FUNDAMENTAL OF MACHINE TOOLS

Machine tools
▪ power operated machine input output
▪ Expend energy to cut metal
▪ Metal removed from blank in form of chips
to develop required product
▪ Required finish and accuracy of the part is to machine tool
be maintained
▪ Uses cutting tool
▪ Non portable
Example-lathe, milling,broaching and so many operator feed back
to operator

Operations- Man machine system

Hold the blank ❖ Input-information of job shape,size
Hold cutting tools -work shape.size, material
Dofferent types of motion-linear, rotary,
combination or intermittent as nedded for - energy,machine tool information
different parts ❖ Output-required shap. Size accuracy
-finish and integrity of surface
-rate of production, mfg cost/piece
Lathe Machine Drilling Machine
 Classification
❑ Based on field of application
i. General purpose-
Highly flexible, wide range of work-piece
Variety and material, cost effective job
Production. Ex-plain turning lathe, turret
lathe, milling machine, grinding machine
etc.
ii. Production purpose-
Less flexible, work variety and material
limited, cost effective batch and mass
Production. High power and rigid. ex- multi
tool lathe, plunge cut grinder etc.
iii. Specialized – same shape but different
size product. Readily can be switched over
from one job to other. Ex-
iv. Single purpose –specialized for a
definite machining operation. Ex. Thread
cutter, gear hobber etc.
v. Special machine tool—tool
grinder, threading by die tap etc.
❑ Based on configuration- horizontal,
vertical, inclined
❑ Based on primary machining operation-
turning, milling, grinding, combination
machine tool
❑ Based on nature of cutting motion-
Rotating tool/reciprocating tool
❑ According to accuracy–
normal accuracy-majority of components
Higher accuracy-critical parts requiring
assembly and alignments
Precision- more stringent accuracy and
narrow tolerance
❑ Based on environment-
Heavy duty->10kw, continuous running
Medium duty-3-10kw, medium load
Small duty- <3KW, small load and minimum
time of running
❑ Based on degree of automation-
Manual-control
Semi automated-
automated-
Major components of machine tools
Components for holding tool and
workpiece
Prime mover to provide power
Kinematic chain for transmission and
transformation of power
Structural body sufficient to support
dead and live load within specified limit
Proper control and automation systems
Specification of machine tools
It is the parameters to express the
functional requirements of the
machine
Tools. generally they are
• Size limit of the work
• Maximum and rated power
• Spindle speed-range, no of divisions
• Feed ranges
• Floor space , weight etc.
• So many others
Types of motion in machining
❖ (i) primary motion—it serve the
purpose of removing metal. It is
two types
(a) principal/ cutting motion-
depends on optimum cutting
speed for tool work-piece
combination and nature of
machining. It may be rotary, linear
or combination of both
(b) feed motion-depends on
required finish of the product. It
may be continuous, intermittent,
compound
❖ (ii) auxiliary motion- it help to
accelerate other processes
involved in production apart actual
machining. This motion may be
hand driven or automated. Ex-
changing of speed and feed,
clamping and unloading of work in
the machine tool etc.
Performance criteria of machine tools Cost effectiveness of machine

▪ Safety tools
▪ Ease of operation-less fatigue for operation,
loading, unloading and bringing tool and wp in
engagement should be easier by automation or 1
quick acting clamp etc.
▪ Production accuracy-geometric, locational and 2
dimensional accuracy with surface integrity as per 3
requirement. Possible if machine tools is designed
with sufficient stiffness and alignment and Cost
manufacturing accuracy of components. Of
▪ Production capacity-max. no. work-piece per unit Prdn.
time would be as per required.
▪ Reliability and maintainability-
▪ Ease of maintenance
▪ Compactness-should be high, fixed and operating
cost should be as low as possible.

Rate of production

1.General purpose
2. NC Mahines
3.Special purpose machine
 General feature of construction, different parts and working of lathe

▪ Oldest and important machine tools.

▪ The principal surface developed is cylindrical
surface
▪ Job is rotated (turned) and tool is slided
relative to job. So it is turning.
▪ Cutting speed V=Πdn/1000 m/min; d in mm ,
n is rpm
▪ d= depth of cut=b cos( ); is side cutting
edge angle, b=width of cut
▪ f= is feed in mm/rev
▪ But many other operations like facing,
parting, taper turning and so on is
performed by this machine tools.
▪ So it is termed as ‘ the father of machine
tools family’.
 Construction of lathe and its components

A lathe is typically consist of basic ▪ Power transmission-

components transmitted through series of kinematic
like- chain/mechanism
Simple train- individual motion has individual power.
Headstock- it is fixed at the left end. It houses
power source, power transmissions and Found in modern machine tools
spindle. Complex train-different motion and power from
▪ Power source single power source
-induction having one or two fixed speed for Compound train- combination of simple and
stepped variation complex train.
-variable speed induction motor, dc motor for
stepless drive
-ac and dc servo motor, stepper motor for NC,
CNC Machine
▪ power of motor-
is to be estimated to overcome power for
machining, friction,inertia forces, auxiliary
motion etc.
▪ Spindle-
It imparts rotary motion, hold centrs/workholding
devices/ work/ tool as required.
It is hollow to take long bar stock. It has an external
tapered surface at the front end to locate driving
plates/chucks. Front side has taper bore to
accommodate centres.
Centres-
The centre held in spindle is known as live
centre having an included angle 60 degree as they
rotate. Live centre is mounted on ball bearing/tapered
roller bearing along with thrust bearing. It is also
preferred during high speed machining to reduce
frictional heat generation.
Centre used in tail stock is called dead centre as it does
not rotate. May be of normal, half ended for turning
and
facing operation, spherical ball ended centre to
accommodate set over. The centre in tailstock is
subjected to heavy wear due to relative velocity
between centre and workpiece. Wear resistance can be
increased by tipping the point with cemented carbide or
wear resistant alloys.
Tailstock- function is to hold dead centre
which supports long workpiece (l/d>4).
It is clamped on the right side of bed. It
consists of two parts. Lower part rests on
bed ways and upper part rest on lower part.
Lower part alongwith upper one can
be slided over bed through guidewauys to
accommodate different length as requird.
Adjustable screw holds two part together. By
loosening it, upper part can be moved away
or
towards the operator to offset tailstock. The
body of the tail stock has a bore for hollow
cylidrical sliding member known as quill.
Drills,reamers,tap and other tools are held
and
fed to the workpiece by the quill.
Carriage: it is moveable components between head
stock and tail stock. Its prime function is to hold the
cutting tool and to provide required relative motion to the
cutting tool ( longitudinsl feed and cross feed). It includes
five major components like –saddle,cross-slide,compound
rest ,tool post and apron mechanism.
Saddle-base of carriage, slides longitudinally along the bed ways.
Cross slide-mounted on saddle by means of dovetail ways,
provide cutting tool motion in cross direction which may be
controlled manually by handle or by power feed.
Compound rest- it has a graduated base that can be
swivelled around vertical axis so that it can be angled with
axis of workpiece. So it is used for angular cut, specifically in
case of short taper.
Tool post- it is mounted over compound rest in a T-slot as
shown. It can be adjusted to tilt with the help of a concave
ring collar and rocker base.
Apron-it contains apron mechanism-reduction of speed
and rotary to linear conversion of speed. It lies under the
saddle in front side of lathe.
https://www.youtube.com/user/munmachineshop go for setting
and working
Bed-bed is the base of lathe which supports all
other components. During cutting operations, majority of
structures are subjected to complex loading like-combinations
of torsion, bending, tension or compression which results
accountable deformations leading to question on accuracy of
parts. In order to achieve good performance of machine tolls,
its supporting structure must be designed with sufficient
strength and stiffness. In order to absorb vibrations, it is made
as a rigid casting part.
Deformations and stresses developed due to torsion and
bending depends on size and additionally on shape. The
section providing maximum moment of inertia and sectional
modoulus should be selected. And hollow box type section is
the best.
The top of bed is planed to form guideways. These are the
rails on which complementary part slides. Less expensive and
low duty lathe have flat ways while medium to heavy duty
lathe have combination of 2 pairs of guideways to provide
motion to saddle and tail stock.
Drive system: mainly two type-primary cutting Speed changing methods-
i) by shifting key (ii) ruppet drive (iii) pre-optive
motion and feed motion. Primary cutting motion drive (variable position clutch ) (iv) engaging clutch
drive enable to achieve certain speed range and (v) by shifting cluster gears.
variation for spindle and feed motion drive enable Engaging clutch-
to
achieve range and variation of feed in linear motion.
Primary cutting motion drive/spindle drive/
▪ in general geared head stock drive is designed
to
get stepped variation in spindle output in multiple of
2 and 3 i.e 3,4,6,8,12,16 and 24.
▪ As no. of variations become more, complexity
of
drive arises.
▪ Variations are arranged in geometric
progression with common ratio 1.06, 1.12.1.26,
1.41,
1.58 and 2. ( as c.r increases productivity loss
increases and as c.r reduces more variation and
complex design)
▪ Common ratio where z is no
of step,
By shifting cluster gears- a set of gears which
can be slided on shaft to mesh with required
gear is known as slider gear or cluster gears.
Gear 1 &2 and 5,6,7 are cluster gear.
Corresponding ray diagram is shown which
indicates six number of speed variation in
output spindle.
Some criteria-
Fixed gears spacing must be > 2b (b width of gears)
Minimum difference in teeth of adjacent gears in a
cluster must be=>4.
Minimum no. of teeth in gears for speed box=> 20.
Advantage – it is more efficient and compact , able
to transmit high power, available power for all types
of speed remains almost same.
Back gears-for low duty smaller lathes,power transmits from motor to the cone puleey mounted on spindle
by means of belt. Spindle speed is changed by shifting belt to different pulley. In order to get more
variations and minimum speed back gears are used.
Cone pulleys and gear A is mounted on sleeve on spindle helps to rotate freely. Whenever lock pin is
engaged rpm is directly drives spindle as gear B is rigidly mounted on spindle and N1, N2, N3 Aare obtained.
When back gears C and D are engaged with A and B respectively and lock pin E is disengaged motion is
reduced to N4, N5 and N6 with transmission ratio i.e N4=N1X
Feed box-work at very low velocities and does not pose serious vibrational problems. There are large number
of speed reduction ratio and feed steps than speed box. Rotary to linear conversion and may be continuous or
intermittent. Feed drive in lathe consist of (a) reversing mechanism (b) change gear quadrant © quick change
gear box (d) lead screw (e) feed rod (f) apron mechanism

Reversing mechanism- function is to reverse

the direction of lead crew/feed rod , thereby
reversing the direction of feed. Consist of four
spur gears with consecutive engagement of
the bracket holding reverse gears.
Gear z2 and z3 are freely mounted on stud iii
and iv of the bracket which is mounted on
shaft ii. Feed reverse lever can be moved to
three positions 1,0,2.
Change gear quadrant- it is two pair gear arrangement with a quadrant proper. It serves to set up feed
drive to different speed of lead screw and feed rod. It is employed in cases- when it is necessary to obtain
precise transmission ratio for required generating motion. The set of change gears are chosen so that almost
practically all transmission ratio can be obtained.

Z2 and Z3 are keyed on a sleeve which can be

mounted freely on stud E which can be
adjusted and clamped along the slot to
compensate centre distance. For the given
case, gearing ratio is
 ▪ The quick change gear box is located in front
side below head stock. Function is to rapid change in
(a)Feed rate (b) rpm of spindle/ feed rate by shifting
corresponding lever.
▪ It contains (i) a number of different size gears (ii)
intermediate gear (iii) tumbler gear (iv) a chart
▪ The tumbler gear can be slided over shaft to
mesh any gear on shaft I via intermediate gear mounted
on shaft II by swinging and sliding lever. Shaft III on
which tumbler gear is mounted is the driving shaft.
▪ The number of gears in cone = number of
transmission required.
▪ Positive features (i) compact design to enable
large number of transmission in simgle group (ii)
simple control by using single lever (iii N feed rate
can be found by using N+2 fears only.
▪ Negative side- (i) insufficient rigidity and
accuracy of meshing (ii) poor lubrication (iii)
possibility of dirt accumulation in housing
Apron mechanism- main function is to transfer
rotary
to linear motion with subsequent speed reduction.
Feed rod 2 has a keyway along its whole length.
Worm 3 with its key slides along the rod. Worm
mesh
with worm wheel 4 and motion transferred to
pinion
5 mounted on same shaft. By turning automatic
feed
knob pinion 5 meshes with gear 6 and rotation
transfers to pinion 7 which runs on rack fastened to
bed. It is employed for turning and other operations.

For thread cutting, instead of feed rod lead screw

take active part. By changing feed change lever to
neutral position feed rod become inoperative and
Lead screw active. Lead screw feed the carriage
Specification
through two halfofnut
lathe:
mounted at the rear wall of
1. distance
Apron betwee centre 2. swing over bed-max. dia of job that canm be turned
when engaged.
3. swing over cross slide- max dia of work turned with job cross slides.
 Work holding devices

Primary functions -to hold work-piece at suitable location by

effective clamping. Used for different machine tools.
Work holding devices in lathe- centre, chuck, collet, face plate,
mandrel, steady rest, follower rest, mandrel etc. are used
depending on shape, size, location of work-piece.
Chucks- chucks are availabkle in many style and types. Size wise it
also varies from small drill chuck to massive lathe chuck. It have
long been useful work holding devices for variety of cylindrical
work. Development of novel accessories and their
implementation
in standard chuck make it more useful.
Three jaw chuck:
▪ 3 jaws move inward or outward simultaneously by same
amount
▪ Jaws are 120 degree apart.
▪ Known as self centring chuck
▪ Although quick centring but limited gripping force; so not
suitable for heavy or precise work as accuracy 0.125 TIR(
Total indicated run out)
▪ Mechanism involve combination of bevel gear drive and a
spiral rack(scroll plate). By turning the bevel pinion, scroll
plate rotare and rotation of scroll plate move jaws by
meshing flat teeth behind jaws with spiral rack.
 4 jaw chuck-
▪ the independence of the jaws movement
▪ make this chuck suitable for holding even non-
circular part, heavy part
▪ with greater clamping force and reasonably
greater accuracy than 3 jaw.
Individual jaw can be moved radially over its
slot by rotating individual jaw screw.
 Collet chuck

Collet chuck:
▪ Most accurate and used for precise job
▪ Each collet has a range of 100ths. Of a mm. over or under
the size marked on it.
▪ Variety- spring collet chuck and Jacob collet chuck. Jacob
collet has wider range of work.
▪ Hold round, square or hexagon shape very fast. Limited to
smaller job.
In the taper of head stock spindle, a special adapter is
fitted. A hollow draw bar with an internal thread is
inserted in opposite end of spindle. Rotation of hand
wheel draws the collet into the tapered adapter causing a
uniform pressure on collet sleve. Sleeve segments are
elastically deflect and clamp the component. As deflection
is within elastic range, upon removal of pressure, sleeve
spring back quickly, thus unloading of work is faster.
Magnetic chucks:-
▪ Magnetic chucks is used to hold magnetic material (iron/
steel).
▪ Parts are thin and prone to damage under heavy clamping
force
▪ Chuck is used when light cut and special grinding
operations.
Chucks are fitted to an adapter mounted on spindle.
For aligning work is held lightly by turning chuck wrench a
little bit. Then work is trued and chuck is turned full-on-
position to hold job securely.
https://www.youtube.com/watch?v=vfhZnJWlcb4
 Lathe dog
▪ When l/d >4, work is held between centre
▪ Work is rotated by driving lathe dog
Drive plate is mounted on threaded nose on spindle
Drive plate has one open slot and three closed slot
A pin inserted in open slot engage tail of the dog, therby impart
rotation from spindle to drive plate to pin to dog to work.
Dog has opening to receive work and a setscrew to fasten dog to
work.
Various size and types to suit various work. dog available as- bent
tail, straight tail, clamp type etc.
 Face plates:-
▪ Used to hold work too large or odd shaped such that can’t be held in
between centre or in chucks.
▪ Face plates are equipped with several slots to use bolt for work
holding
▪ It may also have angle plates so that work axis may be aligned with
lathe axis
▪ When work is mounted off centre a counterbalance should be
designed to prevent imbalance and resultant vibration.
 Steady rest-
▪ it is clamped on lathe bed at desired location
▪ Supports the work by three adjustable screw jaws
▪ Jaws should be adjusted to align the axis of work
▪ Top half can be swung w.r.t lower half for easy
removal of work
▪ it is suitable for long and thin work for a support in
between centre.
▪ As the carriage can’t pass over it, the work need to
be turned in two set up (left hand
▪ portion first and then reversed to set back side in
chuck or vice versa)
Follower rest-
▪ It is mounted on carriage at the rear side so thet it
can follow cutting tool and thereby bear the load at
machining point effectively.
▪ It has two jaws to bear against work surface
▪ Used for long and very thin work for turning and
thread cutting operation.
▪ For both the cases, jaws may be provided with ball/
roller bearing to reduce heat generation during
high speed machining.
 TAPER TURNING

Taper specification: out of 5 parameters (D,d,l,L,α) 3 must be

given to identify it. Ways toi specify
(i) inclination-(1:2x) =

(ii) Half taper angle α=

Standard tapers:
(i) Morse taper-size 0,1,2,3,4,5,6 . Each one has definite size
and definite taper angle.
(ii) Metric taper- sizes 4,6,80,100 etc. indicates larger dia and
all have same taper angle.
Application of taper:
cone clutch, counter shank screw, centre, tool holders etc.
Method of taper turning-
(i) By swivelling compound rest
(ii) by using form tool
(iii) By setting over tailstock
(iv) By taper turning attachment
Taper turning by swivelling compound rest

• Compound slide or compound rest is the

component mounted over a swiveling base fixed
over cross slide.
• Compound slide is set in direction of lateral arc line
of taper so that cutting tool follow the path of
tapered surface.
• Setting is done over swiveling base at half taper
angle and then tool is clamped.
• By rotating handle at the right the tool post is given
feed along axis as there is screw nut assembly
system for conversion of rotary to linear motion.
Tool is fed manually.
• Advancement of tool for depth of cut is assigned by
cross feed of cross slide.
The length of compound slide is limited. the work
is manufactured manually, so only short tapers are
manufactured by this process.
Due to hand feed, accuracy and finish of the part is
not up to the mark.
Taper turning by form tool-
Form tool is the
tool which impart predetermined contour / profile
to the work. The tool is grounded to form the
required angle of the taper and the tool feed is
perpendicular to lathe axis. The width of tool is
slightly exceeds the length of taper.
Large no. of variety tool is required.
Siutable for short taper.
Mass production of non variable shape and size is
cost effective.
Not suitable for variety of work in shape and sizes.
 Taper turning by offsetting tail stock

▪ In compound slide method tool traverse (feed) is parallel

to the surface to be developed i.e at an angle equal to
half taper angle w.r.t lathe axis.
▪ In form tool method tool traverse parallel to axis, work
is set aligned to line of centre but cutting edge ( making
an angle equal to half taper angle ) are parallel to
surface to be developed.
▪ In this case, tool traverse is parallel to lathe axis but
work is set to angle to form the same angle between
line of centre and feed direction.
o Line of centre is set to required angle by shifting tail
stock centre
o When tail stock is shifted towards the operator, larger
dia will be at head stock and away from operator larger
dia will be at tail stock.
o Set over for taper =
o Set over of part length L with tapered length l will
be =

o Set over is obtained by setting upper part of tail stock

from base by amount graduated on the scale.

Set over or offset is to be limited L/50 otherwise work

may slip from tail stock centre or unbalance of work may
occur. Therfore it is used for gentle taper ( <8 degree) of
long length.
It develops non-uniform wear of dead centre.
 TAPER TURNING BY TAPER TURNING ATTACHMENT

▪ Bracket is attached to lathe bed at rear side. Bracket

carries a guide bar which can be swivels against a
pivot point. The required angle = half of taper angle
is set by swivelling bar and fixed the stud at correct
position in the slot of bracket. A guide block
connected to lathe cross slide by tie bar.
▪ Due to longitudinal feed of saddle, guide block will
slide along bar. As guide block is linked to cross
saddle, it is moved in a direction parallel to guide
bar. And the surface is cut
▪ Cross slide will be disconnected from saddle by
removing cross feed screw/ disengaging cross slide
and cross feed screw nut
▪ After each cut, tool is given depth of cut by rotating
handle of compound rest.
Tapers may be turned repeatedly without changing
normal set up of machine. So, same alignment is
maintained and good repeatibilty for the part.
Tapered holes can be bored easily
Tapers are developed by providing longitudal power
feed. So productivity is quite high and suitable for
mass production.
for less no. of job process is not cost effective.