BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

MF F341: DESIGN OF MACHINE TOOL STRUCTURES

II SEM 2019-2020
Comprehensive Examination: Open Book
Max Marks: 50 Duration: 120 min. Date: 30th Nov, 2020
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Q1. Derive the differential equation governing the motion of the system shown in FigQ1, using θ, the
clockwise angular displacement of bar AB, measured from the system’s equilibrium position, as the
generalized coordinate. Also determine the natural frequency of the system. [10M]

Fig.Q1

Q2. Consider the model for static analysis of spindle as shown in Fig.Q2. The spindle is supported on two
antifriction bearings at A and B (Stiffness K A= 3X105N/mm, Stiffness KB= 5X105N/mm). The load F=500N
is applied at the free end of the spindle C’ (Spindle nose). Take E= 205GPa, Diameter of spindle=
40mm.

Fig.Q2

a) Calculate the reactions at bearings supports. [2M]

b) Considering the beam as elastic and supports as rigid, calculate the deflection at spindle nose. Also
draw the deflected diagram of spindle. [4M]
c) Considering the beam as rigid and supports as elastic, calculate the deflection at spindle nose. Also
draw the deflected diagram of spindle. [4M]
d) Calculate the total deflection of spindle nose. Draw the final deflected diagram of spindle. [2M]
Q3. Consider a structure modeled as simply supported beam as shown in Fig.Q3. The beam is of solid
rectangular cross-section of height ‘h’ and width ‘b’.

a) Calculate the support reactions.

[2M]
b) Calculate the maximum bending moment. [2M]
c) Calculate the maximum deflection of the beam. [3M]
d) Calculate the maximum bending stress. [2M]
e) Derive the expression for optimum L2/h ratio. [2M]
f) Consider the above beam made up of mild steel and C.I. The properties of the materials are given
below:

MILD STEEL C.I

4 2
E=5× 10 Kgf /mm , δ permissible =0.001 mm, E=2× 104 Kgf /mm2 , δ permissible =0.001 mm,
σ permissible=20 Kgf /mm2 σ permissible=5 Kgf /mm2

If the failure of the beam is determined by the normal stresses under tensile loading, which material
will you prefer for withstanding the same load conditions? (Hint: explain on the basis of material
required)
[2M]

Fig.Q3

Q4. You are intended to design a twelve speed center lathe to be used for machining mild steel rods of
diameter ranging from 70.735 mm – 3183 mm. Assume the optimum cutting speed is 300 m/min during
turning of mild steel rod using a cemented carbide tool.

i) Determine the percentage productivity loss to machine the cylindrical component at diameter 250
mm and the speeds are laid out in G.P. [3M]
ii) Show the above productivity loss region in the SAW diagram. [2M]

Q5. You are intended to design a four speed gear box for conventional milling machine tool to be used for
machining rods of diameter ranging from 55  120 mm, cubical blocks of length 5 - 500 mm, width 5 –
300 mm, and height 10 - 200 mm at cutting velocity ranging from 42 m/min and 75 m/min. The machine
tool is powered by a 6 HP motor running at 300 rpm and is connected to the gearbox through a belt
drive. The input shaft of the gearbox is rotating at 250 rpm. The gears are to be made from 0.6% C steel
and shafts from mild steel of permissible shear strength of 120 kgf/cm 2. If machine tool can
accommodate the cutting tools of diameter ranging from 95 - 150 mm of different materials, then
suggest an economical design for the gear box using following steps.
Note: Use standard values of progression ratio and corresponding spindle speeds.
i) Draw the structural diagrams. Select the best and justify your selection. [3M]
ii) Draw a speed chart on the basis of material saving. [4M]
iii) Determine the number of teeth of gears. Assume Z min = 17. [3M]

Standard Spindle speeds

ϕ = 1.26 ϕ = 1.41 ϕ = 1.58

10 11.2 10
12.5 16 16
16 22.4 25
20 31.5 40
25 45 63
31.5 63 100
40 90 160
50 125 250
63 180 400
80 250 630
100 355 1000
125 500 1600
160 710 2500
200 1000
250 1410
315 2000
400
500
630
800
1000
1270
1600
2000

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