IPE-431 Machine Tools

Dr. Nafis Ahmad

Professor
Department of IPE, BUET
Email:nafis@ipe.buet.ac.bd
Topics

▷ Introduction
▷ Grinding Machine
▷ Gear Shaper Machine
▷ Installation and acceptance tests of machine
tools etc.
▷ Other Important Topics

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 1.
Introduction to Machine
Tools

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Contents

▷ Introduction
▷ Purpose of the course
▷ Course outcomes
▷ List of topics
▷ Lecture Plan
▷ Hand tools vs. Machine tools
▷ Examples of Machine tools
▷ Conclusions

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Introduction
A machine tool 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. All machine tools have some means of
constraining the workpiece and provide a guided
movement of the parts of the machine.

Thus the relative movement between the workpiece and

the cutting tool (which is called the toolpath) is controlled
or constrained by the machine to at least some extent,
rather than being entirely "offhand" or "freehand".
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Introduction
Today machine tools are typically powered other than by
human muscle (e.g., electrically, hydraulically, or via line
shaft), used to make manufactured parts (components) in
various ways that include cutting or certain other kinds of
deformation.

True machine tools were born when the toolpath first

became guided by the machine itself in some way, at least
to some extent, so that direct, freehand human guidance
of the toolpath was no longer the only guidance used in
the cutting or forming process.

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 2.
Grinding Machine

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Topics

▷ Introduction
▷ Type of grinding machines, grinding surfaces
▷ Movements in grinding operations
▷ Different parts of a grinding machine
▷ Specifications
▷ Working principle of different grinding machines

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Introduction
A grinding machine, often
shortened to grinder, is any
of various power tools or
machine tools used for
grinding, which is a type of
machining using an
abrasive wheel as the
cutting tool. Each grain of
abrasive on the wheel's
surface cuts a small chip
from the workpiece via
shear deformation.

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Introduction
Operations performed by grinding machines are:
 Grinding :
(a) external and internal cylindrical surfaces,
(b) tapered and complex-shaped surfaces,
(c) flat surfaces,
(d) screw threads,
(e) gear teeth
 Cutting off blanks
 Sharpening cutting tools

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Introduction

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Type of grinding machines

• Cylindrical grinding machine

• Centreless grinding machine
• Internal grinding machine
• Surface grinders
• Special purpose grinding m/c

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Type of grinding machines
Cylindrical grinding: generally used for generating external
cylindrical surfaces.

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Grinding machines’ movements
Cylindrical grinder:
- rotation of the work piece (Swk in m/min)
- reciprocation of work table(S1 m/min or fraction of
grinding wheel width/rev of wp)
- intermittent cross movement of the grinding wheel
relative to w/p (cross feed or infeed S2 ) mm per double
stroke or sometimes single stroke.

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Grinding machines’ movements
Cylindrical grinder with plung-cut principle:
- rotation of the work piece (Swk in m/min)
- infeed of the grinding wheel relative to w/p (cross feed or
infeed S1 )
- reciprocation of wheelhead/table(S2 m/min )

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Grinding machines’ movements
Internal grinders:
- rotation of the work piece (circular feed Swk in m/min)
- reciprocation of workpiece or grinding wheel
(longitudinal feed S1 m/min )
- Intermittent cross movement of the wheel head (cross
feed S2 )

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Grinding machines’ movements
Planetary grinders:
-rotation of the grinding wheel about the axis of the hole
being ground (circular feed Swh in m/min)
-reciprocation of workpiece or grinding wheel (longitudinal
feed S1 m/min )
- Intermittent cross movement of the wheel head (cross
feed S2 )

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Grinding machines’ movements
Surface grinders with rectangular
table:
- reciprocation of workpiece/table
(longitudinal feed Swk m/min )
- Intermittent cross movement of
the wheel head per stroke of
the table (cross feed S1 )
- Intermittent vertical movement,
or infeed S1 of the grinding
wheel to the depth of cut (
circular feed S2)

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Grinding machines’ movements
Surface grinders with revolving
table:
- Circular feed of the table Swk.
- Wheel or table feed S1
- Vertical movement of the table
or wheelhead is the vertical
feed S2.

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Grinding machines’ movements
Vertical spindle surface grinders
with rectangular table: movements
- Longitudinal movement of the
table Swk.
- Wheel or table feed S1
- Intermittent vertical movement
of the grinding wheel to the
depth of cut S1.

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Grinding machines’ movements
Vertical spindle surface grinders
with revolving table:
- Rotating movement of the table
S.
- Intermittent vertical movement
of the grinding wheel to the
depth of cut S1.

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Driverless trains:

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Case study-Cylindrical grinding
machine
Main specifications of a typical cylindrical grinding
machine (Model 3M151):
▷ Maximum dimension of workpiece accommodated (mm)
1. Diameter------------------------------------------- 200
2. Length-----------------------------------------------700
▷ Height from table top to centers (mm)------------125
▷ Range of workpiece rotation speed (rpm)------- 50-500
▷ Power of wheel drive motor, (kW) -----------------10
▷ Speed range of table traverse (m/min) ----------- 0.05-5
▷ Mass (Kg) ------------------------------------------------ 6032

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Case study-Cylindrical grinding
machine
Cylindrical grinding machine (Model 3M151):

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Case study-Cylindrical
grinding machine
Cylindrical grinding machine’s movements (Model 3M151):
Principle movement, Circular feed, Longitudinal feed, Cross
feed(infeed), Auxiliary movements

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Case study-Cylindrical
grinding machine

Cylindrical grinding machine’s movements (Model 3M151):

▷ Principle movement -rotation of the grinding wheel
▷ Circular feed -rotation of the workpiece
▷ Longitudinal feed - straight reciprocating movement of the
work table.
▷ Cross feed(infeed) - intermittent radial displacement of the
wheelhead per stroke of the table
▷ Auxiliary movements – hand operated (a) longitudinal traverse
of the table, (b) cross feed of the wheelhead, (c) displacement
of the tailstock and (d) hydraulically-operated positioning
motion of the machine’s operative members

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Cylindrical grinding machine’s kinematic diagram (Model 3M151):

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Case study-Cylindrical
grinding machine
Cylindrical grinding machine’s working principle (Model 3M151):
▷ Workpiece is mounted between the centers of the workhead and
tailstock which are placed on the swiveling plate of the work
table.
▷ Grinding wheel is rotated by motor M2 through a V-belt drive
112/147.
▷ Circular feed or rotation of the workpiece is effected by a variable
d.c. motor M1 through V-belt transmission. Here
Swk=nm.0.985.i.pi.dw
▷ Cross feed/infeed mechanism provides (a) rapid positioning
movement of the wheelhead relative to the leadscrew, hand-
controlled/ automatically-controlled continuous and intermittent,
and periodical cross feed of the wheelhead

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Case study-Cylindrical
grinding machine
Cylindrical grinding machine’s working principle(Model
3M151):
▷ Hand-controlled cross feed of the wheelhead is
effected from handwheel(1), magnetic clutch C1 being
engaged, through bevel gear 39/39, vertical shaft,
worm gearing 2/40 to the infeed screw-and-nut
transmission.
▷ Rapid positioning movement wheelhead is
accomplished from hydraulic motor M3, with magnetic
clutch C1 being disengaged. Motion is transmitted
from the shaft of the motor through a pair of cylindrical
gears 35/35, bevel gearing 39/39, and further, to the
infeed leadscrew.
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Case study cont..
Cylindrical grinding machine’s working principle(Model
3M151):
▷ Automatically controlled intermittent feeds to
wheelhead are powered by hydraulic motor m4, with
magnetic clutch C2 engaged, through worm gearing
1/50, handwheel , clutch C1, bevel gearing 39/39, and
further to the infeed lead screw.
▷ Automatically controlled periodic feed to wheelheads:
are performed by a gear train described above. Here
magnetic clutch is engaged for a specific period of
motion and is then disengaged, stopping the motion of
worm gearing 1/50.
▷ Draw block diagrams for the above mechanisms
mentioning motor/handwheel/shaft/gears/leadsrew etc.:
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 Case study-Cylindrical
grinding machine
Functions of cylindrical grinding machine’s hydraulic drive (Model
3M151):
▷ Work table: reversible traverse of the work table at a working
speed or variable speed; oscillating motion of the table.
▷ Wheel head: Rapid advance and retraction of wheelhead; cross
travel of the wheelhead; continuous cross feed of the wheelhead;
continuous infeed of the wheelhead; automatic withdrawal of
wheelhead
▷ Tailstock: Withdrawal of tailstock spindle
▷ Interlocking of hand operated table motion mechanism
▷ Motions of the diamond dresser
▷ Supply of lubricant to spindle bearing, infeed leadscrew bearings
and worktable guideways
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Case study-Cylindrical
grinding machine

Cylindrical grinding machine’s working principle (Model 3M151):

▷ Write short notes on the mechanisms of
a) Automatically controlled periodic feed to wheelheads

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Surface grinding machine

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Case study-Surface grinding
machine

Surface grinding machine types:

Spindle Table Column Special

Horizontal Reciprocating/
rectangular
Horizontal reciprocating universal
Vertical reciprocating
Horizontal rotary
Movable Single, Movable Planner type
Double, Planner type
movable

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Surface grinding machine-case study

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Centerless grinding machine

1-External and internal surfaces of cylindrical parts having no central

holes can be ground on centerless grinding machines:
 Through-feed centerless grinding

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Centerless grinding machine

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Surface grinding machine-case study

Generap purpose surface grinding machine’s working principle :

▷ 1- Cast Bed, 2-Wheelhead, 3-Column of rigid cast frame with a
through opening at the middle, 4-vertical guide ways which carry
the wheelhead, 5-Cabinet contains hydraulic station and
electrical equipment
▷ Table reciprocates along the bed with the help from two hydraulic
cylinders.
▷ Two speed motor provide wheel speed up to 70m/s. Wheelhead
moves vertically by hand or automatic downfeed mechanism,
mounted on the front wall of the bed. Rapid traverse is effected
by a mechanism mounted on the rear wall of the column.

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 2.2
Microfinishing Machines

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Microfinishing Machines

▷ Intended for final machining of

workpieces.
▷ Most widely used machines are:
▷ Lapping
▷ Honing
▷ Superfinishing

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Lapping
▷ Lapping is done by tools called laps
▷ Lap surface is charged with fine-grained abrasive flour
mixed with oil and paste.
▷ Laps are made of cast iron, steel bronze etc.
▷ Crank shaft, gears, gauge block etc. are machined

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 Lapping
 Abrasive flours: diamond
dust, silicon arbide etc.
 Paste: chromium oxide,
aluminium oxide etc.
 Kerosine or turpentine is
used to wet the flour
 Machining allowance:
0.005~0.02mm

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Lapping Machine

1-Bed, Column, 3,5-Lap, 4-work retainer

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 Lapping Machine
• Spindle 5 and lap 2 is
driven by
motor(7.8kW) through
V-belt drive 150/375,
worm gearing 4/40,
cardan shaft II, and V-
belt drive 320/352
• Lap-1 get rotational
movement from the
same motor through
shaft III and worm
gearing 4/40 and sleev
8
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 Lapping Machine
• For flat surface: forced
oscillation is imparted
to the retainer by
means of crank pin(3)
secured in disc(7)
• Disc-7 is driven from
shaft-III through worm
gearing 4/40 and
cylindrical gears
40/80x34/86 and shaft
I

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 Lapping Machine
• For cylindrical surface
lapping:: the retainer is
kept motionless by
disengaging clutch-9
• Hydraulic mechanism-
used for approach and
pressing lap-2 to the
workpiece being
lapped. Cylinders-4
and 6, piston rod
connected to the
holder of lap 2 are part
of hydraulic system
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Thanks!
Any questions?
You can find me at:
@ahmadn
nafis@ipe.buet.ac.bd

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