1.Whats machine tool?

It is a machine for shaping or machining metal or other rigid materials, usually by cutting, boring,
grinding, shearing or other forms of deformation. Machine tools employ some sort of tool that does
the cutting or shaping.

Main(cutting) motion,

(2) Feed motion and

(3) Auxiliary (adjustment) motion.

Machine tools can generally be classified into 4 main groups;

1.Machine tools that remove chips,

2.Machine tools that do not remove chips (presses, etc.),

3.Machine tools that are used in the processing of plastic materials (extruders),

4.Machine tools that are used in the material processing with physical and chemical methods (non-
traditional methods).

According to the geometrical shapes of workpieces.

1.Machine tools for machining cylindrical surfaces (lathes)

2.Machine tools for machining flat surfaces (milling machines, shapers, planers)

3.Machine tools for making holes (drilling machines)

4.Machine tools for machining profiles (milling machines, hobbingmachine tools)

According to the number of workpieces

1.Simple Machine Tools

2.Universal Machine Tools (general purpose)

3.Production Machine Tools (special purpose)

4.Special Machine Tools (limited purpose)

5.Transfer Machine Tools

6.Numerical Controlled Machine Tools

7.Modular Machine Tools

According to the functions of the machines

•Lathes

•Drilling Machine Tools

•Milling Machine Tools

•Shaper / Planer / Slotter

•Grinding Machine Tools

•Sawing Machine Tools

•Broaching Machine Tools

•Gear Cutter Machine Tools

•Super Finish Machine Tools

According to the types of control

Manual and auto ( mech. Nc )

Production Machine Tools

These machines are used only for special application or aim. These machines provide the work to be
done in a short time without the necessity of qualified worker. These kind of machines can be used
for bulk production in small scales.

TransferMachine Tools

Transfer machine tools can have one station or multi station. In general, these machines have several
stations for performing various machining processes and these stations are designed in a special
range of next to each other. These machines are for the net shape bulk production and generally
automatic.

Workpieces are fed into the machine and automatically indexed from station to station. Each station
simultaneously performs a different operation on the workpiece and they exit the machine as a
partially or completely finished unit. Standard transfer machine systems consist of multiple,
sequential mechanical components, such as machining heads, transfer devices, indexing tables, and
work.

They are used in the mass production of metal parts for a variety of industries, such the automotive
and industrial machinery industries.

Main parts of machine tools

1.Main frame: Main frame (bed) forms the vital part of the machine tool on which table and other
relevant parts of the machine tool move. It is therefore evident that the main frame should be
sufficiently strong and rigid. It should also be easier to remove the chips produced during machining.
The machine tool frame supports all the active and passive components of the cutting tool, spindle,
table, and controls. Main frames of the machine tools are generally made from cast iron or steel.
Grey cast iron with some

The most important parameters for determining the shape of the body:

Position and length of motion axes

Volumetric arrangement of groups such as spindles, slides, speed boxes

Important passageways in installation, operation and maintenance

Magnitudes of cutting forces and moments

Open Frames (C-frames)

Open frames provide excellent accessibility to the cutting tool and the workpiece. Typical examples
of open frames are found in turning, drilling, milling, shaping, grinding, slotting, and boring machine
tools.

Factors governing the choice of frame materials are:

resistance to deformation (hardness),

resistance to impact and fracture (toughness),

limited expansion under heat (coefficient of thermal expansion),

high absorption of vibrations (damping),

resistance to shop-floor environment (corrosion resistance),

specific weight,

modulus of elasticity and modulus of shear,

coefficient of friction,

low cost.

1. Having high static rigidity to maintain geometric accuracy,

2. Vibration damping ability should be good.

3. Dynamic stiffness should be good.

4. It should be designed according to lightweight construction principle.

5. Thermal stability should be good.

6. It should be cleaned easily and should not interfere the chip disposal.

7. Having long life and being ergonomic.

WHY ARE WE USE CASTING FOR PRODUCE FRAMES?

A cast iron structure ensures the following advantages:

Better lubricating property (due to the presence of free graphite); most suitable for beds in which
rubbing is the main criterion,

High compressive strength,

Better damping capacity

Easily cast and machined.

2.Power unit: It provides rotation to main driving mechanism and transmission linkage transfers this
motion to desired sections of machine tool.

3.Driving mechanisms: Machine tool requires variety of speeds and feeds. This is provided by a
suitable designed driving mechanisms such as stepped or steplesstypes. Stepped(Belts, gears,
screws-nutspulleys)

Stepless(mechanical, hydraulic, pneumatic, electrical)

4.Spindle and bearing: The shaft and spindles should be so designed that they can take axial, bending
and twisting loads. The bearings should be so selected that they can resist static and dynamic loads.
The spindle delivers torque to the cutting tool, so its precision is essential to machine tool operation.

The key factors influencing precision are bearing type and placement, lubrication, and cooling.

5.Cutting tool and workpiece holding devices

6.Guideways and guides (slidewaysand slides): Guideways or slideways on which workpiece or

cutting tool with their relevant units move should be strong and should have long life. The surfaces of
the guideways should be perfectly machined so that it maintains good amount of accuracy and
precision. The guideways are made of cast iron or steel. Guideways/slidewayscarry the workpiece
table or spindles. Guideways are required to perform the necessary machine toolmotion at a high
level of accuracy under severe machining conditions. Generally guideways, therefore,control the
movement of the different parts of the machine tool in all positions.

Requirements of guideways:

It should be strong.

It should be possess sufficient stiffness.

There should be less wear.

The pressure distribution should be uniform.

It should provide good guidance.

There should be less friction.

7.Transmission linkage: This is the parts or sections transfers the motions to required parts of
machinetools

8.Couplings: Shaft couplings are used to fasten together the ends of two coaxial shafts. Permanent
couplings cannotbe disengaged while clutches engage and disengage shafts in operation. clutches
engage and disengage shafts in operation. Safety clutches avoid thebreakdown of the engaging
mechanisms due to sharp increase in load.

Safety, Flexible,Solid

1. Stepped Driving Mechanisms

The revolution speeds vary gradually.

Application areas are wide.

Gearing mechanisms and belt mechanisms are included in this group.

2. Stepless Driving Mechanisms

They are the mechanisms in which each required speed can be achieved.

Although they are ideal, they are not widely used due to being expensive and quickly deformed.

Mechanically stepless mechanisms, hydraulic stepless mechanisms and electrical stepless

mechanisms are included in this group.

Arithmetic Progression

n1 – n2 = n3 – n2 = constant

Accordingly, for an economical cutting speed Vmax, the lowest cutting speed V1 is not constant; it
decreases with increasing diameter. Therefore, the arithmetic progressiondoes not permit
economical machining at large diameter ranges.

The main disadvantage of such an arrangement is that the percentage drop from step to step
decreases as the speed increases.

Thus the speeds are not evenly distributed and more concentrated and closely stepped in the small
diameter range than in the large one

Geometric progression

Geometric progression, therefore, allows machining to take place between limits V0 and Vu
independent of the workpiece diameter, where V0 is the economical cutting speed and Vu is the
allowable minimum cutting speed.
As stepped driving mechanisms;

• Belt type mechanisms

• Gear type mechanisms

• Chain type mechanisms

Belt Type Mechanisms: A belt type mechanism consist of a belt and pulley. It is possible to change
the location of the belt according to the selected revolution speed.

Limited n, basic structure,limited app, mechanism size small, easy to produce, easy to use

Gear Type Mechanisms

A wide variety of gearboxes utilize sliding gears or friction or jaw coupling.

Wider n,complex structure,wider app,big size,complex production, some problems in operations

Stepples vs Stepped

1. Possibility of carrying out machining operations at optimum cutting speed. This not only improves

productivity, but also increase the tool life.

2. Ease of changing the speed or feed rate without stopping the machine tool. This helps in increasing
productivity as it cuts down the non-productive time.

3. Noiseless and more smooth rotation and absence of jerks which are characteristic of geared
drives.

Mechanical Stepless Driving Mechanisms

They are commonly used in small- and medium-sized machine tools than hydraulic and electrical
stepless driving mechanisms.

Mechanical stepless driving mechanisms are also known as “variators”. They are mostly friction type,
and therefore, their application is restricted to power transmission of up to 15 kW.

Hydraulic Stepless Driving Mechanisms: The speeds of machine tools can be hydraulically

regulated by controlling the oil discharge circulated in a hydraulic system consisting of a pump and

hydraulic motor, both of the vane type.

The advantages of the hydraulic systems are as follows:

1. Has a wide range of speed variation

2. Changes in the magnitude and direction of speed can be

easily performed

3. Provides smooth and quiet operation

4. Ensures self-lubrication

5. Has automatic protection against overloads

LATHES

A lathe operates on the principle of a rotating workpiece and a fixed cutting tool.

Classification of Lathes

a) According to configuration

i. Horizontal: Most common for ergonomic conveniences

ii. Vertical: Occupies less floor space, only some large lathes are of this type.

b) According to purpose of use

c) According to size or capacity

d) According to degree of automation

e) According to type of automation

f) According to configuration of the jobs being handled

g) According to precision

h) According to number of spindles

GEAR-BOX

Gear-box contains a number of different sized gears for providing various spindle speed