 1.9 Symmetrical face milling operation Dives (€) Vertical milting machine: Asymmetrical face milling operation B > — (Fig. 1.10) length of cutter travel L= 1+ Al +A2 + 03 where 1 = length of the workpiece 3 =AB= Jos —oB? = R= (B-8 = VR?— R?— B+2BR = /B(D-B) L D Fig. 1.10 Asymmetrical face miling operation, B > = (a) Vertical milling machine: Asymmetrical face milling operation B < 2 erie 1.11) length of cutter travel L= 1+ AL +A2 +4342 | Machine Tool Design and Numerical Controt where 1 = length of the workpiece A3 =AB= OA? - 08? = JR? -(R- BY = JR? R?- B?+2BR = JB(D— B) D Fig. 1.11 Asymmetrical face miling operation, B < > Example 1.4 A200 mm long job is to be machined by a plain milling cutter of diameter D = 40 mm and 10 teeth. If the cutting speed is 30 m/min and feed is 0.08 mm/tooth, calculate the machining time for a depth of cut of 4 mm. Assume suitable approach and over travel. Length of travel L = 200 + i(D=0) + Al +2 Assuming Al =A2=2mm cach L = 200+ ,a(40-4) +2+2=216 mm The rpm of the milling cutter is n= 1000v _ 1000 x30 nD mx40 Feed per minute s,, =s;x2*7” = 0.08 x 10 x 100% 3 ~ 191.0 mm/min 7x40 Machining time T,, 1.13 min.Introduction to Machine Too! Drives and Mechanisms 13 Operations on Shaping Machine (Fig. 1.12) Ir AQ, le a At Fig. 1.12 Shaping operation Machining time = on where BY =B+B1+ 62 +B3 B = width of workpiece BI =approach, generally equal to 2-3 mm B2 = over travel, generally equal to 2-3 mm B3 =tcot 6: where ris depth of cut and dis principal or side cutting edge angle; for straight edged tools 9= 90°, hence A3 = 0 s = feed per stroke n= strokes/min which is found from Eq. (1.4) The machining time of planing and slotting operations can be determined in a similar manner. Example 1.5 A100 mm wide and 200 mm long surface is to be machined on a shaper, using feed per stroke of 0.3 mm. If the cutting speed is 20 m/min and the ratio of return time to cutting time is | : 1.25, calculate the time required to machine the job. Assume suitable approach and over travel. ‘Strokes per minute of the shaper is p= 1000vK (K+)44 | Machine Too! Design and Numerical Controt Fora job of length 200 mm, the typical stroke length will be approximately 20% greater. Hence, L= 1.2 200=240mm 1000 x 20x 1.25 A Therefore, n = ——~~—> = 46.29 strokesimin. 240(1.25 +1) Correcting this value to the nearest available value available on the shaper, say 50 strokes/min and assum- ing that the operation is carried out with a straight edged tool and that B1 = B2 = 2 mm each 100+2+2 03x50 = 6.934 min. Machining time T,, = B + Bl + B2 Operations on Grinding Machine (a) Cylindrical Grinding: External-Traverse cut (Fig. 1.13) Grinding time T= K, min Typ kBt where L = length of workpiece 8; = KB mm/rev of workpiece is the longitudinal feed of the reciprocating motion of the workpiece; £ = 0.3 ~ 0.5 for rough grinding and D,, < 20 mm, k= 0.7 ~ 0.85 for rough grinding and D,,, 2 20 mm: k= 0.2 ~ 0.4 for finish grinding h allowance, mm; 1 = s, = radial feed/stroke, mm is akin to depth of cut and is given intermittently at the end of stroke, i.e., on traversing the length of the workpiece; typically £=0.01-0.025 mm K ~ 1.2 for rough grinding and 1.4 for finish grinding Nyp =tpm of the workpiece B = width of the grinding wheel fh ESE Fig. 1.13 External cylindrical grinding—traverse cutIntroduction to Machine Too! Drives and Mechanisms 15 (b) Chlindrical grinding: external: Plunge cut (Fig. 1.14) m A Grinding time T= 5 Sip where s,= 0.0025 — 0.20 mm per revolution of workpiece is the transverse feed ft, Mp and K are the same as in traverse cut external grinding = Fig. 1.14 Extomal cylindrical grinding—plunge cut (c) Gilindrical Grinding: Internal (Fig. 1.15) Internal cylindrical grinding is carried out in two ways; with a rotating workpiece or a stationary workpiece. In the latter case, the grinding wheel not only rotates about its own axis, but also executes a planetary motion such that its centre moves along the planetary motion circle (PMC). This method is employed for large workpieces. Grinding time T= a K, min for internal grinding with rotating workpiece ThupkB waa 2Lh . . . , Grinding time T= ———— K, min for internal grinding with stationary workpiece TpyckBt where B mm/rev of workpiece is longitudinal feed; 0.25-0.45 for finish grinding feed/double stroke, mm; typically ¢ = 0.005-0.03 mm for rough grinding and 0.002-0.1 for finish grinding. It is given at the end of one complete to-and-fro stroke (double stroke), which explains the presence of 2/ in the formula of machining time calculation = 0.4-0.8 for rough grinding and46 | Machine Tool Design and Numerical Controt Nyy = 1pm of the workpiece npyc =rpm of planetary motion of the grinding wheel B =width of the grinding wheel ‘fh =allowance, mm; K =1.3 forrough grinding and 1.6 for finish grinding () Fig. 1.15. Internal cylindrical grinding (a)_ with rotating workpiece (b) with stationary workpieceIntroduction to Machine Too! Drives and Mechanisms 17 (@) Surface grinding: Peripheral-Planer feed (Fig. 1.16) Grinding time T= gH min; 5, where _L =length of stroke; L =/+ 10 mm, where / is length of workpiece ‘B, mm/siroke is the transverse feed which is given at the end of stroke, i.e., on traversing the length of the workpiece; k= 0.4-0.7 for rough grinding and 0.25-0.35 for finish grinding 1 =0.015-0.15 mm for rough grinding and 0.005-0.015 for finish grinding. It is akin to depth of cut and is given intermittently at the end of stroke, i.e., on traversing the length of the workpiece H=By,+B+5 mm; Sn = feed of table, mm/min f= allowance, mm K = 1.25 for rough grinding and 1.4 for finish grinding Fig. 1.16 Peripheral surface grinding (©) Surface grinding: Face-Planer feed (Fig. 1.17) Surface grinding with the face of grinding wheel is generally carried out with grinding wheels having diameter D greater than the width of the workpiece B. Therefore, the transverse feed s, is not required (see Fig. 1.17a). If the feed in depth is given at the end of stroke, i.e., on traversit grinding time is determined from the expression, 7 AK, min Sut the length of the workpiece, then where L=/+ Al +A2+D (see Fig. 1.17¢) If the feed in depth is given at the end of one complete to-and-fro stroke (double stroke), then grinding time is determined from the expression,48 | Machine Tool Design and Numerical Controt 2H: min +A1+A2+A3; length of workpiece pproach; generally equal to 2-3 mm A2 =over travel; generally equal to 2-3 mm 3 =0.5(D — JD? — B? )as in symmetrical face milling (see Fig, 1.17b) Sip and hare the same as in peripheral surface grinding Fig. 1.17 Face surface grindingIntroduction to Machine Too! Drives and Mechanisms 19 | Example 1.6 A 940 and 210 mm long step is to be machined on a cylindrical grinding machine. Grinding wheel diameter is 600 mm and its width 63 mm, Allowance is 0.2 mm and radial feed 0.005 mm per stroke. Transverse feed (mm per revolution of work) s;= kB, where k= 0.3. If peripheral speed of the grinding wheel and workpiece is 30 m/s and 35 m/min, respectively, determine the machining time. Length of stroke of the table = 210 mm. . 1000) _ 100035 _ 875 rpm of the workpiece Muy = ——* = ——~ = => TDyp x40 Allowance h = 0.2 mm Longitudinal feed of reciprocating motion of workpiece s; =k» B = 0.3 x63 = 18.9 mm/rev Radial feed 1= 0.005 mm/stroke Assuming it to be case of fi ish grinding we take K = 1.4 Eh gs NOXO2 4 = 999 min, mpstt $75 18.9 x 0,005 x Machining time T,, = MACHINE TOOL DRIVES The machine tool drive is an aggregate of mechanisms that transmits motion from an extemal source to the operative elements of the machine tool. The external source of energy is generally a three-phase ac motor which has a rotary motion at its output shaft. The rotary motion of the output shaft of the motor is transmitted to the operative element to provide an appropriate working or auxiliary motion. When the required motion is rotary, the transmission takes place through mechanisms that transfer rotary motion from one shafi to another. However, ifa translatory motion is required, the transmission invariably includes a mechanism for transforming rotary motion into translatory. It is a general requirement for machine tool drives that they should have provision for regulating the speed of travel of the operative elements. The regulation may be available in discrete steps or it may be stepless, i.e., continuous. The former are known as stepped drives and the latter stepless. Transmission of motion from the external source to the operative element can take place through mechani cal elements, such as gears, chains, belts, etc., or by means of hydraulic and electrical circuits. The drives are correspondingly known as mechanical, hydraulic and electrical. Mechanical drives may be of stepped or stepless type, but hydraulic and electrical drives are invariably stepless in nature It may be thus seen that a machine tool drive consists basically of 1. anelectric motor, and 2. a transmission arrangement. The procedure of selecting the electric motor will now be explained followed by a brief description of the elements that constitute the transmission arrangement in mechanical and hydraulic drives. The detailed design of the transmission arrangement will be discussed in Chap. 2.20 | Machine Tool Design and Numerical Controt 1 Selection of Electrical Motor As stated above, three-phase asynchronous ac motors (also known as induction motors) are generally used as the source of power in machine tools. The power rating of the electric motor in general-purpose machine tools is calculated by the formula N, Nn kw (18) 1 where ower rating of the electric motor, KW. (otal power required for removing metal, kW 1) = coefficient of efficiency of the drive The power spent on a cutting operation consists of the power required to overcome each component of the cutting force. In general, the cutting force can be resolved into three mutually perpendicular components P,, P,, and P.. In a simple tuming operation let P. be the component of the cutting force coinciding with the velocity vector, P,—the component coinciding with the direction of axial feed and P,—the component coinciding with the direction of radial feed. Let the corresponding velocities be v, s, and s,, where v is the cutting speed, s, the feed in the axial direction and s, the feed in the radial direction. The power required for the cutting operation will be Pp. Pp a Ee pt oo _ 6075x136 60 75*1.36x1000 60 x 75x 1.36 x 1000 “Sycn Ne ‘The first factor on the right-hand side represents the power required for removing metal, while the second and third factors represent the power required for the feed motion in radial and axial directions, respectively. Ina cylindrical turning operation s,=0, hence the second factor becomes zero, Also, the third factor is gener- ally negligibly small as compared to the first, and therefore, the simplified expression for the motor power rating can be written as Pow N. 6100 kW (9) The value of NV, calculated from Eq. (1.9) should be increased by about 5% to accommodate the power requirements of the feed motion. The value of m may be expressed as MMM Mss Mi where 1), Ni, Ms, ... Mare the coefficients of efficiency of the individual transmissions involved in transmit- ting motion from the motor to the operative element. These values for different transmissions and supports are given in Table 1.1,Introduction to Machine Too! Drives and Mechanisms 21 | Table 1.1 Values of coefficient of efficiency for various transmission and supports! Type of Transmission or Support Coefficient of Efficiency Belt drive with flat belt 0.98 Belt drive with V-belt 0.96 Spur gear drive 0.98 Helical gear drive 0.97 Bevel gear drive 0.96 Ball or roller bearing 0.995 Crank and slider mechanism 0.90 Jaw clutch. 0.95 Multiple-dise friction clutch operating in oil 0.90 The overall transmission efficiency generally lies between 1) = 0.8-0.85 for machine tools with rotary primary cutting motion and 7) = 0.6--0.7 for machine tools with reciprocating primary cutting motion. The value of N, for various cutting operations (for different cutting tool and workpiece materials) can be determined from empirical formulae that are available in textbooks on the theory of metal cutting. The power required for cutting should be calculated for the following conditions: rough machining of a soft material with cemented carbide tool using maximum workpiece diameter (in lathes and boring machines), maximum cutter diameter (in milling and drilling machines) and maximum stroke length (in shaping and planing machines). On the basis of the calculated N,,, value, a standard induction motor is selected having the nearest available power rating that is equal to or slightly greater than the calculated value. The selection of electric motors that work under conditions of variable loading is done by a different pro- cedure® which is explained below. This procedure is expedient for single purpose and special machine tools that machine identical parts according to a set sequence of operations which is continuously repeated. An example of such a loading is shown in Fig. 1.18, ‘The power rating of the motor is determined from considerations of permissible overloading and heating, and the higher of the two values is taken for selecting the motor. From Consideration of Overloading Nm = (1.10) n where Niyax = maximum power required in the whole cycle (Ny, in the example of Fig. 1.18) A = permissible overloading coefficient for the given type of motor 1) = coefficient of efficiency of the driveMachine Too! Design and Numerical Contro! Ne An, len he? 4 & t tf Dpadpuahmdneanianienal <—_—_ |, ———_ >| Fig. 1.18 Variable loading cycle in which the motor temperature comes down to the ambient temperature From Consideration of Heating The calculation of power rating from the consideration of heating consists in determining an equivalent average load of constant value such that heating of the motor due to this load is equal to the sum of heat due to individual load components of the variable loading cycle. The power rating is determined by the expression (LAL), where Neg = equivalent power rating N, =power required for ith sequence of the variable loading cycle 1, = duration of the ith sequence of the variable loading cycle /, = cycle time n ‘otal number of sequences in the cycle 1| = coefficient of efficiency of the drive In the variable loading cycle of Fig. 1.18, the time ratio of cutting and idle sequences of the cycle was such that at the end of the cycle, the motor temperature came down to the temperature of the surrounding atmosphere, However, the variable loading cycle may be such that the motor temperature tends to acquire a more or less stable value higher than that of the surrounding atmosphere (Fig. 1.19). In such cases, it is pos sible to select a motor used for continuous loading based upon the equivalent power rating calculated from Eq, (1.11). However, special motors can also be employed. These special motors are alternatively switched on and off, and are characterised by the ratio, a x 100 fon + lost € Where faq ~ time during which motor remains switched on for = time during which motor remains switched off Generally, standard motors are manufactured for ¢ values of 15, 25, 40, and 60%.Introduction to Machine Too! Drives and Mechanisms 23 | The value of € according to the time of cutting and idle sequences in the variable loading cycle is deter- mined as tc = —— x 100 htt In general, the €, value for a cycle differs from the standard value provided on the motor. Therefore, the nearest standard value of €y is selected and the power rating is determined from the express Nu sy, fe (1.12) q where Nj ~ Neq/s/€,3 Neq being the equivalent power rating calculated for the given cycle from the consid- eration of heating as discussed above In machine tools, electric motors are selected by this method for €, < 60%. For higher values of ¢,, the motor is selected on the basis of the equivalent power rating from the consideration of heating nye i pt |b >| Fig. 1.19. Variable loading cycle in which the motor temperature acquires @ stable value greater than the ambient temperature 1.4 HYDRAULIC TRANSMISSION AND ITS ELEMENTS Hydraulic transmission is used in machine tools for providing rotary as well as translatory motion, although the latter application is more common, Hydraulic transmission, as a rule, provides stepless regulation of the speed and feed rate. ‘The functioning of a rotary hydraulic drive can be explained with the help of Fig. 1.20. The electric mo- tor rotates the rotor of vane pump through gear pair Z,/Z>. During rotation, the pump sucks in oil from the reservoir and delivers it under pressure to the hydraulic motor. The hydraulic motor is, in principle, another vane pump mounted in the reverse manner, so that oil delivered under pressure rotates its vanes and hence the rotor. From the output shaft of the hydraulic motor, rotary motion is transmitted to the machine-tool spindle through a belt drive. A pressure value in the delivery line limits the maximum pressure at which oil is deliv- ered to the hydraulic motor. The actual pressure can be read on the pressure gauge.24 | Machine Tool Design and Numerical Controt Pressure Pressure Hydraulic Belt drive Motor Fig. 1.20 Schematic diagram of a rotary hydraulic drive The principle of operation of a translatory hydraulic drive is discussed below. The drive (Fig. 1.21) con sists of a gear pump which sucks oil from the reservoir and delivers it to the direction control value through a throttle. The function of the throttle is to enable regulation of the speed of travel of the operative element. In the position of the control valve drawn by firm lines, oil is delivered into the right-hand chamber of the hydraulic cylinder, moving the piston towards the left. The machine-tool table which is rigidly attached to the piston is also moved leftwards. Oil from the left-hand chamber of the hydraulic cylinder returns to the reservoir through the direction-control valve. It can be seen from Fig. 1.21 that the control-valve piston is coupled to the operative element by means of a rocking lever. Therefore, the leftward movement of the machine-ool table is accompanied by a movement of the control-valve piston in the same direction. The leftward movement of the table stops when the control-valve piston comes to occupy the position shown by dotted lines. In this position, oil begins to flow in the left-hand chamber of the hydraulic eylinder, pushing the piston rightwards, thus reversing the direction of translatory motion of the table. The hydraulic circuit has a pressure valve to drain off excessive oil which does not pass through the throttle aperture. Operative element Hydraulic cylinder Rocking. lever Direction— control valve Throttle vreau i valve Gear pump Fig. 1.21 Schematic diagram of a translatory hydraulic driveIntroduction to Machine Too! Drives and Mechanisms 25 | From the description of simple rotary and translatory motion hydraulic drives, it may be concluded that these drives are made up of individual elements and units which are appropriately joined into a circuit by means of pipe lines. The important elements of a hydraulic transmission are: Pumps Hydraulic cylinders Direction-control valves Pressure valves Throttles yeep These elements will now be dealt with to the extent necessary for a proper appreciation of their application in machine tools, Besides these elements, the hydraulic circuits of machine tools include auxiliary elements, such as filters, accumulators, seals and packings, relays, etc. Students are advised to consult a basic text on hydraulics and hydraulic machines for a detailed insight into the functioning of the hydraulic equipment. 1,Pumps The pumps primarily serve the purpose of sucking oil and delivering it under pressure to various hydraulic devices. On the basis of the operating principle, pumps can be classified as constant delivery pumps and variable delivery pumps. ‘The constant delivery pumps generally employed in machine tools are gear pumps and vane pumps. The working principle of a gear pump can be explained with the help of Fig. 1.22. The pump consists of a pair of meshing gears of which the driving gear is directly coupled to an electric motor. The oil is sucked into the gap between the meshing teeth on the suction side and squeezed out under pressure on the delivery side. 4 YA OKO j YZ Ve, Fig. 1.22 Schematic diagram of a gear pump The volume of oil delivered by a gear pump is given by the expression, Faolde~ 40. m/min (1.13) 10° itch circle diameter of the gears, mm Q where do de addendum circle diameter of the gears, mm26 | Machine Tool Design and Numerical Controt b = width of gears, mm n= rpm of the driving gear ‘The power rating of the motor required to run a pump is determined from the expression, —P2 wy (1.14) 6 x10 My where —_p = pressure developed by the pump, N/m? Q = volume of oil delivered by the pump, m*/min Tw = coefficient of mechanical efficiency of the pump; generally 1],,=0.7-0.9 ny = coefficient of volumetric efficiency of the pump (leakage losses); generally Ny =0.7-0.8 ‘The schematic diagram of a constant delivery vane pump is shown in Fig. 1.23. The rotor mounted on a splined shaft rotates inside the stator, whose profile is shown in Fig. 1.24. As the rotor rotates, the vanes reciprocate radially and complete two complete cycles of suction and delivery in one revolution of the rotor. Pockets 1 and 2 serve for suction, and 3 and 4 for delivery. Fig. 1.23 Schematic diagram of a constant-delivery vane pump The volume of oil delivered by a constant delivery vane pump is given by the expression, g= 2h m3 —1)- (y= n)ytez Jin (1s) 10 COS Of where B = width of rotor, mm n= rpm of rotor ry = major semi-axis of the stator profile, mm r| = minor semi-axis of the stator profile, mmIntroduction to Machine Too! Drives and Mechanisms 27 | ¢ = thickness of vanes, mm z = number of vanes oc = angle which the vane makes with the radius; generally a= 13° “Lo Circular ‘Archimedian ae sprial Fig. 1.24 Profile of the stator of a constant-delivery vane pump ‘The variable delivery pumps commonly used in machine-tool hydraulic drives are vane pumps and radial piston pumps. ‘The schematic diagram of a variable delivery vane pump is shown in Fig. 1.25. The vanes reciprocate in radial slots of the rotor which is eccentrically mounted with respect to the stator. The rotor axis is generally fixed but the stator can be displaced to vary eccentricity and hence pump delivery. The stator in this case has a circular profile, and therefore, no delivery takes place if the rotor and stator axes become concentric. The radial reciprocation of vanes is controlled by means of rollers, attached to the vanes, that move in an annular guiding ring concentric with the stator. The volume of oil delivered by a variable delivery vane pump is given by the expression, iba = 12)+ And) m*Imin (1.16) Q where B= width of rotor, mm n = rpm of rotor e = eccentricity, mm D = stator bore, mm = diameter of rollers, mm b = width of annular guiding ring, mm 1 = thickness of vanes, mm z = number of vanes28 | Machine Tool Design and Numerical Controt es, I Y Gy * e=0 la) (b) (c) Fig. 1.25 Schematic diagram of a variable-delivery vane pump The working principle of the radial piston pump is similar to that of the variable delivery vane pump. The only difference is that the vanes are replaced by mini pistons, each of which reciprocates in its cylinder. The manufacture of cylindrical sliding surfaces of pistons and cylinders is easier than that of rectangular vanes. Therefore, piston pumps can be manufactured with tighter fits and are distinguished by lower leakage losses. The volume of oil delivered by a radial piston pump may be determined by the expression, nd?ezn Q © 2x10? m/min ay where — d = diameter of pistons, mm. e = eccentricity, mm z = number of pistons n = 1pm of rotor Gear pumps are used for pressures up to 100 kgf/em?, vane pumps for pressures up to 25 kgi/em? and piston pumps for pressures up to 140 kgffem?. All pumps described above can in principle be used as hydraulic motors by reversing their operation. However, in practice, only variable delivery vane pumps and radial piston pumps are used because they ensure a wider range of speed regulation and also have higher efficiency than gear pumps, especially at low speeds 2. Hydraulic Cylinders Hydraulic cylinders are used in hydraulic drives where translatory motion of the operative element (generally of the machine-t0o1 table) is required. A simple cylinder with the piston rod only on one side (Fig. 1.26a) provides different piston velocities in two directions, while a double-end rod cylinder (Fig, 1.26b) provides identical piston velocity in both directions. The piston speed and flow rate of oil to the cylinder are related as follows: Q=A-v (1.18)Introduction to Machine Too! Drives and Mechanisms 29 | where Q = amount of oil fed to the cylinder per unit time, m/min effective area of cross section of the piston, m? v = velocity of piston, m/min ‘The minimum pressure required to move the piston can be determined from the expression, P kgf po 7ke where P= resisting force, kgf A = effective area of cross section of the piston, cm? —I 5 (a) 4 i C _] (b) Fig. 1.26 Cylinders: (a) Single-piston rod type (b) Double-end rod type 3.Direction-control Valves The function of these valves is to change the direction of fluid flow. Direction- control valves are generally available in two design versions —with a rotary spool and with a sliding piston. ‘The working of a rotary, spool-type direction-control valve can be explained with the help of its schematic diagram shown in Fig. 1.27. The valve is divided into two halves by a partition. The valve has four ports 1,2, —) a) Fig. 1.27 Schematic diagram of rotary, spodl-type direction-control valve30 | Machine Tool Design and Numerical Controt 3,4, of which ports 1 and 2 are connected to the two chambers of the hydraulic cylinder, while ports 3 and 4 are connected to the pump line and reservoir, respectively. The direction of oil flow is reversed by rotation of the partition inside the valve body. When the partition occupies the position shown in Fig. 1.27 by firm lines, port | is connected to the pump and oil is delivered to the left-hand chamber of the cylinder; at the same time the oil in the right-hand chamber of the cylinder is discharged into the reservoir through ports 2 and 4. When the partition occupies the position, depicted in Fig. 1.27 by dotted lines, the port connections get reversed, i.e, the pump gets connected to the right-hand chamber of the cylinder through port 2, while the oil in the left-hand chamber is discharged into the reservoir through ports | and 4. The direction of travel of the piston is thus reversed by shifting the pattition from one position to the other. ‘The working of a four-way, two-position, piston-type direction-control valve was explained while discuss- ing the translatory motion hydraulic drive of Fig. 1.21. This valve (Fig. 1.28) has five ports. Ports | and 2 are connected to the left- and right-hand chambers of the hydraulic cylinder, respectively. Port 3 is connected to the pump line, while ports 4 and 5 are interconnected and serve for draining oil into the reservoir. In the position of the piston shown by firm lines, oil is fed into the left-hand chamber of the cylinder through port 1 and the oil from the right-hand chamber is drained into the reservoir through ports 2 and 5. When the piston occupies the position shown by dotted lines, port 2 gets connected to the pump line, thus delivering oil to the right-hand chamber of the cylinder, while the oil in the left-hand chamber is drained back to the reservoir through ports | and 4. —l J sh 2 m7 TT m1 i 4 358 [4 Fig. 1.28 Schematic diagram of a four-way, two-position, piston-type direction-control valve A four-way, three-position, piston-type direction-control valve is schematically shown in Fig. 1.29. This valve also has five ports which are connected in the same manner as the ports of the four-way, two-position valve, When the valve piston is in the central position, all the ports are connected to each other and the oil which is pumped into the valve returns to the reservoir without affecting any change in the position of the hydraulic cylinder. When the valve piston occupies the extreme left position, oil is fed into the right-hand chamber of the cylinder through port 2, as the draining port 5 is closed. Oil in the left-hand chamber is drained back to the reservoir through ports | and 4. When the valve piston is shifted to the extreme right position, draining port 4 gets closed and oil is delivered to the left-hand chamber of the cylinder through port 1 in this position oil from the right-hand chamber is drained through ports 2 and 5. In machine-tool hydraulicIntroduction to Machine Too! Drives and Mechanisms 31 | systems, the sliding piston direction-control valves are used more extensively than rotary spool valves. Two-position valves are used in machine tools in which machining operation is done in several passes, eg., grinding machines. The three-position valves are used in single-pass machine tools, such as drilling and milling machines. Multiple-position valves find application in automatic drilling, milling and other machines, in which machining of the workpiece is completed in one pass. 1 Vs 2 SY Fig. 1.29 Schematic diagram of a four-way, three-position, piston-type direction-control valve 4, Pressure Valves The function of pressure valves is to limit the pressure in a particular line of the hydrau- lic circuit. Pressure valves are used as safety valves (as in Fig. 1.20) to protect the system against excessive pressure and as bypass valves (as in Fig. 1.21) to drain off the excessive amount of oil. The basic design of safety and bypass pressure valves is identical; however, design details differ on account of different func- tional requirements of the two, Safety valves are not operated frequently, and therefore, they are designed to be oil-tight when closed. On the other hand, bypass valves operate almost continuously, and therefore, the design requirement for these valves is not oil tightness of joints but higher wear resistance of seals and packings. The simplest type of pressure valve is the ball or poppet valve which is shown in Fig. 1.30. The ball (or poppet) is pressed against the opening by a spring, whose force can be regulated by means of a threaded sleeve. When the pressure of oil coming through port 1 exceeds the spring pressure, the ball is raised and the oil is drained back into the reservoir through ports 2 and 3, The ball or poppet valve is generally used only asa safety valve. Its application as a bypass valve is not recommended as it suffers from serious drawbacks, such as pressure pulsations and vibrations. ‘A spool-type pressure valve which has better performance characteristics is shown in Fig. 1.31. Ports 1 and 2 of the valve are connected to the pressure line, the former direcily and the latter through a constricted passage. Port 3 is connected to the reservoir. In the condition of equilibrium, P+F=P+W where P = force acting at the head end of the valve F = friction force P, = spring force W = weight of the spool32 | Machine Tool Design and Numerical Controt Threaded sleeve Spring Ball 1 Fig. 1.30 Schematic diagram of a ball-type pressure valve ‘When due to increase in the pressure, force P + F exceeds P, + W, the spool gets displaced upwards and port I gets directly connected to port 3, thus allowing excessive oil to be drained back to the reservoir and resulting in a fall of pressure. Pl Le mal Hq 3 1.31 Schematic diagram of a spool-type pressure valve Astill better design of pressure valves is shown in Fig. 1.32. This valve is known as a pision-type pressure valve or a compound relief valve. The pressure line is connected directly to the pilot end and the lower faceIntroduction to Machine Too! Drives and Mechanisms 33 | of pision by ports 1 and 2, respectively; it is also connected to the piston end by port 3 through a constricted passage. Port 5 is connected to the reservoir. In the condition of equilibrium, Pot Pi + F=P2+ Pat W where Pp = force acting at the pilot-valve end P, = force acting on the lower face of the piston F = friction force Py = force acting on the piston end P., = force of spring | W = weight of the piston and pilot When the pressure in the line increases, the equilibrium gets disturbed and a resultant force begins to act in the upward direction, As long as this resultant force P,, is less than spring force P,z of the ball valve, the piston remains stationary. However, when P,.> P., the ball valve opens, pressure at the piston end drops, the piston along with the pilot moves upwards and gets directly connected to the draining port 5. Excess of oil is drained back to the reservoir and the line pressure drops. ‘Spool and piston-type pressure valves are used mostly as bypass valves. The piston-type pressure valve has the ability to absorb minor pressure variations and is, therefore, the best from the point of view of pres- sure pulsations and dynamic behaviour. Fig. 1.32 Schematic diagram of a compound-relief valve 5.Throttles Flow control valves with a fixed orifice are used in machine tools to minimise vibrations and smooth out transient flow (e.g., constricted passages used in the hydraulic circuits of Figs 1.31 and 1.32). Flow-control valves or throttles which have provision for changing the area of the constricted passage are34 | Machine Tool Design and Numerical Controt used to regulate the oil flow in machine-tool hydraulic systems (e.g., the hydraulic circuit of Fig 1.21). The schematic diagrams of a few of the simplest throttle valves are given in Fig. 1.33. Cc Cc Dise & Neoale a Y =] é Ni y (a) (b) Fig. 1.33 Throttle valves: (a) Globe valve (b) Needle valve In all these valves, the area of the constricted passage is varied by displacing a movable member; for instance, the moving member in the globe valve (Fig. 1.33a) is a disc, and in the needle valve (Fig. 1.33b) a needle, In simple valves of this type, changes in oil temperature and pressure go uncompensated. Therefore, if the pressure or temperature of the oil changes, the flow through the valve can change even at a fixed setting of the constricted passage. The chief aim of compensating for variations of oil pressure and temperature is to provide uniform travel of the machine-tool operative element. This aspect has been dealt with in See. 2.9.1 in which stabilisation of the motion velocity with the help of reducing valves has been discussed. | 1.5 MECHANICAL TRANSMISSION AND ITS ELEMENTS. Mechanical transmission is employed for transmitting rotary as well as translatory motion to the operative element, This transmission can provide both stepped and stepless regulation of speed and feed rates. Stepless regulation is achieved through special devices called variators, which will be discussed in Sec. 2.9.3. A me- chanical transmission that provides for stepped regulation of speed and feed rates is made up of elementary drives and mechanisms. For ease in presentation, the elements of mechanical transmission can be classified into the following groups: Elementary transmissions that transfer rotation Elementary transmissions that transform rotary motion into translatory motion Devices for intermittent motion Reversing and differential mechanisms Special mechanisms and devices Couplings and clutches av aeNe 1.5.1 Elementary Transmissions for Transmitting Rotary Motion ‘The important elementary transmissions which are used for transmitting rotary motion from one shaft to another are described below.Introduction to Machine Too! Drives and Mechanisms 35 | Gear Transmission Ina gear transmission, the rpm of the driven shaft is determined as mom: 2 2, where ny = rpm of the driven shaft ny = rpm of the driving shaft Z, = number of teeth of the driving gear = number of teeth of the driven gear The ratio Z)/Z> is known as the transmission ratio of the gear drive and is constant for a particular gear pair. (a) (b) (c) Fig. 1.34 Gears: (a) Spur (b) Helical (c) Herringbone Rotation is transmitted between parallel shafts by means of spur, helical and herringbone gears (Fig. 1.34). Spur gears have teeth parallel to the axis of rotation, while in helical gears the teeth are inclined with respect to the axis of rotation at an angle known as the helix angle. The herringbone gear is essentially a pair of heli- cal gears in which the helix angle is oppositely directed. Spur gears are used in sliding gear blocks, while helical gears are preferred when the gear pairs arc permanently in meshing. ‘Transmission of rotation between inclined intersecting axes is done with the help of bevel gears. A bevel gear is shown in Fig. 1.3Sa. The angle between the inclined axes is generally 90° and the bevel-gear transmis- sion (Fig. 1.35b) is commonly employed for transmitting rotation between perpendicular shafts. Transfer of rotation between skewed axes, i.e., axes that are inclined to each other but do not intersect, is achieved by means of a spiral gear transmission (Fig. 1.36a) or a worm-worm gear transmission (Fig. 1.366). The spiral gear transmission is characterised by point contact between the meshing gears, and therefore, it cannot be employed for transmitting large torques. In machine tools, the worm-worm gear transmission is commonly employed to achieve heavy speed reduction. Also, since the contact between the worm and worm gear is along a line, this pair can transmit large torques. It should be noted that the worm-worm gear36 | Machine Tool Design and Numerical Controt transmission is irr versa. The worm relationship, rotation may be transmitted from the worm to the worm gear, but not vice le, a helical screw and the spm of the worm gear can be determined by the (a) (b) Fig. 1.36 (a) Spiral gear pair (b) Worm-worm gear pairIntroduction to Machine Too! Drives and Mechanisms 37 mon & where 1) = spmoof the worm gear 2, = rpm of the worm Z = number of teeth of the worm gear k = number of passes of the worm Fora single pass worm, k = 1, for a double pass worm, & = 2. If a transmis cied in series, the overall transmission ratio of the chain is obiained as the product of transmission ratios of the elementary transmissions, In general, the transmission ratio of a gear drive may be >I (speed increase) or <1 (speed reduction), except the worm-worm gear transmission which always has a transmission ratio <1. ion chain consists of a number of elementary gear transmis Belt Transmission The belt transmission is used for transmitting rotation between shafis that are located ata considerable distance from each other. It is distinguished by smooth and jerk-free rotation which enables its application in high-speed machine tools, e.g., grinding machines, Belt transmission can be employed for transmitting rotation between parallel and skewed shafts. The most commonly used arrangements are shown in Fig, 1.37 re) Fig. 1.37 Bolt drives: (a) Open-belt arrangement (b) Cross-belt arrangement (c) Quarter-tumed arrangement38 | Machine Tool Design and Numerical Controt ‘The open-belt arrangement (Fig. 1.37a) is employed for transmitting motion between parallel shafts rotating in the same direction, The cross-belt arrangement (Fig. 1.37b) is used when rotation is transmitted between parallel shafts rotating in opposite directions and the quarter-turned arrangement (Fig. |.37c) is used for transmitting rotation between skewed shafts. In machine-tool drives flat, V-shaped and round belts are used. Round belts find application in table model machine tools in which torques are of smal! magnitude. Flat belts are the most versatile as they can be em- ployed in all the three arrangements shown in Fig. 1.37. The load-carrying capacity of the flat belt can be improved by increasing its width, and therefore, in flat belt drives only one belt is used. In V-belt transmission a number of V-belts (generally two to four) are used for varying the load-carrying capacity in order to avoid large bending stresses in one V-belt, which would otherwise be of unduly large dimensions, V-belts are usu- ally employed only in the open-belt arrangement. For proper functioning of the belt drive, it is essential to provide some mechanism which keeps the belt tight during operation; this increases their cost. Other major drawbacks of the belt transmission are its rela- tively large dimensions and inability to guarantee constant transmission ratio due to unavoidable slip between the belt and pulleys. The rpm of the driven shaft in the belt drive may be determined by the relationship, Dil) "DD n. where ny = rpm of the driven shaft ny = rpm of the driving shaft D, = diameter of the driving pulley D) = diameter of the driven pulley & = relative slip between belt and pulley The value of & varies between 0.01-0,02 depending upon the belt material. ‘The belt transmission can be employed to provide transmission ratios > 1 as well as <1. Chain Transmission The chain transmission (Fig. 1.38) is employed for transmitting rotation only between parallel shafts that are located at a considerable distance. The chain transmission consists of a driving sprocket, driven sprocket and chain. Chain transmission is used in machine tools when it is essential to keep the dimension of the drive within reasonable limits and also ensure transmission without slip. The rpm of the driven shaft is determined as, mom Ze where m, = rpm of the driving shaft ny = 1pm of the driven shaft Z; = number of teeth on the driving sprocket Zz = number of teeth on the driven sprocket The chain transmission is also capable of providing transmission ratios <1 and >1Introduction to Machine Too! Drives and Mechanisms 39 | Driven Zz sprocket Driving sprocket Fig. 1.38 Chain transmission Elementary Transmission for Transforming Rotary 1.5.2 Motion into Translatory ‘These elementary transmissions are employed in feed mechanisms of most of the machine tools and also in the drives of machine tools having a reciprocating primary cutting motion. ‘The important elementary transmissions that are used in machine tools for transforming rotary motion into translatory are briefly discussed below. Slider Crank Mechanism The schematic diagram of a slider crank mechanism is shown in Fig. 1.39. The mechanism consists of a crank, connecting rod and slider. The forward and reverse sirokes each take place during half a revolution of the crank. Therefore, the speeds of forward and reverse speeds in the slider crank mechanism are identical. Since metal removal occurs during one stroke (generally the forward stroke), it is desirable from the point of view of productivity to have a higher speed of the other stroke (the reverse stroke). Due to this property, the slider crank mechanism is used only in machine tools with small strokes (< 300 mm), where an inerease of the reverse-stroke speed does not result in an appreciable increase of productivity, e.g., in the drive of the primary cutting motion of gear shaping machines. The length of stroke may be changed by adjusting the erank radius and is equal to L = 2R, where R is the crank radius. Crank-and-Rocker Mechanism The crank-and- rocker mechanism (Fig. 1.40) consists of a rotating crank which makes the rocker arm oscillate by means of a block sliding along the groove in the rocker arm. The forward cutting stroke takes place during the clockwise rotation of the crank through angle o, and the reverse (idle) stroke during rotation of the crank through angle f. Since a > B and the crank rotates with uniform speed, the idle stroke Gratien. voonnecting rod Slider Fig. 1.39 Slider crank mechanism Rocker arm —») « Fig. 1.40 Crank-and-rocker mechanism40 | Machine Too! Design and Numerical Control is completed faster than the cutting stroke. The length of stroke can be varied by adjusting the crank radius. With a decrease in the crank radius, the ratio of angles o/ decreases and the speeds of cutting and reverse strokes tend to become equal. The crank-and-rocker mechanism is, therefore, preferred in machine tools with large strokes (up to 1000 mm) where it can be effectively employed, ¢.g., in the drive of the primary cutting motion of shaping and slotting machines. The length of stroke can be calculated from the expression, where L = length of the rocker arm, mm ¢ = off-set distance between the centres of rotation of the rocker arm and crank, mm. R = radius of the crank, mm Cam Mechanism The cam mechanism (Fig. 1.41) consists of a cam and a follower. The cam mechanism can provide the desired translatory motion ifa suitable profile is selected. The profile may be provided 1. on the periphery of a dise—dise type cam mechanism (Fig. 1.41a), 2. on the face of a disc—face type cam mechanism (Fig. 1.41b), and 3. ona cylindrical surface—drum type cam mechanism (Fig. 1.41c). fa) (o) () Fig. 1.41 Cam mechanism: (a) Disc type (b) Face type (c) Drum type The main advantage of cam mechanisms is that the velocity of the operative element is independent of the design of the driving mechanism and is controlled by the cam profile. For example, in a disc-type cam, if the radius changes fom Ry to Ry (Fig. 1.42a) along an Archimedes’ spiral while the cam rotates through angle « the velocity of the follower can be determined from the expression: P= ® 369." mimin a 000 where 1 =rpm of the cam Ry, Ry = radii, mmIntroduction to Machine Too! Drives and Mechanisms 41 | eo) wen (a) (b) Fig. 1.42. (a) Profile of a disc-type cam (b) Development of the profile of a drum-type cam Similarly, in face- or drum-type cam mechanisms, the speed of the follower depends upon the steepness of the groove. Consider, for instance, the profile development of the drum cam shown in Fig, 1.42b. Segment a depicts the steep rise of the follower corresponding to the rapid advance, segment b depicts the slow rise corresponding to the working stroke and segment c the steep fall corresponding to the rapid withdrawal of the cutting tool. The speed during, say, the working stroke, can be determined by the following relationship: h nD + —— -nm/min b 1000 where ht = rise during the working stroke, mm b = length of the working stroke, mm D = diameter of the drum, mm n= rpm of the drum It should be kept in mind that cam mechanisms are costly and anew set is required whenever any change in working conditions is sought to be incorporated. Cam mechanisms are, therefore, generally used in auto- matic machine tools for mass production of components. Nut-and-Screw Transmission A nut-and-screw mechanism is schematically depicted in Fig. 1.43. The _ <<— serewand nut have a trapezoidal thread, When the serew, fixed axially, is rotated, the nut moves along the screw Lhe LLL aris, The dhecton of movement can be revered by po UU NRA reversing the rotation of the screw. The nut-and-screw transmission is compact, but has a high load-carrying pacity. ls other advantages are simplicity, ease of manu facture, and possibility of achieving slow and uniform movement of the operative member. The speed of the operative member can be found from the relationship, Fig. 1.43 Schematic diagram of a nut-and-screw transmission ¢-K-nmm/min Se42 | Machine Too! Design and Numerical Control where 5», = feed per minute of the operative member ¢= pitch of the thread, mm K = number of starts of the thread n= rpm of the screw ‘The major drawback of the nut-and-screw transmission is its low coefficient of efficiency due to large frictional losses. This restricts its application in machine tools to feed and auxiliary motion drives. Nowadays, rolling friction nut-and-screw transmission is finding increasing application in machine tools. In this transmission, the sliding friction between the nut and screw is replaced by rolling friction by introduc- ing intermediate members, such as balls and rollers. An anti-friction nut-and-screw transmission with balls as rolling members is shown in Fig. 1.44. The balls run along the thread between the screw and the nut and there is provision for their continuous recirculation. For instance, in the transmissions shown on Fig. 1.44, the balls return through an axial channel drilled in the nut (Fig. 1.44b) and through an external return chute (Fig. 1.44a). The thread of the screw and nut in this case is usually half-round and the transmission has provi- sion for backlash elimination by preloading. The efficiency of the anti-friction aut-and-screw transmission reaches 0.9--0.95 as compared 10 0.20.4 of the sliding-friction transmission. The anti-friction nut-and-screw transmission is mainly used in the feed-motion drive of precision machine tools, such as grinding, jig-boring machines, ete. Itis used in numerically controlled machine tools in which backlash is extremely undesirable. (b) Fig. 1.44 Schematic diagram of anti-friction nut-and-screw transmission Rack-and-Pinion Transmission A rack-and-pinion iin: transmission is shown in Fig, 1.45. When the rotating gear (pinion) meshes with a stationary rack, the centre of the gear moves ina straight line. On the other hand, if the gear axis is stationary, then the rack executes translatory motion. The direction of motion can be reversed by reversing the rotation of the pinion. The speed of the operative member in this zl transmission can be found from the relationship, Ce =am-Z-nmm/min Rack 1.45 Rack-and-pinion transmission where s,, = feed per minute of the operative member m = module of the pinion, mm Z = number of teeth of the pinion n= rpm of the pinionIntroduction to Machine Too! Drives and Mechanisms 43 | Rack-and-pinion transmission is the simplest and cheapest among all types of transmissions used in re- versible drives. It also has high efficiency and provides a large transmission ratio which makes it possible to use it in the feed as well as main drive motions of machine tools. Lack of uniformity in movement due to un- avoidable meshing errors between rack-and-pinion teeth preclude its application in precision machine tools. Also, due to absence of self-locking, rack-and-pinion transmission cannot be applied for vertical movement of the operative element, 1.5.3 Devices for Intermittent Motion In some machine tools, it is required that the relative position between the cutting tool and workpiece should change periodically. This requirement is generally essential in 1. machine tools with a reciprocating primary cutting motion, e.g., shaping machines in which the workpiece must be fed intermittently upon completion of one full stroke of the cutting tool, and 2. machine tools with reciprocating feed motion, e.g., grinding machines, in which the workpiece must be infed intermittently after each half or full stroke of the reciprocating table. In machine tools, intermittent motion of the operative element is generally obtained with the help of the mechanisms discussed as follows. Ratchet-Gear Mechanism The ratchet-gear mechanism is schematically shown in Fig. 1.46. It consists of a paw! mounted on an oscillating pin. During each oscillation in the anti-clockwise direction, the pawl tums the ratchet wheel through a particular angle. During the clockwise oscillation in the opposite direction, the pawl simply slides over the ratchet teeth and the latter remains stationary, The ratchet wheel is linked to the machine-tool table through @ nut-and-screw transmission. Therefore, the periodic rotation of the ratchet wheel is transformed into the intermittent tanslatory motion of the table. For ¢ particular nut-and-screw pair of some constant transmission ratio, the feed of the table during each oscillation depends upon the swing of the oscillating, pawl. Generally, the rotation of the ratchet wheel in one stroke of the pawl should not exceed 45°. The ratchet-gear mechanism is most suitable in cases when the periodic displacement must be Ratchet completed in a short time, e.g., in feed mechanisms of shaping, wheel planing and grinding machines in which the intermittent fecd Fig. 4,4 Pawi-and-ratchet mechanism motion takes place during the over travel of the cutting tool or during the reverse stroke. GenevaMechanism The schematic diagram of the Geneva mechanism is shown in Fig. 1.47. It consists of a driving dise which rotates continuously and a wheel with four radial slots. The ares on the driving disc and wheel provide a locking effect against rotation of the slotted wheel, e.g., in the position shown in Fig. 1.47a, the wheel cannot rotate. As the disc continues to rotate, point 4 of the disc comes out of contact with the arc and immediately thereafter pin P mounted at the end of the driving arm enters the radial slot. The wheel now begins to rotate (Fig. 1.47b); when it has tuned through an angle 90°, the pin comes out of the44 | Machine Too! Design and Numerical Control radial slot and immediately thereafter point B comes in contact with the next arc of the wheel preventing its further rotation. Thus the wheel makes 1/K revolutions, where K is the number of radial slots. ( == I Fig. 1.47 Geneva mechanism In the Geneva mechanism, the angle of rotation of the wheel cannot be varied. Therefore, this mechanism is mainly used in turrets and single-spindle automatic machines for indexing cutting tools and in multiple- spindle automatic machines for indexing spindles through a constant angle. Reversing and Differential Mechanisms Reversing Mechanism Reversing mechanisms are used for changing the direction of motion of the operative member. Reversing is accomplished generally through spur and helical gears or bevel gears. A few reversing arrangements using spurand helical gears are shown in Fig. 1.48. In the arrangement of Fig. 1 48a the gears on the driving shaft are mounted rigidly, while the idle gear and the gears on driven shaft III are mounted freely. The jaw clutch is mounted on a key, Rotation may be transmitted to the driven shaft either through gears (4/B) - (B/C) or through D/E depending upon whether the jaw clutch is shifted to the left to mesh with gear C or to the right to mesh with gear £. In the transmission (4/B) - (B/C) the direction of rotation of the driving and driven shafis will coincide, whereas in the transmission D/E the direction of rotation of the driven shaft will be opposite to that of the driving shaft. In this arrangement, use of helical gears should be preferred. In the second arrangement shown in Fig. 1.48b, the gears on the driving shaft are again rigidly mounted, and the idle gear is free. On the driven shaft, a double cluster gear is mounted on a spline. By sliding the clus- ter gear, transmission to the driven shaft may again be achieved either through gears (4/B), (B/C) or through gear pair D/E, Only spur gears may be used in this reversal mechanism. In the arrangement of Fig. 1.48c gear 4 on the driving shaft and gear D on the driven shaft are both rigidly mounted. A quadrant with constantly meshing gears B and C can be swivelled about the axis of the driven shaft. By swiveling the quadrant with the help of a lever, transmission to the driven shaft may be achieved through (A/C) - (C/D) or through (4/B) « (B/C) - (C/D). In the first case, the direction of rotation of the drivingIntroduction to Machine Too! Drives and Mechanisms 45 | and driven shafts will coincide while in the second it will be opposite. In this mechanism also only spur gears can be used. D D A A \ ou i B wf i wf 5 | uL l mt i c c Jaw clutch 7 7 (a) (b) Fig. 1.48 Reversing mechanisms: (a) using spur gears (b) using helical gears It should be noted that in the reversing mechanisms of Fig. 1.48a and b the ratio of direct and reversal speeds will depend upon the transmission ratio of gear pairs A/C and D/E, By selecting A/C = D/E we can ensure identical speeds in both directions. However, if desired, a faster reversal speed can be achieved by selecting a larger transmission ratio for the gear pair used in the reversal train (gear pair A/C, as the transmis- sion with the idler gear is usually employed for reversal). Examples of reversal mechanisms using bevel gears are shown in Fig. 1.49. In these devices, shaft | is the driving shaft and shaft II the driven shaft, In the arrangement of Fig. 1.49a, the double-cluster bevel gear is mounted on a splined shaft, and by shifting it the direction of rotation of shaft II can be changed by getting cither gear B or gear C to mesh with bevel gear A which is rigidly mounted on the driving shaft, In the arrangement of Fig. 1.49b, gears B and C are freely mounted on the driven shaft, while the jaw clutch is mounted on splines. By shifting the clutch to the left or right, rotation to shaft II can be transmitted cither through bevel gear pair 4/B or A/C and thus the direction of rotation of the driven shaft can be reversed. (a) (b) Fig. 1.49 Reversing mechanisms using bevel gears46 | Machine Too! Design and Numerical Control Differential Mechanism Differential mechanisms are used for summing up two motions in machine tools, in which the operative member gets input from two separate kinematic trains. They are generally employed in thread-and-gear cutting machines where the machined surface is obtained as a result of the summation of two or more forming motions. ‘A simple differential mechanism using spur or helical gears is shown in Fig. 1.50. The mechanism is es sentially a planetary gear mechanism consisting of sun gear A, planetary gear B and arm C. The planetary gear is mounted on the arm which can rotate about the axis of gear 4. Suppose gear 4 makes n, and arm C, nc revolutions per minute in the clockwise direction. The relative motion between the elements of the mechanism will remain unaffected if the whole mechanism is rotated in the anti-clockwise direction with ne revolutions per minute. Then the arm becomes stationary and the mechanism is reduced to a simple gear transmission with gear 4 making 1, — Mc revolutions per minute and gear B making ng — nc revolutions per minute. The transmission ratio of the mechanism may be written as: Bares (the minus sign denotes the extemal gear pair) y= Ne B * c = (&) A Fig. 1.50 Difierential mechanism using spur or helical gears where Z,, and Zyare the number of teeth of gear 4 and B, respectively. The above expression may be rewritten as follows: Z Zz r=re(l + Zz } =ng: zs i.e., the rpm of any one element of the differential mechanism is a function of independent motions of the remaining two elements. Differential mechanisms using a double-cluster planetary gear are shown in Fig. 1.51. The mechanisms consist of gear 4, cluster gear block BB’ mounted on arm C and ger D. If ny, ncand np are the rpm’s of gear A, arm C and gear D, respectively, then the transmission ratio of the kinematic train between gears A and D may be expressed as np-nc _ Z4_ Zh (for Fig. 1.51a) la Nc Zs ZpIntroduction to Machine Too! Drives and Mechanisms 47 Ba C * WS ¥ tT y — " A ™ A j D (a) D (b) Fig. 1.51 Differential mechanisms using double-cluster planetary gears +4 mi Differential mechanisms consisting of bevel gears are shown in Fig. 1.52. These mechanisms are widely used in automobiles to provide different rotational speeds to the wheels powered by a single source. This is essential for the functioning of an automobile because, while tackling a tum, the outer wheel of the automo- bile must rotate faster than the inner wheel. This mechanism is also widely used in machine tools on account of its compactness. The mechanism consists of bevel gears A and D and planetary bevel gears B and C, Planetary gears can be rotated about the common axes of gears 4 and D 1. by means of a ring gear (Fig. 1.52a)—this differential is used in automobiles, and 2. by means of a T-shaped shaft (Fig. 1.52b)—this differential is used in machine tools, = B of N x x A c Lol | S§ (a) Fig. 1.52 Differential mechanisms: (a) used in automobiles (b) used in machine tools48 | Machine Too! Design and Numerical Control If gears A, B and D make 4, ng and np revolutions per minute, respectively, then the transmission ratio of the kinematic train between gears 4 and D can be written as nya np mp" Za Zp where Z,, Zp and Zp are the number of teeth of gears A, B and D, respectively. The minus sign indicates that gears A and D rotate in opposite directions if the rotation of the arm is stopped, ie., it, = 0. If Z, = Zp, the expression becomes myn Mp - Ne wherefrom ny +np=2np In the automobile differential, the constancy of the sum 7, + np indicates that when the vehicle is taking a turn a reduction in the rpm of one wheel is accompanied by an increase in the rpm of the other. If the auto- mobile is travelling on a straight line, my =p = mp, but if on a bend , = 0, wheel D begins to rotate at twice the speed of the ring gear, ie., mp = 2g. | 1.5.5 Special Mechanisms and Devices Special mechanisms and devices are employed in machine tool feed boxes. These mechanisms are 1. Gear cone with sliding key 2. Norton gear mechanism 3. Meander’s mechanism They are discussed in Sec. 2.8.2. 1.5.6 Couplings and Clutches Couplings and clutches are devices used for connecting one rotating shaft to another. If two shafts are per- manently connected so that they can be disengaged only by disassembling the connecting device, the latter is known as a coupling. Devices that can readily engage shafts to transmit power and disengage them when desired are known as clutches. Couplings Couplings are of two types: 1. Rigid 2. Flexible Rigid couplings require that axial alignment between the connected shafts be maintained strictly. In flexible couplings, there is provision for compensating slight misalignments between the coupled shafts. A rigid coupling is shown in Fig. 1.53a anda flexible coupling in Fig. 1.53b.Introduction to Machine Too! Drives and Mechanisms 49 (a) c Ve (b) Fig. 1.53 (a) Rigid coupling (b) Flexible coupling ‘The flange coupling (Fig. 1.53a) consists of two flanges which are either press fitted on the ends of the shafts to be connecied or mounted on keys. The flanges are drawn together by means of bolts. Torque is transmitted from one shaft to another either by the friction force between the faces of the flanges or by bolts. The double slider or Oldham coupling consists of flanges 4 and B with diametrical slots and an intermediate plate C with projections that correspond to the slots of flanges A and B. Slight misalignment between the connected shatts is compen- sated by the plate sliding along the slots in the flanges. If there is considerable misalignment between the shafts to be connected, an elastic flexible coupling (Fig. 1.54) can be used. In this coupling, the shafts are connected through a Car- dan or Hooke’s joint, which consists of yokes that are mounted on the ends of the shafts and a cross that provides a pivot joint between the yokes. 1.54 Elastic coupling80 | Machine Tool Design and Numerical Controt ‘Couplings are generally used in machine tools for connecting the motor shaft to the first shaft of the speed or feed box. Clutches Clutches can be roughly classified into two major groups: 1. Positive-action clutches 2. Friction clutches A positive-action clutch is incapable of slipping. It can be engaged only when the shafts to be connected are stationary or are rotating at identical speed. The most commonly used positive-action clutch is the jaw clutch (Fig. 1.55). The clutch consists of two halves, of which one is rigidly fixed on one of the connected shafts and is stationary, while the other is mounted on the second shafi on a key or splines and is moved into engagement. The faces of both the halves have projections, or so-called jaws and recesses such that the jaws of one fit into the recesses of the other and vice versa. 2) lp) = On 1.55 Jaw clutch A friction clutch, as the name implies, transmits torque by virtue of friction between the two halves. It can engage shafts rotating with different speeds or a rotating shaft with a stationary shaft. Friction clutches are generally not capable of transmitting large torques on account of slip. The commonly used friction clutches are discussed below. A disc-type friction clutch consists of one or more dises which are pressed against each other between the flanges. Accordingly, the clutch is known as a single-disc or multiple-disc clutch. A multiple-disc clutch is schematically shown in Fig. 1.56. It consists of a cylindrical housing | with internal splines, flanged hub 2 with external splines, outer discs 3 with splines on their periphery and inner dises 4 with slines on their bore hole. The housing is rigidly mounted on one of the shafis and the sleeve on the other. Now, the discs are as- sembled by slipping them alternately along the splines of the housing and the hub. Thus, the outer discs rotate with the housing but are free to slide axially along its internal splines. Similarly, the inner dises rotate with the hub but can slide along its external splines. If the dises are to operate in oil, they are made of hardened steel. Since oil greatly reduces friction between dises, most clutches are operated dry. In such a case, the metal dises experience extensive wear, and therefore, one group of discs (generally outer one) is made of solid asbestos ora layer of asbestos is bonded on the metal discs.Introduction to Machine Too! Drives and Mechanisms 51 Fig. 1.56 Multiple-disc friction clutch When the engaging sleeve 5 is moved towards the left, it exerts an axial force which is multiplied by the lever arrangement and applied on the friction discs. The discs get pressed against each other and the clutch gets engaged to transmit rotation between the two shafts. The lever system is so designed that it holds the clutch in engagement so that it is not necessary to continuously apply a force on the operating handle. Disc-type friction clutches have large load-carrying capacity with small overall dimensions. They are distinguished by smooth engagement and their capacity can be easily varied by increasing or decreasing the number of discs according to the requirement. Generally, the number of discs does not exceed 10-12 because otherwise there is wear between rotating discs even when the clutch is disengaged. In machine tools, electromagnetic clutches are lately finding increasing application. The electromagnetic clutch is essentially a multiple-dise friction clutch in which friction discs are pressed by an electromagnet. These clutches are particularly suitable for automatic control and are, therefore, being widely used in numeri- cally controlled machine tools. A cone-type friction clutch is shown in Fig. 1.57. It consists of two halves: one with an intemal tapered surface TRE is mounted on one shaft, while the other with an identical external taper is mounted on the other. One half is mounted rigidly, while the other is mounted on splines to permit axial displacement. The tapered surfaces are made of materials NEN which have a large coefficient of friction and the clutch is _t t engaged by pressing the two halves against cach other. If the contacting surfaces are made of hardened steel, half-taper Nn J angle or= 810°, while if the surfaces have an asbestos lining 0: = 12-15°, Because of the taper of the friction surfaces, a relatively small axial pressing force provides a large force normal to the contacting surfaces which holds them together once the clutch is engaged. Therefore, in cone-type friction Fig. 1.87 Cone-type friction clutch82 | Machine Tool Design and Numerical Controt clutches, an elaborate linkage system is not required. This gives the cone clutch the advantage of simplicity. The major drawbacks that restrict the application of cone clutches in machine tools are their large dimensions and strict requirement of coaxiality between the connected shatts. TECHNICO-ECONOMICAL PREREQUISITES FOR 1.6 UNDERTAKING THE DESIGN OF ANEW MACHINE TOOL The design and manufacture of a new machine tool can be undertaken only if it is economically justified. ‘The design of a new machine tool can be justified in individual cases on the basis of higher productivity and accuracy, lower metal requirement per machine tool, less floor area per machine tool, etc. In general, all these indices which account for the cost of manufacture of the machine tool and its operation can be unified into a general index of economic effectiveness. The economic effectiveness of a machine tool, and for that matter ofany equipment, can be quantitatively expressed through the total annual cost which is represented as G=C+k- Cl where — C, = total annual cost C = annual production cost CI = capital investment k = factor of capital recovery along with interest, generally k= 0.15~0.2 The design and manufacture of a new machine tool can be considered economically feasible if Cm 75m, y = 1.5 Expenditure on building the servicing premises Es = Ebsm = expenditure on building the servicing premises mean expenditure on building | m? of servicing premises = total area of servicing premises where £,, Exsm Thus C1= Ey + Epp + Ens Annual Cost of Production (C) The annual cost of production of the designed machine tool is N da c nnual cost of production = annual output ‘ost of the ith part of machine tool n = number of parts in the machine tool34 | Machine Tool Design and Numerical Controt ‘The production cost of a part includes 1. cost of material of the workpiece; this is fixed cost and may not be taken into account when two versions are being compared, 2. wages paid to labour, 3. overheads; these cover the recurring expenditure on cutting tools, expenditure on the maintenance and repair of equipment and fixtures, expenditure on preparing skilled workers and technical personnel, expenditure on operating the equipment, etc. All cost factors need not necessarily be taken into account when two versions are being compared; it gen- erally suffices to restrict the analysis only to those expenditures, which substantially differ in the compared versions. ‘The design and manufacture and subsequent industrial application of new models of machine tools is one of the major factors in increasing productivity. Periodic renovation of production capacities is essential to ensure a normal economic growth rate. Each industrial application of new equipment is accompanied by some initial investment; this must be recovered during the pay-back period, and for the remaining period of its life till obsolescence, the new production capacity should bring in profit due to reduced production cost. The search for new design and production solutions must, therefore, be based upon a thorough economic analysis on the lines discussed above. | 1.7, GENERAL REQUIREMENTS OF MACHINE TOOL DESIGN Any machine tool should satisfy the following requirements: High productivity Ability to provide the required accuracy of shape and size and also necessary surface finish Simplicity of design Safety and convenience of controls Good appearance Low cost of manufacturing and operation av eey ‘We shall discuss how these requirements are met in the design of machine tools. 1, Productivity Productivity of a metal cutting machine tool is given by the expression, 1 2 Q= 7 (1.22) fo Ino where f, = machining time = non-productive time that includes job handling time, tool handling time, time of idle travel prior to commencement of cut, time of idle travel for guiding the tool to home position after completion of cut, set up time, inspection time and time spent on unscheduled delays, tno 1 = factor that accounts for stoppages for maintenance as well as unscheduled stoppages on ac- count of breakdowns.Introduction to Machine Too! Drives and Mechanisms Based on Eq, (1.22), productivity of a metal cutting machine tool may be raised by the following methods: (i) Cutting down machining time: This is possible if high cutting speeds and feed rates are available on the machine tool in accordance with the latest developments in cutting tool materials and design. At the design stage itself, the machine tool must be provided with a margin to accommodate future developments so that it does not become obsolete in a short period of time. The application of stepless mechanical, hydraulic and electrical drives also helps in reducing machining time as the optimum cutting speed can be accurately set without reducing its value to the nearest available rpm on the machine tool with a stepped drive. Machining time can also be reduced by making provision for simultaneous multiple cuts and use of coolants. (ii) Cutting down non-productive time: This can be achieved by using jigs and fixtures that reduce clamping and unclamping time, and mechanising and automating machine tool controls. During the last few decades, developments in machine tool design have been largely directed at reducing the non- productive time through automation. Hard automation in the form of automatic machines, mechanised flow lines and transfer lines reflected this trend till the 60s. However, with growing affluence in the industrialised nations, the consumers became more discerning and since the 70s the demand pattern has changed from mass produced goods to batch produced and custom built goods. This triggered a change in the manufacturing philosophy from one of herd automation to soft automation that is manifested today in the increasing proliferation of numerically controlled and computer numerically controlled machine tools, machining centres, robots, flexible manufacturing systems, etc. (iii) Machining with more than one tool simultaneously: This principle is employed in multiple-spindle lathes, drilling machines, etc. (iv) Improving the reliability of the machine tools to avoid break downs and adopt proper maintenance policy to prevent unscheduled stoppages and delays. 2. Accuracy The accuracy of a machine tool depends upon its geometrical and kinematic accuracy and its ability to retain this accuracy during operation. Accordingly, the ability of a machine tool to consistently machine parts with a specified accuracy within permissible tolerance limits can be improved by the following methods: (i) Improving the geometrical accuracy of the machine toot: This is mainly determined by the accuracy of guiding elements, such as guideways, power screws, ete. It is also essential to ensure uniform, jerk- free movement of the traversing member of the machine tool. (ii) Improving the kinematic accuracy of the machine tool: The kinematic accuracy determines the relationship between velocities of two or more forming motions and it depends upon the length of kinematic trains and the accuracy of manufacture and assembly of components. Obviously, the kinematic accuracy of a machine tool can be improved by using as short kinematic trains as possible, and manufacturing and assembling the components with a high degree of accuracy. (iii) Increasing the static and dynamic stiffness of machine-tool structures: The greater is the static stiffness of the machine-tool structure, the smaller will be its deformation due to the cutting forces and hence the higher will be the accuracy of machining. A high dynamic stiffhess reduces the vibrations during machining and hence provides better accuracy and surface finish. (iv) Providing accurate devices for measuring distance of travel: This concerns the accuracy of manufacture of dials, scales, verniers, optical systems, etc. The accuracy of measuring instruments is of paramount36 | Machine Tool Design and Numerical Controt importance in machine tools with automatic size control during machining, ¢g., automatic machines, machine tools with adaptive controls, ete. (v) Arranging the machine tool units in such a manner that the thermal deformations during the machining operation result in the least possible change in the relative position between the tool and the workpiece. This factor is especially important in machine tools used for finishing operations, e.g., grinding machines. 3. Simplicity of Design Simplicity of design of machine tools determines the ease of its manufacture and operation, The design of a machine tool can be simplified by using standard parts and subassemblies as far as, possible. The complexity of design ofa machine too! depends to a large extent upon the degree of its “univer- sality’. Thus a general-purpose machine tool is, 28 a rule, more complex than a special-purpose machine tool doing similar operations. The design of a machine tool can, therefore, be simplified by putting restrictions on its range of application, e.g., on the type of different operations that may be carried out, or on the size of parts which may be machined, ete 4, Safety and Convenience of Controls A machine tool cannot be deemed fit for use unless it meets the requirements of safety and convenience of operation. Safety of controls is achieved by taking. among others. the following measures: (i Shielding the rotating and moving parts of the machine tool with hoods. (ii) Protecting the worker from chips, abrasive dust and coolant by means of screens, shields, etc. (iii) Providing reliable clamping for the tool and workpiece. (iv) Precluding the possibility of accidental pressing of push buttons and handles. (v) Providing reliable earthing of the machine. (vi) Providing devices for safe handling of heavy workpieces. (vii) Providing blocking devices which preclude simultaneous engagement of conflicting transmissions. (viii) Providing travel limiting devices for traversing machine tool members and also devices for overload protection. The convenience of machine-tool controls is intimately linked with their safety. Convenient controls will protect the worker from excessive fatigue and thus contribute towards safety. The convenience of controls also determines to a large extent the quality of the workers’ performance. Machine tool controls should be simplified and made convenient for which a few guidelines are given below: 1. The control system should be rationally selected and should be automated to as large an extent as possible, 2. The control system should be designed by giving due consideration to ergonomic principles. 5. Appearance Good appearance of the machine tool influences the mood of the worker favourably and thus facilitates better operation. It is generally conceded that a machine tool that is simple in design and safe in operation is also good in appearance, although factors, such as external finish, colour, etc., do substantially contribute to the overall aesthetic quality of the machine tool. For instance, painting of machine tools in grey-green o green-blue colours impart a bright and pleasing appearance to the shop. Nowadays, painting of machines in different colours according to the production purpose is becoming popular, e.g., transportation facilities within the shop are painted yellow with black stripes, eteIntroduction to Machine Too! Drives and Mechanisms 57 | 6. Low Cost of Manufacturing and Operation The cost of manufacturing a machine tool is determined by the complexity of its design. Therefore, factors that help in simplifying the machine tool design also con- tribute towards lowering its manufacturing cost. The cost can also be brought down by reducing the amount of metal required in manufacturing the machine tool. This is achieved by using stronger materials and more precise design calculations pertaining to the strength and rigidity of parts to keep the safety margins as low as possible. For instance, considerable saving of metal can be achieved by using welded steel structures instead of cast iron for heavy parts, such as beds, columns, bases, etc. It should also be noted that a reduction of the weight and dimensions of the machine tool also makes transportation and installation of the machine tool easier and cheaper, thus indirectly contributing to a further reduction of the overall cost. ENGINEERING DESIGN PROCESS APPLIED TO MACHINE TOOLS Design is undoubtedly a creative process. Many people mistakenly attribute this creativity to a flair for design inceriain persons who become successful designers. In fact, the engineer with a ‘flair’ for design is, as a rule, a man with a logical decision-making ability by which he explores all possible solutions to a given problem and arrives at an optimum after carefully analysing all the altematives. Until a decade or so ago, any design which was technically feasible, i.e., capable of being manufactured, would generally go through to production, irrespective of the time or cost involved. However, the need to find principally new design solutions to keep ensuring higher productivity has in recent times greatly increased the expenditure on design. Design is progressively becoming a team activity as optimum solutions can be found only by considering a large number of factors of diverse nature with which the designer may not always be well conversant. The block diagram of Fig. 1.58 shows how design is related to different engineering, economic, natural and social sciences ‘Social economy Y [Economics Manufacturing Engineering sciences like Physics: ‘Science like ‘welding, forging and |» material science, id machining, ete. mathematics | — | theory of machines tc. Y Engineering aesthetics Fig. 1.58 Block diagram depicting the influence of various sciences on design In view of the heavy responsibilities on the designer and the large expenditure involved in designing a new machine, itis necessary to streamline the design process so that a sound design solution is achieved with minimum expenditure.Machine Too! Design and Numerical Contro! Requirement (Goal) y Precise Gefintion of requirementafter | modification, expansion, etc, | -——> Technical specifications }«—J Design proposal ¥. Development of proper >| kinematic solution and. = |} selection of proper layout |—_______¥ v Design calculations for various units of machine ool Preliminary design Standard ‘components and subassemblies g i 8 ¥ Design of components and parts. Part and assembly drawings. Technical specifications y Prototype fabrication {¢— Production and marketing Fig. 1.59 Block diagram of the design process in respect of machine tools The design process for designing a new machine tool is presented in the form of a block diagram in Fig. 1.59. It is evident from Fig. 1.43 that the design process is carried out in three important stages: 1. Design proposal 2. Preliminary design 3. Detailed design Atthe end of each stage, the design must be subjected to a critical feasibility analysis, and a technical re- port prepared and submitted to the customer. The steps involved in the design process will now be elaborated one by one. 1. Requirement ‘The customer outlines the requirement by furnishing information about the parts for ma- chining of which he wants the machine tool to be designed. The information should include the nomenclature of parts and their annual output, the dimensions and shapes of surfaces to be machined, materials of the parts,Introduction to Machine Too! Drives and Mechanisms 59 | machining tolerances, and the quality of surface finish required. This information serves as the basis for se- lecting appropriate machining methods and cutting tools. ‘The customer, owing to his lack of specialist knowledge, may often not be in a position to define his need exactly. The designer must first of all check that the requirement of a new design is genuine and a suitable product does not already exist, A consideration in undertaking a new design, in the presence of available solutions, may be the need to make the product economically viable by reducing its cost. The designer must, therefore, make a preliminary assessment of the requirement to see whether it is economically feasible. If necessary, he may, in consultation with the customer, modify or expand the requirement to increase the mar- ket potential of the designed machine tool. 2. Technical Specifications The technical specification is a listing of parameters that are essential for the design. The information furnished by the customer about the parts forms the basis of determining important machine tool specifications, such as the range of the speed of the main motion, speed of auxiliary motions, power rating of the electric motor, ete, Besides quantifiable items, the designer must also specify factors that in themselves cannot be quantified but are of utmost importance to design, e.g., the method of speed and feed rate regulation, degree of mechanisation and automation to be employed on the machine tool, appearance of the machine tool, etc. In general, the designer should frame the specifications in a manner that does not un- necessarily narrow the range of possible solutions. It should be remembered that incorrect specifications are one of the major sources of overdesign and redundant features in the finished product. The final design depends to a great extent upon the relative importance of the different specification items. A comparison of the importance of specification items for a vacuum cleaner and aircraft is given in Fig. 1.60°. A listing of specifications in this manner helps the designer in properly appreciating his priorities and prevents him from deviating from the basic goal. oO 12 3 4 0 42 3.4 Cost Cost Reliabity Reliabilty Weight Weight Appearance ‘Appearance Ease of inspection ese of inspection @ ©) Fig. 1.60 Importance of specification items for: (a) Vacuum cleaner (b) Aircraft 3. Selection of Proper Kinematic Solution and Layout After technical specifications have been laid down, the designer explores the combinations of relative motions that can ensure machining of surfaces of required shapes and dimensions. The different possibilities are evaluated and those found technically feasible are selected. Kinematic solutions on the basis of basic motion combinations are now developed. All these so- lutions are analysed for their technical feasibility and infeasible solutions are screened. A kinematic solution correlates the motions of the workpiece and cutting tool and can be realised in a number of layouts of major machine tool units. A technical feasibility analysis, keeping in mind the constraints of the requirements and technical specifications, is again carried out to select the best possible layout, This aspect will be elaborated in See. 1.9,60 | Machine Tool Design and Numerical Controt 4. Design Calculations Design calculations cover the design of the major units of the machine tools, such as the speed box, feed box, bed, spindle, etc, These calculations are done in accordance with design proce- dures only for those versions that are found most suitable on the basis of the preceding analysis, The final version is selected by comparing the economic feasibility of implementation of alternatives. 5. Drawings of Components and Assemblies These drawings are made for the version that is finally selected. The drawings must be complete with dimensions, tolerances and manufacturing specifications (including the manufacturing method to be employed). Special care should be taken during the stages of design calculations and detailed drawing to make use of standard components and assemblies as far as possible. It should be appreciated that design is essentially an iterative process. The feedback that is received after prototype fabrication and testing, and particularly after marketing the product must be carefully analysed to make appropriate changes in technical specifications and subsequent design. In the design process itself, the designer should adopt a flexible attitude and be prepared to make modifications in the technical specifications and even the requirements, if these are conducive to more sound and/or economic design. These aspects are indicated in the design process (Fig. 1.59) by feedback loops. | 449 LAYOUT OF MACHINE TOOL The layout of the machine tool must provide the required combination of forming and setting motions that are necessary for the given machining process. The required relative motions between the cutting tool and workpiece are generally realised by means of a set of translatory and rotary motions. The layout of the ma- inc tool will typically consist of one stationary block and a number of moving blocks divided by linear or circular guideways, the number of guideways being equal to the number of elementary motions provided on the machine tool. A particular layout is obtained by placing the stationary and moving blocks in a particular order. Different layouts are obiained by changing the order of these blocks. It is the task of the designer to analyse the various layout alternatives and select the best possible version, consistent with the constraints of the particular machine tool. ‘The selection of a suitable layout can best be carried out by structural analysis using the Boolean-algebra technique, In this method, the machine tool structure of any complexity can be represented in the form of a combination of symbols. Let us introduce a set of symbols for this purpose. Let.X, ¥, Z represent the basic reciprocating displacements along the corresponding co-ordinate axes and U,V. W the additional displacements in the same directions. A,B, C represent rotary motions about axes X, Y, Z while D and E represent the additional rotary motions. The lower case letters of all the symbols defined above indicate the auxiliary setting motions for the corre- sponding coordinate axes, e.g.,.x represents auxiliary setting motion in the x-direction, while a represents an auxiliary rotary motion about the same axis, Boolean algebra permits the consecutive linking of blocks which is represented as a conjunction (AND) and parallel linking which is represented as a disjunction (OR). The consecutive linkage of blocks may not be indicated by anything or may be indicated by a full stop (-). Parallel blocks are written in brackets and parallel linking is indicated by a plus sign (+). The layout formula begins with the block carrying the workpiece and ends with the block carrying the cutting tool.Introduction to Machine Too! Drives and Mechanisms 61 | Some examples of machine tool layouts and their layout formulae are given in Fig, 1.61.4 Figure 1.6la shows the layout of a knee-type vertical milling machine with consecutive linking of blocks. In the layout formula XYZOC,, x represents table travel y represents cross-slide travel Zz represents knec travel oO represents the stationary block (column) iG represents rotation of spindle about the Z-axis subscript v indicates that the spindle is vertical. The lathe layout shown in Fig. 1.61b also consists of blocks linked in series, In the layout formula AOXYewd, Mp draw 2 number of horizontal lines; if 7, < n,, draw as many additional horizontal lines as are necessary so that 7,, can be located on the speed chart. In our example ri, = 1440 rpm and 7. ny; = 1410 rpm. Therefore, we draw 13 horizontal lines. On the 13th line, m3 = 2000 rpm which is greater than rp. 3. Draw the rays depicting transmission between the last shaft and the shaft preceding it. The rays are drawn for the lowest rpm of the last shaft keeping in mind the transmission ratio constraints of jjnax $2 and jin > 1/4. In our problem, the transmission range of the last group is = ¢°, which for @= 1.41 can be divided only in one possible manner jinx 72° 9? i geil, fnin ™ > o the rays depicting these transmissions are depicted in Fig. 2.3a for the lowest speed. to vy 1410 1410 1000 1000 710 710 500 500 355 355 \ 250 250 180 180 wa 125 125 90 90 63 63 y 45 “ 45 31.5 31.5 (@) (b) Fig. 2.3 (a) Ray diagram, (b) Speed chart 4. In the transmission between shafts II and IV, the transmission range as per Eq. (2.12) is @'. The transmissions between shafis III and IV may be arranged in three different ways as shown in Fig. 2.4a, bande.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 93 5. Analyse the structural diagrams. Diagram (a) Between shafts |and II, Imin Between shafts Il and 111, 22 iin Hence maximum transmission range of the feed box = ¢°. Diagram (b) Between shafts Iand II, 22 Snin Between shafts Il and Ill, “2% ‘min Hence maximum transmission range of the feed box = ¢*. Diagram (c) Between shafts | and 1, = g 0! Imin Between shafts II and III, 4% = g@-)4= 4 tin Hence maximum transmission range of the feed box = ¢*. Diagram (d) Between shafts land II, 8 = gf)? = 9° Frnin Between shafts II and I, =~ =92 Dag Hence maximum transmission range of the feed box = ¢°, It may be recalled that the group transmission range constraint in feed boxes = 14. Therefore, For diagram (a), 6° < 14, i.e. @S 1.55 For diagram (b), 0* 5 14, i.e. @S 2.41 For diagram (c), $4 < 14, i.e. 9S 241 For diagram (d), 6° < 14, ie, @< L41 Since the selected value of ¢ = 1.41, allthe structural diagrams satisfy the transmission range constraint condition. The selection of the best possible version is, therefore, determined by the condition d= min, ic...) <.X> This condition is satisfied by diagrams (a) and (c). However, diagram (a) is preferred because the minimum rpm value on shaft II is higher and the maximum rpm value on the same shaft lower than the corresponding values of diagram (c). 6. Determine the rpm values of the output shaft of the gear box per revolution of the spindle which ensure the desired feed rates.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 97 Motor Motor 1 W ul Vv 1 ul Vv | | (2) 2(2) 314) 2(1) (0) 208) 1) 266) Fig. 2.8 Structural diagrams of speed boxes with multiple speed motors: (a) two-speed motor, 9 = 1.41, (b) two-speed motor, 6 = 1.26 Let us illustrate the plotting of the speed chart fora 12 speed gear box using a two speed motor. The struc- tural formula is 12 = 2(2) 3(4) 2(1) and 9= 1.41, i.e., Xp, = 2. RPM nj» will be obtained at the higher of the two motor speeds. Let us mark it with a circle (Fig. 2.94). If the motor speed is now changed (wvithout shifting the gears), the output rpm obtained on the gear box will be ny. As this rpm is obtained at the lower of the two motor speeds, it is marked with a cross. By similar logic. ny, will be obtained at the higher speed of the motor and no at the lower, they are, therefore, marked by circle and cross, respectively (Fig. 2.9b). In this manner, all the output 1pm values of the gear box are marked by circles and crosses corresponding to the two settings of the motor (Fig. 2.9¢). M2 Myo Nye May my my, Pag M0 Me AWN My ns n Mo " ty fe "i m ‘5 "% ”, fe n, - WW, 2 ny ny ny mn ny 2(2) (4) 21)” -2(2) 2(1) 314) n (a) ) © @ le) 2(3) 3(1) 2(6) 2(3) 2/6) 3(1) Fig. 2.9 Steps in developing speed chart of a speed Fig. 2.10 Speed charts of 12-speed gear box box with two speed motor ith two speed motoraa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 101 | 4. Calculate the number of non-coinciding speed steps “oom ow sy from Eq. 2.19. 5. If zy. exceeds the number of required speed steps by more than one step, then the limiting value of X, should be reduced by 1, i.e., the transmission range of the group should be increased by @ and the whole procedure repeated from step (2), 6. Write the corrected structural formula. For example, given R, = 80, = 1.26: Na VY we assume z, = 24, which may be written as CLR, E 1. From Eq. (2.6), i AIK 2 eg 2004 SS ASSAF Xr 2,=3X2X2x2, 2. Write the normal structural formula 2 = 24= 3(1)2(3)2(6)2(12) limiting value of X, given in Table 2.12. 3. Reduce the characteristic X, from 12 to 9 which is the \ 4. Calculate (Xy- Xu D 24-(12—9)2—1)=21 3(1)2(3)2(6)2(9) 5. Zye differs from z = 20.04 by less than unity, and therefore, the structural formula is accepted. The corresponding structural diagram is given in Fig. 2.12. Fig. 2.12 Structural diagram of a speed box with overlapping speed steps The major drawback of drives with overlapping speed steps is that a complicated transmission is employed to obtain less number of spindle speeds than what the transmission is capable of providing. If the number of overlapping speed steps is more than 3, itis better to employ a drive with broken geometrical progression or with a combined structure which are discussed below. | 2.5.2 Speed Box with Broken Geometrical Progression In drives using a broken geometrical progression, the progression ratio is equal to $ in the middle and ¢ in the lowest and highest extreme speed steps. This reduces the number of speed steps and transmissions but increases the range ratio without complicating the drive A speed box with broken geometrical progression can be employed if z ~ 2 is equal to or less than the limiting value of z, given in Table 2.11 ‘The structural formula of a drive with a broken geometrical progression is written as follows: D(X) pa A2)px(%) «.. PAX) (2.20) where X{= (5 —p,)aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 105 | ZS — = Cu) aaizey == ; j}—= 2(4) 2(8) Fig. 2.17 Gearing diagram of a speed box with combined structure having structural formula z = 2()) 2(2) [1+ 2(4) 2(8)] GENERAL RECOMMENDAITIONS FOR DEVELOPING 2.6 THE GEARING DIAGRAM While developing the gearing diagram on the basis of a given structural diagram, attention must be paid to the following two aspects: 1. All requirements that are essential for the proper functioning of a gear transmission must be satisfied and gear-box dimensions kept minimum. These essential requirements for proper functioning ofa gear transmission may be summed up as: (i) The number of tecth on the smallest gear of a transmission should be such that there is no un- dercutting of gear teeth; generally for gears with an uncorrected profile and 20° pressure angle, Zpyin 2 17- (ii) If gear pairs on parallel shafts have the same module, the sum of the number of teeth of mating gear pairs must be the same. (iii), The spacing between adjacent gears on a shaft should be such that one gear pair gets completely disengaged before the next begins to mesh (Fig. 2.18). (iv) The number of teeth of adjacent gears must differ by at least four. This point may be proved by considering the following example (Fig. 2.19). The sliding block mounted on shaft I provides three speeds on shaft Il depending upon which of the gear pairs is used for transmission. The centre distance between the shafts is m A= (Zi +Z 23 4)aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 109 x: x =F = it Brake («Hh Fig. 2.22 Gearing diagram of a lathe based upon the structural formula 2(1)3(2)2(6) and the speed chart of Fig. 2.36 U-« Transmission to feed trai In general, it is recommended that Z;,iy > 20 in speed boxes and > 16 in feed boxes. However, ifa smaller value of the number of teeth has to be assigned due to space limitations, then Zy» should be calculated from the following relationship which precludes undercutting: (2.24) where XK =tooth addendum coefficient 7 = transmission ratio o: = pressure angle It is evident from Eq, (2.24) that Zin can be reduced by decreasing the value of K and increasing @. The Zpin Values for different values of o, K and i are given in Table 2.13aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 113 ‘The maximum shear stress in the shaft occurs at the surface and is given by the expression, My‘ 1, Tmax i where r= radius ofthe shaft and 4 J}, = polar moment of inertia of the shaft = > = 2M _16Mia md The shaft dimensions are found from the condition tax = [7] where [4] is the permissible shear strength of the shaft material, Consequently, Hence, Tox 6M. 5 Mua alr] (1) Gear Dimensions Before describing the procedure of determining the gear dimensions, it is pertinent to recall that the gear teeth of all the gears are already known. Therefore, all that is required is to find the module of the gears to obtain their dimensions. A simple method of determining the module based on beam strength of gear teeth provides the following expression Mug mm (2.25) where M,, = design torque, Kgfmm A = bim, wherein b is width of gear, A lies between 8-12 for spur gears and 10-20 for helical gears Z = number of teeth of the gear C = material constant The value of C is taken from the following table: Material Cast iron Mild steel 0.6% Csteel_| 16MnCr05 steel | High alloyed steel c 1 2 4 3 10 In gear boxes, the main criterion of the durability of gear teeth is contact strength, Based on this criterion, the module is determined from the following formula’: (2.26) where My = design torque; kgf. cm Jnin = minimum transmission ratio in a given transmission groupaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 117 Transmission group 3(2) As gear Zo of the previous transmission group 2(1) is serving as a link gear, the module of gear Z,) meshing with Zy will also be the same as that of Zy, i.c m = 3. Hence, all the gears of the transmission group 3(2) con- Z: 5 Z 21 Z 53 sisting of gear pairs <2 = 35, Zit <2) ang 28. = 33 should have the module may = 3. It may be noted Zo 10 Z) 84 Zy4 here, that in view of the use ofa link gear, the modules of the gears the transmission group 3(2) have not Zu _t been determined on the basis of the transmission with the minimum transmission ratio ( 3} However, 12 it is necessary to check whether this module can ensure adequate strength for the gear of the transmission 1 having imin = For the transmission group 3(2), the transmission with minimum transmission ratio is fy = 2 1 ang the gears have teeth Z,, = 21 and Z, = 84. 4 Applying the method based on beam strength of the gear teeth, we find from Eq. (2.25) 3 2M at mm min Fez, As before, taking = 10 and C= 4, we find 1 2175248 \3 \ muy = | 2224 } = (41.7257)! = 3.468 mm. 10x 4x21 We select my yy = 3.5 ftom the standard series. Based on this check we decide that my, yy = 3.5 be taken as module for all gears of the transmission group 3(2). Also since gear Zio of the transmission group 3(2) meshes with gear Z, of the previous transmission group 2(1), the module of the gears of transmission group 2(1) be modified as mu m= 3.5 Transmission group 2(6) Zp 1 17 The transmission with the minimum transmission ratio in this group is nin ~ = compressed volume of oil, cm* P\ = initial pressure of oil, kgf/cm” p> = final pressure of oil, kgficm? B = coefficient of compressibility of oil, em*/kef Compressibility coefficient 8 depends upon oil pressure and temperature. However, the effect of both pressure and temperature on fis negligible as compared to that of air inclusions in the oil. Air inclusions inaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 129 In the meireing-in circuit counter pressure p in the right-hand chamber of the cylinder is equal to zero. Therefore, if load P suddenly drops, the piston jerks forward. This shows that the metreing-in circuit can- not be employed in machine tools in which the machining process is intermittent in nature, e.g., milling machines. In such machine tools the metreing-out circuit (Fig. 2.30b) must be employed because in this arrangemert, the counter pressure p3 is not equal to zero. As the load decreases, counter pressure ps increases, and therefore, the piston speed is again not independent of the load, Hydraulic circuits with parallel installation of the throttle are extremely sensitive to leakage losses and load varia~ tions. They are, therefore, rarely used in machine tools and their application is limited mainly to servo-mechanisms. _ As explained above, non-uniformity of motion is inher- ent in both metreing-in and metreing-out hydraulic systems with flow-control valves due to leakage losses and varia- » 4 s tion of pressure drop due to variation of load. The motion of traversing unit can be stabilised by means of reducing valves which are capable of maintaining an approximate- t } ly constant pressure drop (constant-Ap-type valves) when my Pe properly connected to the flow-control valve. The constant- Fig. 2.34 Ap-type valve is shown in Fig, 2.31. The balance equation of the valve may be written as follows: Pi(Ap—A,) + pz A3 = pi(A3— Ay) + pa Ay + Fp Pi(Ap~ Ay) = (Ap ~A3)p2 + pis Ay) + Foy Foy Constant-4P-type reducing valve IFit is assumed that 4, ~ Ay, then A, —A, = A,— 43 = Acis the effective piston area and the balance equa tion can be rewritten as @1-P2) de = Fp Fy Pi —P = Ap=—2 = const Ag In metreing-in circuits the reducing valve is connected in parallel with the throttle, while in metreing-out circuits the flow-control valve and reducing valve are connected in series. The efficiency of hydraulic speed-regulation systems with oil-delivery control is higher than that of sys- tems with a flow-control valve. Therefore, consiant-delivery pumps used in the second type should have a higher mechanical efficiency than vane or piston pumps used in the first type of systems to somewhat com- pensate for the difference. Hydraulic drives with flow-control valves have a wider speed-variation range (R, = 70-100) and a response. They are commonly used in systems with low power consumption up to 3-5 kW. ster Hydraulic circuits employing variable delivery pumps with flow-control valves are more expensive than the ones using constant delivery pumps, but have a higher efficiency. Their full benefits can be derived in closed hydraulic circuits which are generally applied in rotary drives.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 133 | when a high quality of stepless regulation in a wide range is required. They permit slow setting movements, feed motion and also rapid traverse motion, In machine tools, these systems are used mainly in feed mecha- nism Lately, speed-regulation systems of de motors using magnetic amplifiers have found application in the industry. The main advantage of these systems over the generator-motor and amplidyne-motor systems is their higher reliability. They have an efficiency of about 50% and a speed range of up to 100. These systems are used mainly in feed mechanisms of milling and grinding machines. A recent advance in stepless regulation of speed and feed rates in machine tools is the development of speed control systems of de motors by means of thyristors and ionic devices such as thyratron, ignitron and excitron. With the fast growth of the electronics industry, it is expected that these systems will find wider application in machine tools in the future. The speed range of these systems is up to 200 and the power trans- mitted up to 10 kW. Ingpite of higher efficiency compared with ac motors, the use of de motors for siepless speed regulation suffers from the following drawbacks 1. High cost 2. Not readily available 3. Frequent replacement of carbon brushes 4, Less rugged In view of the above, ac variable speed drives with variable frequency and variable voltage control hold out promise for the future and are already finding ready acceptance, These drives have the following features: R,=50, W=1-75 hp 2. Operation in constant torque mode at speeds below 3000 rpm and constant power mode above 3,000 rpm. The block diagram of a variable frequency, variable voltage control ac drive is shown in Fig. 2.34, Three phase ac power is fed to the motor via a contactor and full wave three-phase rectifier. The rectifier output Input contactor Three-Phase -3-—_Tthrao_Phasel = Transister mains = 8] rectifier inverter input 2 ttt Switch Base mode drives power supplies x (SMPs) 535 —> [men fEs interface 352 —> | and control >| Regulator >} ee asf logic: 8 Fig. 2.34 Block diagram of variable frequency, variable voltage control ac driveaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 145 This speed box consists of three major components: 1. Stepped gear box 2. Mechanical variator 3. Control of the mechanical variator The stepped gear box hes electromagnets clutches M1, M2 and M3 which are used for engaging, revers- ing and stopping the spindle, respectively. The Svetozarov mechanical variator has a speed variation range 2 1 x * . see between © and = (Rn = 4). Stepped speed variation in the gear box is achieved by varying the position of double cluster gear blocks B1 (88-60) and B2 (22-49) to obtain four speed steps The block B3 is shown as a double cluster gear, but in fact these two gears are used as single gears. The gear pair (72-36) is used for fixed reduction of the speeds in the single kinematic train of Range | and the gear pair (27-54) for increase of the speeds in the three kinematic trains that provide Ranges 2, 3 and 4 described below. From the motor (= 14 KW, n= 1450 1pm), the rotation to the spindle is provided through the mechanical variator, belt drive (200-192) and stepped gear box by the following four kinematic trains, each allowing the variation of spindle rpm in a particular range Range 1: By disengaging B1 and engaging B3 as shown in the figure. 1450 iG to 5) 3) (Z| 3000 — 750 rpm 1° 2) 192138 136 Range 2: By shifting B1 to the right, engaging B2 as shown in the figure and shifting B3 to the right. 075) ele Lalella Range 3: By shifiing B1 to the right B2 to the left and B3 to the right. 14s0(2 © 7) 200/15 60) 22] 27)- 190—47 rpm 1° 2) 19238 |L60 |. 88 || sa ing B2 to the left and B3 to the right. aso o£) 20/222] 22 yg 1” 2/192 138 JU 88 JL 38 JL 54 Thus, this gear box provides continuous variation of spindle rotation between 12 and 3000 rev./ min. For reversal of spindle rotation, single sliding gear 49 is made to mesh with gear 19, electromagnetic clus- tet ML is disengaged and M2 is engaged. The transmission now occurs through the gear pair (19-49) and the gear train (69-idle gear-44), Henceforth, the transmission occurs through the four kinematic trains described above. The additional reversal path has a transmission ratio [ZI 0.60 a the direct path, Thus, the reversal speeds of the spindle are 20% higher than the direct speeds. 50 ~ 190 rpm Range 4: By engaging 1 as shown in the figure, shil compared to [2] =0.50f 38, ‘The control of the mechanical variator is executed through an independent kinematic train, From the 1 kw electric motor rotation is transmitted to the drum cam through belt drive 125-125 and two, triple start wormaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Regulation of Speed and Feed Rates 153 Shaft I-11 (four gear block 23-60, 30-53, 43-40 and 36-47) 1410 ZSI2) [| = 540, 798, 1080, 1515 60 JL53 L471 L40 Adjusted to 500, 710, 1000, 1410 with an error of 8% Shaft I-III (through gear pair 29-30) (500, 710, 1000, 1410) [2]- 200.412, 580, 818. Adjusted to 355, 500, 710, 1000, Shaft I-IV ( double gear pair 21-72 and 50-43) 355, 500, 710, sooo| 24] 52] = 103, 146, 207, 291, 413, 581, 825, 1162 Adjusted to 90, 125, 180, 250, 355, 500, 710, 1000 Shaft IV-V (double gear pair 20-61 and 61-47) (i) 90, 125, 180, 250 (22) = 29.5, 41, 59, 82, 117, 162, 234, 324 (ii) 355, 500,710, 100, ({] =460, 649, 921, 1297 Total speeds on shaft V (spindle) 29.5, 41, 59, 82, 117, 162, 234, 324, 460, 649, 921, 1297 (12 speeds) Adjusted to 31.5, 45, 63, 90, 125, 180, 250, 355, 500, 710, 1000, 1410 of the standard series of Table 2.9. 20 It is noteworthy that the transmission ratio [2 has not been utilised in (ii) above with the speeds 355, 500, 710 and 1000 as this would only have provided the speeds overlapping with the existing rpm values of 125, 180, 250 and 355 obtained in (i) Feed Box The inputto the feed box comes from the last shaft (shaft V) of the speed box. The nine steps of feed rate are obtained by means of two triple gear blocks. The structural diagram and feed ‘chart’ are shown in Fig. 2.52 and the gearing diagram in Fig. 2.53. From shaft V of the feed chart, the rotation is converted to translatory feed motion through gear pair 36-53, worm-worm gear pair of transmission ratio [4] and rack and pinion transmi: indle of module 4 and number of teeth of pinion = 12. 60 ‘The structural formula of the feed box is z=3(1) 2(3) 2(3), which should actually yield 12 steps but one of the transmission in the last stage is not utilised as it provides only overlapping steps. Thus, effectively only nine steps are realised in the feed box.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Design of Machine Too! Structures 169 | 2 P(e V5 = bhi =| — 34 “" ° a(S) en where V;is the minimum volume of metal required to ensure that deflection of the beam under load does not exceed the specified value, The condition of optimum design is Ve=Vs5 ee) ll 5 2folLh) 4E[6\h wherefrom, P _ 6E(6) P_ 66(3) 35 “ ae (3.5) Equation (3.5) indicates that for every structure, there exists an optimum ratio //h depending upon: 1. operation constraints, expressed in this case through [6], and 2. the material of the structure, expressed in this case through [o] and E. Consider, for instance, two beams of mild steel and cast iron with mechanical properties: for mild steel, E = 2.0 x 10* kgfmm”, [o] = 14 kgf/mm’, [6] = 0.002 mm; for cast iron, £ = 1.2 x 10* kgf/mm”, [o] = 3 kgfimm’, [5] ~ 0.002 mm. For the steel beam (£) _ 62x10! x 0.002 _ ont nh 14 For the cast iron beam —— 4x 1.2104 x 0.002 P 4x 2x 104 x 0.002 (48)? = 13.07 (17.14)? i.e., if the failure of the beams is determined by the normal stresses under tensile loading, the volume of the steel heam required to withstand the same load is 13.07 times less than that of the cast iron beam. ‘The variation of /, and Vs for mild steel and cast iron beams with change of /?/h is shown in Fig. 3.2. For identical beam length, the height of the steel section must be 48/17.14 = 2.80 times greater. Since the volume of the steel beam is 13.07 times less and height 2.80 times greater than that of the cast iron beam, the thick- ness of the mild steel beam will be 36.5 times less.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Design of Machine Tool Structures 173 | If we compare the weights of two bars of identical length subjected to a bending moment M, it follows that We _ Woy)? ny _ Wy Wor) The quantity of/yis an index of the ability of a material to resist bending and is known as the wnir strength under bending. The commonly used materials for machine tool structures are cast iron and steel. Cast iron structures were almost exclusively used in machine tools till a few decades ago, but lately welded steel structures are finding wider application due to advances in welding technology. The choice of whether the structure should be made from cast iron or steel depends upon a number of factors which are discussed below. 1. Material Properties The material properties of relevance are: (i) Steel has higher strength under static and dynamic loading. (ii) The unit rigidity of steel under tensile, torsional and bending loads is higher. (iii) Cast iron has higher inherent damping properties; damping in steel structures occurs mainly in welds; if welded joints are properly designed, the damping of steel structure may approach that of cast iron. (iv) Cast iron has better sliding properties. 2. Manufacturing Problems Another important factor for deciding the choice of material concerns the problems of manufacturing that are associated with the use of stee! or cast iron structures: (i) Wall thickness: For a given weight of the structure, high strength and stiffness can be achieved by using large overall dimensions and small wall thickness. Thus, walls of minimum possible thickness should be employed. Generally, reduction of wall thickness in cast iron structures is restricted by process capability and depends upon the size of the casting, These values are given in Table 3.2. Table 3.2. Recommended minimum wall thickness for cast iron structures Size factor N, m Thickness of external | Thickness of internal walls walls, mm cand ribs, mm 04 6 5 0.75 8 7 1.0 10 8 LS 12 10 18 14 12 20 16 14 25 18 16 3.0 20 16 3.5 22 18 4S 25 20aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Design of Machine Too! Structures 177 | (a) (b) Fig.3.6 Schematic diagram depicting the cross stiffnesses (a) influencing workpiece accuracy, (b) influencing dynamic stability workpiece, and is the relative displacement normal to the surface of cut, This displacement determines the variation of the chip thickness, which is of maximum significance for stability of the machine tool against chatter vibrations (for details see Chap. 6). As already stated, a machine tool consists of a number of elements. These elements experience deforma- tion during operation of the machine tool, and therefore, can be looked upon as elastic bodies (springs) with a certain stiffiess (spring constant). The machine tool is thus reduced to a system of springs which are joined in series or parallels, Some important conclusions about the cumulative stiffness of the machine tool system may be drawn from a study of simple spring systems connected in series and parallels. Consider a set of springs of stifthess Ky, K, Ks, joined in series (Fig. 3.7). The springs are acted upon by a common force and the resultant deformation is obtained as the sum of deformations of individual springs, ie, or or G9) If the machine tool elements are used for transmission, then the resultant stiffiness of the system of springs (clements) is obtained by adding reduced stiffinesses. Consider a set of shafts which transmit rotation from the motor to the output shaft (Fig, 3.7b). Let the torsional compliances of the shafts be C), C3, C3, Cy and the transmission ratio ij 2, 73,3, is. Here, torsional compliance represents the angle of twist between the shaftaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.Design of Machine Tool Structures 181 | requires sophisticated equipment and expertise, which, unfortunately, every design organisation or laboratory may not have. On the other hand, the behaviour of a machine tool structure under static loading can be easily examined by relatively inexpensive equipment. In this context, it may be useful to remember that the weak links of the system determined from static and dynamic considerations generally differ only in the higher modes. In the basic modes of vibrations the contributions of static and dynamic stiffnesses of individual ele- ments in the overall corresponding stiflnesses of the machine tools are approximately the same. Thus, it may be safely presumed that in a majority of cases, improvement in the stiffness of elements leading to a higher overall static stiffness will also result in a higher overall dynamic stiffness. ‘The reader will do well to recall an important conclusion derived earlier from the results shown in Fig. 3.8, regarding judicial selection of the natural frequency of the element vis-a-vis the frequency of excitation. The natural frequency of an undamped spring-mass system is given by the expression, f= {Kin (3.16) By varying K and m, the natural frequency of a particular mode of vibration can be controlled. The fre- quencies of the modes of vibration correspond to natural frequencies of the elements of the machine tool. Therefore, while designing the elements of machine tools, their natural frequencies should be checked at the design stage and it should be ensured as far as possible that 1. the lowest among the natural frequencies should desirably be 2.5 times greater than the highest excitation frequency or 2. the highest among the natural frequencies should desirably be 2.5 times less than the lowest excitation frequency. In machine tools, the excitation frequencies generally appear from rotating shafts, gears, spindles, etc. They are relatively low in most of the machine tools, e.g., ifa lathe spindle rotates with a maximum speed of Nyax = 1200 rpm, it would produce a maximum excitation frequency of f, = 1200/60 = 20 Hz. Correspond- ingly, the heaviest lathe unit should have a natural frequency of > 50, In such machine tools, increasing the stiffness of an element which is the same as increasing its natural frequency, will improve the dynamic behaviour of the machine tool. It is this group of machine tools for which the statement regarding identical variations of static and dynamic stiffnesses holds. In machine tools which are characterised by high cutting speeds, e.g., grinding machines, the rpm will be large if small-sized grinding wheels are used and relatively small if grinding wheels of large diameters are used. Keeping in mind that the average cutting speed of grinding operations is 1800 m/min, the excitation frequency will be 1000 x 1800. ———_H m-D-00 where D = diameter of the grinding wheel in mm If the diameter of the grinding wheel = 500 mm, the excitation frequency f, = 19.1 Hz; if the grinding wheel diameter is D = 50 mm, the excitation frequency will be f, = 191 Hz. Grinding machines of two fun- damentally different designs are manufactured keeping this point in mind, These are: 1. Light-weight construction grinding machines using large-size grinding wheels in which the frequencies of modes of vibrations are kept high by using stiff but light structures; high natural frequency at the cost of stiffness is not desirable as it results in poorer accuracy.