Machine Tool Engineering

BITS Pilani Girish Kant Garg

Department of Mechanical Engineering
Pilani Campus
 BITS Pilani
Pilani Campus

Introduction to Machine Tool Drives and

Mechanisms-
General Principles of Machine Tool Design
Chapter - 1
 Machine Tool
• Machine tool is a system of devices in which energy is
expended to produce jobs of desired dimension and finish by
Machining. i.e removing excess material from the workpiece
in the form of chips with the help of cutting tool moved past
the work surface at controlled speed and feeds.

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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Machine Tool Classification
• According to Degree of Specialization

• According to Type of Surface Produced

• According to Type of Motion

• According to duty cycle

• According to degree of automation

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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working and Auxiliary Motions in
Machine tools
Working Motion:
Motions which are essential to impart the required shape to
the workpiece.
 Drive motion or Primary cutting motion
 Feed motion
Auxiliary Motion:
Motions that do not participate in the process of formation of
the required surface but are necessary to make the working
motion fulfill their assigned function
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working and Auxiliary Motions in
Machine tools

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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Parameters defining Working
Motions of a Machine Tool
Cutting Speed:
Distance travelled by the work surface in a unit time with reference
to the cutting edge of the tool. It is usually expressed in m/min.
Feed:
Distance advanced by the tool for each revolution of the
workpiece. expressed in mm/rev.
Depth of Cut:
Perpendicular distance between the machined surface and the
unmachined surface or the previously machined surface. (mm)
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working Motions for Lathe

Cutting Speed: DN

v m/min
1000
Where
– D is the diameter of the job (mm)
– N revolution per minute of the job (rpm)

Tool post Workpiece

Chip N (rev/min)
S
Tool peripheral
D
speed
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working Motions for lathe

Feed:

Distance the tool advances for every rotation of workpiece

(mm/rev)

D1 D2

f
Feed
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working Motions for Lathe

Depth of Cut:

Perpendicular distance between machined surface and

uncut surface of the Workpiece.
d = (D1 – D2)/2 (mm)

D1 D2

d Depth
of Cut

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BITS Pilani, Pilani Campus
Working Motions for Reciprocating
Primary Cutting Motion
Cutting Speed:
υ= ( L / 1000 Tc) m/min

where L= length of stroke, mm

Tc = time of cutting stroke, min

If Ti=time of idle stroke in min

Then number of stroke per min
n= 1/( Ti +Tc)
K= Tc / Ti
n= K / Tc (1+K)
Therefore,
υ= n L (K+1) / 1000 K
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working Motions for Reciprocating
Primary Cutting Motion
Feed per revolution and feed per stroke are related by:
sm = s.n
where sm = feed per minute
s = feed /rev or feed/stroke
n = number of revolutions or strokes per minute
Feed per tooth in multiple tooth cutter is related by:
s = sz .Z
where sz = feed per tooth of cutter
Z = number of teeth of cutter

Therefore machine time,

Tm = (L / sm) min
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ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Lathe)
Turning operation (Workpiece clamped between centers)
d

ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Lathe)
Turning operation on workpiece clamped in chuck

Length of Tool Travel = l + Δ1 + Δ3

l= length of workpiece

Δ1= Approach (2-3 mm)

Δ3 = t cot ɸ,

t= depth of cut

ɸ = Side cutting edge angle

ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Lathe)
Facing Operation

Length of Tool Travel = D/2 + Δ1 + Δ2+ Δ3

D= Diameter of workpiece

Δ1= Approach (2-3 mm)

Δ2 = Overtravel (1-2 mm)

Δ3 = t cot ɸ,

t= depth of cut

ɸ = Side cutting edge angle

ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Lathe)
Boring operation in partial length of workpiece

Length of Tool Travel = l + Δ1 + Δ3

l= length of bore

Δ1= Approach (2-3 mm)

Δ3 = t cot ɸ,

t= depth of cut

ɸ = Side cutting edge angle

ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Lathe)
Boring operation in full length of workpiece

Length of Tool Travel = l + Δ1 + Δ2+ Δ3

l= length of bore

Δ1= Approach (2-3 mm)

Δ2 = Overtravel (2-3 mm)

Δ3 = t cot ɸ,

t= depth of cut

ɸ = Side cutting edge angle

ME G532, Machine Tool Engineering, Lecture-2, 05/08/19 BITS Pilani, Pilani Campus
Working Motions for Reciprocating
Primary Cutting Motion

Depth
of cut
C ut
A'
E A
Fe
ed
B' D
B p i e c e
W o rk
C

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ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Shaper

Clapper box

Tool cleared Lifted

from machined clapper
surface box
Workpiece
(a) Forward/Cutting stroke (b) Return stroke

ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Cutting speed

C u ttin g S tro k e

R etu rn S tro k e
W o rk piece n L (1  k )
v m/min
c Lj c C learan ce 1000k
L en g th o f stro k e L

 L is the Length of the stroke in mm

 N is number of double (cutting + return) strokes/min
 k is the ratio of cutting stroke time and return stroke time
ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Operating conditions
Feed

 Motion of workpiece in a direction perpendicular to the axis

of reciprocation of ram
 mm/stroke

Depth of cut

 Thickness of material removed in one cut

 mm

ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Machining time

Time for machining surface is

f
mm
w
w mm L mm
T
f n

Material Removal Rate

NL(1  k ) fd
MRR  mm3 / min .
k

ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
Shaper

ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
Shaper

Length of Tool Travel = B + B1 +B2+ B3

B= Width of workpiece

B1= Approach (2-3 mm)

B2 = Overtravel (2-3 mm)

B3 = t cot ɸ,
t= depth of cut
ɸ = Side cutting edge angle
s= feed per stroke, n = strokes / min
ME G532, Machine Tool Engineering, Lecture-3, 07/08/19 BITS Pilani, Pilani Campus
Working motions for Milling and Drilling
feed

 Feed is expressed in three ways:

mm/tooth or mm/revolution or mm/minute

f m  fN  f z zN
Feed/cutter revolution (f)
f = fz  z mm/rev
Feed/tooth (fz)
Feed/minute (fm)

ME G532, Machine Tool Engineering, Lecture-4, 14/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Milling Machine)
Horizontal milling machine: Plain milling operation

Length of workpiece Travel = l + Δ1 + Δ2+ Δ3

l= length of workpiece
BC  OC 2  OB 2

R 2  OB 2
R 2  (R  t)2

R 2  ( R 2  t 2  2 Rt )

2 Rt  t 2  t(D  t)
ME G532, Machine Tool Engineering, Lecture-4, 14/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Milling Machine)
Vertical milling machine: Symmetrical Face milling operation

Length of workpiece Travel = l + Δ1 + Δ2+ Δ3

l= length of workpiece
AB  OA  OB
 R  OC 2  BC 2
2
B
R  R  
2

2


0.5 D  D 2  B 2 
ME G532, Machine Tool Engineering, Lecture-4, 14/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
Drilling Machine

Length of Tool Travel = l + Δ1 + Δ2+ Δ3

l= Height of workpiece

Δ1= Approach (2-3 mm)

Δ2 = Overtravel (2-3 mm)

Δ3 = t cot ɸ,

t= d/2

2ɸ = Lip angle of drill

ME G532, Machine Tool Engineering, Lecture-4, 14/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Grinding Machine)
Cylinderical Grinding: External – Traverse cut
L= Length of workpiece
sl= Longitudnal feed of Reciprocatory
motion of workpiece = kB mm/rev
k=0.3-0.5 (rough grinding)
= 0.2-0.4 (finish grinding)
h= allowance (mm)
t=sr = radial feed/stroke (0.01-0.025)mm
K=1.2 for rough and 1.4 for finish grinding

nwp = r.p.m of workpiece

B = width of grinding wheel

Lh
Grinding Time = K , min
n wp kBt
ME G532, Machine Tool Engineering, Lecture-5, 16/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Grinding Machine)
Cylinderical Grinding: External – Plunge cut
h= allowance (mm)
st = transverse feed
= (0.0025-0.20)mm per rev
h
Grinding Time = K , min
s t n wp

ME G532, Machine Tool Engineering, Lecture-5, 16/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Grinding Machine)
Cylinderical Grinding: Internal (workpiece rotating)
L= Length of workpiece
sl= Longitudnal feed of Reciprocatory
motion of workpiece = kB mm/rev
k=0.4-0.8 (for rough grinding)
= 0.25-0.45 (For finish grinding)
t=sr = radial feed/ doublestroke
= (0.0051-0.03)mm for rough grinding
= (0.002-0.1)mm for finish grinding

Given at the end of one complete to and fro

Stroke (double stroke) 2 Lh
Grinding Time = K , min
n wp kBt
ME G532, Machine Tool Engineering, Lecture-5, 16/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Grinding Machine)
Cylinderical Grinding: Internal (workpiece stationary)
L= Length of workpiece
sl= Longitudnal feed of Reciprocatory
motion of workpiece = kB mm/rev
k=0.4-0.8 (for rough grinding)
= 0.25-0.45 (For finish grinding)
t=sr = radial feed/ doublestroke
= (0.0051-0.03)mm for rough grinding
= (0.002-0.1)mm for finish grinding
n PMC = r.p.m of planeteary motion
of grinding wheel
Given at the end of one complete to and fro
2 Lh
Stroke (double stroke) Grinding Time = K , min
n PMC kBt
ME G532, Machine Tool Engineering, Lecture-5, 16/08/19 BITS Pilani, Pilani Campus
Calculation of Machining Time
(Operations on Grinding Machine)
Surface Grinding: Peripheral – Planer feed
L= Length of stroke, L = l + 10 mm
sl= transverse feed at end of stroke
= kB mm/rev
k=0.4-0.7 (for rough grinding)
= 0.25-0.35 (For finish grinding)
t= depth of cut
= (0.015-0.15)mm for rough grinding
= (0.005-0.015)mm for finish grinding
sm= feed of table, mm/min

2 LhH
Grinding Time = K , min
s m kBt
ME G532, Machine Tool Engineering, Lecture-5, 16/08/19 BITS Pilani, Pilani Campus
 Machine Tool Drives
• It is an aggregate of mechanisms that transmit motion from
an external source to the operative elements of machine tool.
• It should have provision for regulating the speed of travel of
operative elements.
• A machine tool drive consists of
i. An Electric Motor
ii. A Transmission Arrangement

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Selection of Electrical Motor

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Hydraulic Transmission and
its Elements

Rotary Hydraulic Drive

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Hydraulic Transmission and
its Elements

Translatory Hydraulic Drive

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Pumps

Gear Pump

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Direction Control Valves

Rotary, Spool type valve

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Direction Control Valves

Four way, two position piston type valve

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Pressure Valves

Ball type pressure valve

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Throttles

Throttle valve

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Elementary transmission that
transfer rotation

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
 Gear Transmission
• Toothed wheels, which transmit power and motion from one
shaft to another by means of successive engagement of teeth.

• Most suitable drive, if the center distance is small

• It is a positive drive, velocity ratio remains constant.

• The efficiency of gear drives is very high compared to other

mechanical drives ( up to 99 %)

• Changing a velocity ratio over a wide range is possible, with

the help of special provision called gear train.

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Gear Transmission
Gears are arranged between two shafts, which are

• Parallel

• Intersecting

• Non parallel & Non intersecting

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Gear Transmission
GEARS

Parallel shaft Non Parallel &

Intersecting Shaft
Non Intersecting Shaft

Spur Helical Bevel

Crossed
Hypoid Worm
Double helical
Single
(Herringbone)

Bevel Zero Bevel Spiral Bevel Miter

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Gear Transmission
i. Used to transmit motion
between two parallel shafts
ii. Teeth parallel to the axis of
rotation
Spur Gear
iii. It has the largest applications
and easy to manufacture

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
 Gear Transmission
• Also used for parallel shafts, like
spur gears

• Teeth inclined to the axis of

rotation.

• The inclined tooth develops Helical Gear

thrust loads and bending couples

• Quiet in operation

• Teeth engage gradually reducing

shocks
ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
 Gear Transmission
• Two helical gears with opposing helical angles side-by-side

• Axial thrust gets cancelled

Herringbone Gear

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
 Gear Transmission
• Used for large speed reductions (more than 3) between two
perpendicular and non-intersecting shafts

• Driver called worm resembles a screw.

Worms and worm gears

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Transforming Rotary Motion into
Translatory
• Slider Crank Mechanism
• Crank and Rocker Mechanism

• Nut and Screw Transmission

• Rack and Pinion Transmission

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Slider Crank Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Crank and Rocker Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Crank and Rocker Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Rack and Pinion Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Devices for Intermittent Motion

• Ratchet Gear Mechanism

• Geneva Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Devices for Intermittent Motion

Ratchet Gear Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Devices for Intermittent Motion

Geneva Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Reversing Mechanism

ME G532, Machine Tool Engineering, Lecture-7, 04/09/19 BITS Pilani, Pilani Campus
Thanks

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BITS Pilani, Pilani Campus