Benha University 4th Year Production (2019/2020)

Shoubra Faculty of Engineering Design of Machining and Forming

Mechanical Engineering Department Machine Tool

Assignment (1) Principles of Machine Tools

1. Illustrate graphically the main (working) and the auxiliary motions in some of machine
tools, (center lathe, milling, drilling, Shaping, grinding…)
2. What are the factors influence machine tool designs?
3. Why is it important to connect the electric motor and the machine tool by means of a belt
drive?
4. Determine the rpm of a lathe spindle if a work piece of diameter 100 mm is to be turned
at a cutting speed of 88 m/min.
5. A 175 mm long work piece is to be machined on a shaper which has a cutting stroke to
idle stroke velocity ratio of 0.85. Calculate the strokes/min of the shaping tool if the
cutting speed is 30 m min. Assume an approach and overshoot of 5 mm.
6. Find the forces needed to cut a steel work piece of diameter 200 mm, feed 3 mm/rev,
depth of cut 2mm at 100 m/min cutting speed, Then calculate the necessary power of the
motor of this machine tool if the total mechanical efficiency is taken 80%. Specific cutting
resistance is 8500 kg/cm2.
7. For a Center Lathe, it is required to calculate precisely the needed motor power. Given
the diameter of work-piece is 80 mm turned at 600 spindle rpm. The total mechanical
efficiency is 0.8. The feed is 0.2 mm/rev in the axial direction and no feed in the radial
direction. The tangential, radial and axial components of the cutting force were measured
on a dynamometer and found to be 3000, 800, and 1000 N respectively. Comment on
your result.
8. A 120 mm diameter work piece is being turned on a lathe at 400 rpm and a feed of 3
mm/rev. The tangential, radial, and axial components of the cutting force were measured
on a dynamometer and found to be 3250, 1200, and 1300 N respectively. Calculate the
power rating of the motor assuming a coefficient of efficiency of 0.85 for the drive.
9. For a lathe with the following specifications:
Min. Max.
Workpiece diameter (mm) 20 200
Feed rate (mm/rev) 0.3 3
Specific cutting pressure (kgf/mm2) 50 160
Depth of cut (mm) 0.1 2
Cutting speed (m/min) 20 100
Calculate the motor power rating. Draw a nomogram for different materials of workpiece
with reference to charts. Then determine the power requirements according to the
specifications given in the table above.

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

Assignment (2) Design of Gearbox

1. Draw the structural diagrams of a machine tool speed box for nmin = 44 rpm, nmax = 500
rpm in two stages and f = 1.41. Which layout is best and why?

2. It is required to design a gear box of 6 speeds, which satisfies the following specifications:
Maximum & minimum speeds: 710 & 125 rpm. Motor power = 10 kW at 1500 rpm. Draw
all possible structural diagrams and select the best one, then discuss why? Also draw a
layout of the gear box indicating the number of teeth of each gear and its module.

3. Draw the structural diagrams and layout for a machine tool gear box of a center lathe
satisfying the following conditions: Maximum cutting speed: 95 m/min. Minimum
cutting speed: 40 m/min. Maximum workpiece diameter: 200 mm. Minimum workpiece
diameter: 30 mm. Number of speeds: 9. Motor power: 7 kW at 1450 rpm. Find number
of teeth of each gear and the belt drive ratio.

4. Draw a structural diagram and layout for a gear box of a milling machine satisfying the
following conditions: Maximum cutting speed; 150 m/min. Minimum cutting speed: 40
m/min. Maximum cutter diameter: 350 mm. Minimum cutter diameter: 40 mm. Number
of speeds: 12. Motor power: 7 kW at 1450 rpm. Find number of teeth of each gear and
the belt drive ratio.

Standard spindle speeds and number of intervals for various values of φ:

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

6/17

3/17

6 7/10

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

Assignment (3) Design of Spindle

1. Calculate the cutting forces on a tungsten carbide tool when machining a 120 mm
diameter workpiece rotating at 400 rpm if the depth of cut is 2.5 mm and the feed rate is
1.1 mm/rev. Estimate the power required if the overall efficiency is 70% and the specific
cutting resistance is 7500 MPa. Calculate the spindle deflection in the direction of radial
component of the cutting force. Knowing that span length is 80 cm, overhang length is
30 cm, outer to inner diameter ratio is 2, radial to tangential force components ratio is 0.3,
bearings stiffness is 60000 kg/mm, and modulus of elasticity is 200 GPa.

2. While turning a 750 mm long workpiece of 100 mm diameter between centers, the radial
cutting force was found to be 1500 N when the tool was 200 mm from the tailstock.
Calculate the machine tool and system compliances if the stiffness of the saddle,
headstock and tailstock is 30000, 40000 and 25000 N/mm respectively.

3. Find the spindle diameters for the overhanging part, and the part between the antifriction
bearings, for the spindle shown in the figure. The spindle is powered by a 2.5 kW motor,
running at speeds ranging from 400 to 2400 rpm. The gear generates a radial separating
force of 1010 N. The spindle is subjected to fluctuating load and made of steel C45, the
permissible bending stress is 55 MPa. The reactive bending moment can be taken as 10%
of the bending moment due to overhanging load. You have to calculate the reactions,
draw S.F.D and B.M.D, then calculate the diameters. It is required to calculate the total
deflection at the nose of the spindle if the stiffness of the front and rear bearings are 100
and 65 N/μm respectively. (Dim mm)

180
450 120

4. A solid steel spindle transmits a torque of 40 kg.m through a gear of module 3 mm and
number of teeth of 80. The ratio a/b = 2 and compliances of front and rear bearings are
0.1 and 0.15 µm/kg respectively. Determine the optimum l/c ratio to ensure minimum
deflection of the spindle nose if force P1 = 150 kgf.

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

Assignment (4) Design of Guideways

1. Find the forces on flat guideways and the pressure between the saddle and guideways on
a lathe, if the guideways are 25 mm thick and 50 mm wide. The center distance between
the guideways is 400 mm. The machine has 110 mm height above the guideway top faces.
The machine is powered by 5.5 kW motor. The machine mostly shapes steel work pieces
at a speed 40m/min. The total frictional force Py is 30% of the cutting force Pz, the axial
force Px is 20% of the cutting force Pz, weight of the saddle is 500 N and its length is 250
mm. The maximum diameter of workpiece is 200 mm. Also, calculate the pulling force
Q, if the coefficient of friction between the slide ways and carriage is 0.2.

2. A center lathe has two flat cast iron slideways (figure 1) of equal width and height half
the width. While turning a 100 mm diameter workpiece, the tangential, radial, and axial
components of the cutting force were found to be 2.8, 1.25, and 1.18 kN respectively. The
lathe carriage weighs 1.5 kN and 300 mm long. Calculate the slideway width assuming
suitable values for affecting parameters. Knowing that the maximum pressure should not
exceed 0.8 MPa.

3. If the right-hand slideway in problem 1 is replaced by a non-symmetrical Vee guideway,

with angles α and β, with the horizontal faces of guideway "C", Find the forces between
surfaces A, B and C if α = 50°.

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

4. A parting operation is being done on a center lathe having a combination of V and flat
slideways as shown in figure 2. Calculate the d/b ratio at which the saddle will lift from
face “A”. Assume h/b = 0.5, α = 50o. The resultant cutting force makes an angle of 37o
with the vertical and apex angle of the V-shaped side is 90o.

5. For a center lathe guide-way with the following specifications: The front side has an
unsymmetrical V-shape with inclined angles α & β with the horizontal. The widths of
surfaces are 24 mm and 20 mm for α & β inclinations respectively. The rear side is a flat
shape with a width 18 mm. The front and rear sides are spaced by a distance of 400 mm
and the swing of the workpiece from the slideway is 300 mm. The length of the active
sliding part which carries the cutting tool is 250 mm. You are required to check the
suitability of the slideway for correct performance. If the tangential, and radial cutting
forces are 2800 & 1200 N respectively, and workpiece diameter is 120 mm.

Dr. Gerges Edwar Mehanny Beshay

Benha University 4th Year Production (2019/2020)
Shoubra Faculty of Engineering Design of Machining and Forming
Mechanical Engineering Department Machine Tool

Assignment (5) Design of Hydraulic Drives

1. Design a hydraulic circuit suitable for operating the table of a milling machine having the
following specifications: Motor power: 16 HP. Maximum and minimum diameters of the
cutter are: 250 & 60 mm. Maximum cutting speed: 120 m/min. Maximum feed rate: 0.5
mm/tooth. No. of teeth: 10. Material specific cutting resistance: 9800 kg/cm2

2. A hydraulic shaping machine is used to machine a workpiece material of specific cutting

resistance of 9600 kg/cm2. If the piston rod is made of steel with allowable operating
stress of 800 kg/cm2, and the maximum cutting speed is 10 m/min. Design the required
hydraulic system for operating the machine ram.

Dr. Gerges Edwar Mehanny Beshay