IPE

Previous Years’ Question (Last 4 years: according to our syllabus) + Important Questions

Shahriar Akbar Sakib

January 1, 2020

1 Engine Lathe [Masud Sir]

1.1 At a glance:

Main Units: Locations, Purpose and Motion transfer:

belt pulley
• Induction Motor −−−−−−−→ Headstock → Spindle → Workpiece rotation = Principle move-
ment

• Spindle Shaft rotation → Change gear box → Feed gear box → Lead Screw →
Half Nut Mechanism → Carriage movement = Feed (high feed) used for threading

• Spindle Shaft rotation → Change gear box → Feed gear box → Feed Rod →
Apron Mechanism → Carriage movement = Feed (low feed) used for turning

• Induction Motor: Below Headstock, inside box, above base [above solid foundation → to ensure
less vibration]

• Headstock: aka "speed gear box": contains gear train. Lever Position → select gear train →
get different rpm in spindle

• Spindle: Hollow shaft. held over 2 bearings. When spindle deforms → chuck is required to
grab the w/p.

• Bed: base, contains guideways for carriage and tailstock

• Tailstock: support long w/p, hold drill, reamer etc, used for centering. To offset the tailstock,
screw is used.
motion
• Feed gear box: Transmit motion Spindle −−−−−→ feed rod/lead screw . Change feed rate.

• Change Gear: Between headstock and feed gear box. Located outside left side. contains 4 gears.
Used for precision threading when different gears are used.

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• Standard Threading: 2 types of standards for threading: British and American. Standard pitches
→ Interchangeable when required. → Easy maintenance.

• Feed rod Vs. Lead screw: Feed rod is used for low feed → Turning. Lead Screw is used for
high feed → Threading.

• If feed rod is used for both operations: could be used. but, Continuous change between high
feed and low feed { Fatigue failure of feed rod.
Apron mechanism
• Apron: Rotary motion of feed rod −−−−−−−−−−−−−→ Linear motion of carriage

• Carriage: Provides feed movement of cutting tool. contains : Saddle, Cross slide, Swivel plate,
Top slide, Back tool holder.

• Half Nut Mechanism: Lever → Half nuts engaged with lead screw. Rotation of Lead screw →
Linear movement of nut → Linear motion of Carriage.
90◦ rotation
• Apron Mechanism: Feed rod = shaft with key slot. Feed rod → Worm −−−−−−−−→ Worm Gear
Rotation to linear motion
→ Gears → pinion −−−−−−−−−−−−−−−−−→ rack → Carriage . Key slot engages feed rod with
worm. Watch
Screw Mechanism
• Cross Slide: Provides Crosswise movement to tool. Handwheel −−−−−−−−−−−−−→ Cross slide:
Cross wise movements. [If no screw mechanism, cross slide would move freely]

• Swivel Plate: Angular positioning ±

• Compound Rest: acts as guide.

• Top slide: Handwheel → feed movement of top slide. [For angular feed of tool, first rotate the
swivel plate, then give feed to top slide.]

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Kinematic Diagrams for speeds and feeds:

• Flow Chart for Principle Movement:

• Principle movement (Short gear train)

• Motor rpm = 1460 rpm, Belt slip factor = 0.985

•
148 51 56 21 38 29 30 60
1460 × 0.985 (or, ) (or, or, ) (or, ) = 𝑛𝑠 𝑝
268 39 34 55 38 47 60 48

• With Reversing:

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•

•
148 50 36 21 38 29 30 60
1460 × 0.985 (or, or, ) (or, ) = 𝑛𝑠 𝑝
268 24 38 55 38 47 60 48
• Long Gear Train: (forward rotation)

•
148 51 56 21 38 29 15 45 18 30
1460 × 0.985 (or, ) (or, or, ) (or, ) = 𝑛𝑠 𝑝
268 39 34 55 38 47 60 45 72 60
• Total speeds: 24, Duplicate =2, Different speeds =22. 𝑛𝑚𝑎𝑥 = 1600, 𝑛𝑚𝑖𝑛 = 12.5

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• Spindle to Lead screw (Metric Thread)

•
60 30 40 86 28 30 42 28 28 18 28 15 35
1sp.rev (or, or, or, ) (or, ) (or, )12 = 𝑝
60 45 86 64 28 25 30 35 28 45 35 48 28
• Spindle to lead screw (Inch Thread)

•
60 30 40 86 28 38 25 30 35 28 30 18 28 15 35
1sp.rev (or, or, or, ) (or, ) (or, )12 = 𝑝
60 45 86 64 28 34 30 42 28 28 33 45 35 48 28

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• Spindle to Lead screw (Precision thread)

• Spindle to Feed Rod

•
1sp.rev𝑖const.𝑖rev.m.𝑖change gear𝑖f.g.b𝑖ap 𝜋𝑚𝑧 𝑝 = 𝑆
mm/rev

•
60 30 40 86
𝑖const. = , 𝑖rev.m. = , 𝑖change gear = , 𝑧 𝑝 = 10, 𝑚 = 3mm
60 45 86 40

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 •
28 30 42 28 28 18 28 15 35 23 24 28
𝑖f.g.b. = (or, or, or, ) (or, ) (or, )
28 25 30 35 28 45 35 48 28 40 39 35

•
30 32 32 4 36 17
𝑖ap =
32 32 30 21 41 66

Turning Taper surfaces:

Setting Over the tail stock:

• Offsetting the tailstock → Straight Turning → Taper Turning. [Useful when, Taper angle < 4 ◦ ,
otherwise, w/p will deform]

ℎ 𝐷−𝑑
=
𝐿 cos 𝛼 2𝑙

Where, ℎ = Tailstock offset, 𝐿 = total length of the w/p, 𝐷 = Major dia of taper, 𝑑 = Minor dia of taper,
𝑙 = Taper length.

Swivelling the compound rest:

• Working Principle: Swivel the compound rest → feed top slide → taper. [for taper angle 𝛼,
swivel angle 𝛼2 ]

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Using taper turning attachments:

• Method requires a special device called: Taper turning attachment (TTA)

• TTA 3 Guide plate, bracket.

• Guide plate is secured to bracket

• Brackets: Bolted to rear side of the bed.

• The guide plate can be set at an angle 𝛼 in ref. to centerline.

• Guide plate is linked to the cross slide.

• Cross slide is disconnected from the saddle by removing the cross feed screw.

• A cross movement occurs due to the travel of guide block along guide plate.

• Accurate taper can be generated upto 15◦ or 18◦

• Length of taper < length of guide plate

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 Using two feeds: Used when power longitudinal feed and cross feeds are available. Compound
rest will be set at an angle 𝛽
𝑆® = 𝑆®𝑙𝑔 + 𝑆®𝑐
𝑆𝑙𝑔 = Longitudinal feed, 𝑆 𝑐 = Cross feed, 𝛼 = Required Taper Angle, 𝛽 = angle between two feed =
Compound rest angle
𝑆𝑙𝑔 𝑆 𝑆𝑐
= =
sin (𝛽 − 𝛼) sin 𝛽 sin 𝛼
Find the required 𝛽 for taper turning at an angle of 𝛼

Accessories of lathe machine

• Standard Accessories: These accessories are given when lathe machine is bought. 3 Chuck (3
jaw, 4 jaw), Mandrels (conical and expanding), Rest (steady and follower), Face Plate and Lathe
Dog

• Not standard Accessories 3 2 jaw chuck, magnetic chuck, drill chuck

• 3 Jaw Self Centering Chuck: Watch: Mechanism

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• 3 Jaw Chuck 3 3 Jaws (bottom face = toothed), scroll plate(Top face: scroll (spiral slot), Bottom
face: circular rack), 3 pinions, Wrench.

• Wrench makes 1 of 3 pinions rotate → pinions meshed with circular rack →

Scroll plate rotates → 3 Jaws’ bottom faced tooth mesh with spiral slot → Jaws move
in unison

• 3 Jaw chuck Used when: to grip regular shaped/ circular shaped object

• 4 Jaw independent Chuck 3 4 jaws (bottom face: half nut), Screw, Half Nut

• 4 jaw Chuck: Each jaw moves independently. Jaws are stepped. Stepping helps griping w/p for
internal threading.4 jaws used for gripping irregular shape w/p.

• 2 Jaw Universal Chuck: One jaw fixed, other jaw moves. Used for gripping rectangular bar.

• Drill Chuck: Watch: Mechanism

• Drill Chuck Used: for holding drill tool, bore tool, reamer (set at tailstock)

• Problem: Small dia + Soft Metal Gripping cannot be done with 3 jaw chuck, if done → w/p
deforms

• Solution: Drill chuck (held in 3 jaw chuck) holds the w/p.

• Magnetic Chuck:

• Mandrels: When used: Turning a short w/p with internal hole. → Mandrel is pushed inside the
hole of w/p. better gripping.

• Mandrels: 2 types: Conical and Expanding Watch from 5:44 for Expanding Mandrel

• Conical Mandrel: Working principle: W/p (2) moves inside the conical mandrel (1) through
w/p’s hole → tighter

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 • Expanding Mandrel: Working Principle: W/p moves inside the expanding mandrel. Gripping:
Rotate Nut (3) → Sleeve (2) is displaced along conical rod (1) → Sleeve (2) expands → W/p
is gripped. Un-Gripping: Un-rotate nut (3) and Rotate Nut (4) → sleeve (2) is displaced along
conical rod toward lower diameter region. → Sleeve (2) contracts. Work piece can be removed.
To hold the mandrel, driving dog grips at flat end (5) of the conical rod.

• Rest: Long work piece can deform at the middle. Rest pushes the workpiece towards centerline.

• Steady Rest: 3 jaw frictionless face. Adjustment screws → jaws hold the work piece and keep
it un-deformed.

• Follower Rest: Located on right side of carriage. When tool moves, it also moves. Resist
instantaneous deformation of the w/p. It can also reduce deflection of w/p that can arise from
cutting tool force.

• Face Plate and Lathe Dog: Spindle rotates → faceplate rotates → lathe dog rotates. Lathe dog
grips the workpiece.

1.2 Rizvi’s Suggestions:

1. Function of Half nut. How threading is done

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 2. Can threading and turning be done with same feed rod? What would be the problem?

3. How does the three Jaw chuck rotate in unison?

4. Locations of clutches and their functions.

5. Functions of change gear box.

6. Functions of follower rest and steady rest.

7. Taper Turning Attachment ***

8. Functions of Mandrels in engine Lathe.

9. Why is expansion mandrel pushed in one side and pulled out from another side?

10. Explain: Cutting of milling is discontinuous but cutting of lathe is continuous

11. What is Universal Milling Machine?

12. Write down the kinematic Equation of metric thread and inch thread

1.3 Previous Years’ Questions:

1. Which workpiece holding device could be used for drilling holes in components having irregular
shapes? Explain with suitable diagram.

2. Why does the feed gear box of engine lathe designed for only standard threads? Describe the
location and purposes of change gears in lathe machine.

3. What are the locations and purposes of half nut and worm gearing in feed drive of an engine
lathe?

4. In which taper tuning method do you need to disengage the feeding screw of cross slide? Discuss
the method in detail with necessary sketches.

5. What are the functions of the clutches in the gear train of certain engine lathe? Mention
specifically at least three locations of clutches in gear train of an engine lathe.

6. What are the main features of scroll plate? How does it help all the jaws to move on unison?
Explain briefly.

7. Where do you exactly set the follower rest in a lathe machine? Explain the purposes of follower
rest.

8. Which workpiece holding devices can be used in a lathe machine to secure a rectangular shaped
job having a hole in the middle? Discuss their relative advantages.

9. State the locations and functions of the head-stock, tailstock. carriage and work- tool holding
devices in center lathes with the help of simple line diagram.

10. What are the basic differences between a jig and a fixture?

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 11. What is 3-2-1 locating principle? How many motions can fix pins and a clamp restrict according
to this principle?
12. If the work piece is too thin that it can bend and wrap easily, which jig will be suitable to hold
it? Explain with a neat diagram.
13. Describe the working principle of a three jaw chuck. What are the limitations of it?
14. Engine lathes is the most commonly used machine cool in typical workshops, — Explain why.
15. With the help of kinematic diagram shown in Fig. for Q. 5(b), discuss the mechanism for cutting
metric and inch thread using the lathe machine. Provide necessary kinematic equations for this
purpose.

16. Taper turning is one of the important applications of engine lathes. Briefly discuss dilferent
methods for turning taper using lathe machines.

2 Turret Lathe [Masud Sir]

2.1 At a glance

• Advantages over Engine Lathe: 1] Use of Multiple tool holder → Simultaneous Machining of
w/p with tools of cross slide and turret → Reduce Machining Time → Batch Production 2]
Presetting of turret with different tools → reduce non-cutting time ∵ Tool changing time ↓ →
Batch Production

• Collet Chuck: widely used to clamp a bar in machining on a lathes. Colllet ≡ steel sleeve with
split tapered portion forming jaws. 3 types: 1] Pull-in 2] Push-out 3] Immovable

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• Classification of Turret Lathes: 1] Bar type 2] Chucking type

• Classification of Turret Lathe: 1] M/c with vertical axis of turret rotation 2] M/c with horizontal
axis of turret rotation

• Machining Sequence: Centering, Facing, Drilling, Turning, Boring, Reaming, Chamfering

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2.2 Rizvi’s Suggestions:
1. Why do we use collet chuck? With schematic Diagram.
2. P. 168 of Chernov: diagram: Serially
3. Turret bar type. chucking type: Use:

2.3 Previous Years’ Questions:

1.

3 Milling Machine[Masud Sir]

3.1 At a glance:

Basics:

• Functions of Milling: Slot cutting, Facing, holing, Gear (form cutting)

• Cutting gears with milling (Form Cutting): Cutter profile → Tooth space profile. Involute profile
is not obtained ∵ Milling applies concentrated load while involute profile requires distributed
load. Could obtain involute profile: if special cutters considering (d, T, addendum, dedendum,
base circle dia of gear) are made. Changing any of the dimension → no longer Involute profile.

• Knee and Column Type Milling Machine:

• Work piece: 3 motions: Vertical feed with knee (Up/down), Cross feed with saddle (in/out),
Longitudinal Feed with table (left/right).

• Knee: Vertical feed

• Table: Longitudinal feed

• Saddle: Cross feed

• Arbor: connected with spindle. Hold cutter

• Arbor Support:

• Overarm:

• Types of Knee and Column Type Milling Machines:

• Plain Horizontal K/C m/m: No swivel plate below table

• Universal K/C m/m: Swivel Plate (Below table, above saddle) Table can be angularly positioned
with vertical axis.

• Vertical K/C m/m: No overarm. Spindle = vertical

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 • Ram-head K/C m/m: Horizontal spindles at ram head.

• How Cutter is set up in arbor: Arbor 3 spacers. First, remove some spacers → set up the cutter
in the place of spacers → add spacers to tighten it.

• Short Arbor use: can contain cutter in its head → used for facing.

• Cutters: Cutter with holes can be set up in horizontal spindle. Cutter without holes (e.g. drill)
are set up in vertical spindle.

• Not continuous cutting in milling:

• Fly cutter: when gear’s grooves decay → Melt some metal in the groove → Use fly cutter (with
gear tooth space profile) → groove repair

• Upmilling Vs. Downmilling:

Indexing:

• Dividing Head:

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•
• Index Plate: contains concentric circles with equal distance holes.
• Index Crank: Contains index crank pin. Index crank can be rotated. Index plate does not rotate
with index crank rotation when crank pin is not pushed inside index plate. During differential
indexing, crank pin is pushed inside index plate so that with the rotation index crank, index plate
also rotates.

•
• 3 types: Simple Indexing (a), Differential Indexing (b), Helical groove cutting [Not in our
syllabus]
• Simple Indexing: Index plate is locked. index crank rotation → shaft rotation → Gear trains →
90◦ rotation
worm −−−−−−−−→ worm gear → Spindle
• 𝑛𝑐 rev. of index crank → 1
𝑧 rev. of the spindle. [z = no. of teeth in gear to be made]

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 •
𝑍 1
𝑛𝑐 × 1 × =
𝑧𝑜 𝑧

• 𝑛𝑐 = 𝑧𝑜
𝑧𝑍 [Usually, 𝑍 = 1 and 𝑧 𝑜 = 40]

• Here, 𝑍 = No. of starts in worm, 𝑧 𝑜 = No. of teeth in worm gear.

• Differential Indexing: Index plate unlocked (can rotate). Same as before. But, Spindle rotation
→ Change gears → Bevel gears → Gear train → Index plate rotates.

• let, 𝑧 𝑥 = Suitable no. of teeth for which index plate’s concentric circles are available.

• 𝑛𝑐 = 𝑛𝑐/ 𝑝 + 𝑛 𝑝 Where, 𝑛𝑐 = Rev. of index crank (absolute), 𝑛𝑐/ 𝑝 = Rev. of index crank relative
to plate, 𝑛 𝑝 = Rev. of index plate (absolute).
𝑧𝑜
• 𝑛𝑐 =
𝑧𝑍
𝑧𝑜
• 𝑛𝑐/ 𝑝 =
𝑧𝑥 𝑍
1 𝑎𝑐
• × = 𝑛𝑝
𝑧 𝑏𝑑
𝑧𝑜 𝑧𝑜 1 𝑎𝑐
• ∴ = + ×
𝑧𝑍 𝑧 𝑥 𝑍 𝑧 𝑏 𝑑
𝑎 𝑐 𝑧𝑜
• for Z =1, = (𝑧 𝑥 − 𝑧)
𝑏 𝑑 𝑧𝑥
𝑎𝑏 𝑎
• If the fractions are negative, [i.e. 𝑧 𝑥 < 𝑧] b gear will be idle gear. change gear ratio = = .
𝑏𝑑 𝑑
Only a and d’s teeth no. are to be found. b gear can be of any teeth no.

3.2 Math Indexing:

3.3 Rizvi’s Suggestions:

1. Types of milling machine

2. Simple Differential Indexing (math)***

3. How is cutter set in horizontal spindle?

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 4. Function of short arbor:

5. Fly cutting process. Where do we use:

6. Why gear cutting is problematic in milling

7. Is it possible to get an involute profile of gear in milling?

8. Why does index plate not rotate during simple indexing?

3.4 Previous Years’ Questions:

1. What are the purposes of spacer in arbor? Explain briefly. What are the purposes of fly cutting
process?

2. Why does the index plate rotate during differential indexing? Discuss the mechanism related to
rotation of index plate.

3. By sketching a simple line diagram of a milling machine, visualize the location and position of
the tool. work piece, base, spindle, column and motor in that machine.

4. Classify milling machines. Briefly explain various external and internal surfaces produced by
milling machine. Provide neat sketches with tool position for each of them.

5. Suppose you have to cut a helical gear using a universal knee and column type milling machine.
If number of teeth of the gear is 37 and helix angle is 300. explain the procedure for indexing
and setting table for the helical grooves. Assume a common dividing bead is attached with the
machine.

6. What are the main specifications of a typical universal knee and column type milling machine?
Give typical values for each of these specifications

7. What are the movements available in a universal knee and column type milling machine? With
the help of kinematic diagram shown in Fig. for Q. 7(c), explain these movements. Also provide
kinematic equations for them with maximum and minimum values.

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4 Bearing and Spindle [Masud Sir]

4.1 At a glance:

Bearings: Basics

• Bearing: 2 types: Journal and rolling-contact bearing.

• Rolling contact bearing: 2 types: Ball bearing, Roller Bearing

• Ball Bearing Main Elements: 1] Outer Ring 2] Inner Ring 3] Ball or rolling element 4] Separator
(retainer)

• Function: Hold and support Rotational part. Resist deflection . Deflection → vibrate

• Problem: If there is a clearance between inner and balls, then Loading ↑ → Inner ring will be
off-centered → Eccentric rotation of shaft → Spindle will deflect.

• Solution: Pre loaded bearing (aka shrunk bearing). Outer ring = shrunk. [If there is little load
on bearing → no need of preloaded bearing.]

• Roller Bearing: Line contact, Ball Bearing: Point Contact

• Problem with Roller Bearing: Line contact is difficult. Roller dimension has to have high
precision.

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 • Advantage of Roller bearing: Line contact provides high load capacity

• But, generally ball bearings are used.

Spindle

• Spindle = expensive [∵ accuracy]

• Strong Short spindle → High bending strength, torsional strength, buckling, strength.

• Deflection of spindle = depends on Stiffness of spindle, rigidity of bearing, rigidity of structure,

location of bearing.

• Total deflection of spindle due to load 𝐹 , 𝛿 = 𝑥 1 + 𝑥 2 Where, 𝑥 2 = deflection of spindle due

to elastic deformation of bearings (when bearings have less rigidity) and 𝑥 1 = deflection due to
bending of spindle (When bearings are highly rigid)

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•

• The minimum deflection determines the optimum - bearing distance. According to Honrath,
this ratio lies generally between 3 and 5.

𝑏
• ∴ 𝑥1 + 𝑥2 = 𝑓 ( )
𝑎
• Preloading: Honrath found that the deflection of a spindle nose is high at initial loading and
reduces with increasing load

• Why Preloading: The deflection can be reduced if the rolling bearing is pre-loaded. Honrath
has shown that the contribution of the bearing to the deflection of the spindle hose can be
reduced from 16 𝜇 (for 15𝜇 play) to 5𝜇, if the bearing was preloaded to a play of -15𝜇 (Fig. 4.
17). Consequently, the total displacement of the nose was reduced from 30𝜇 to 16𝜇. [play =
clearance, -play = interference]

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 • The loading of the spindle causing skewness of the bearings may result in vibrations, loss of
energy, poor finish of the job and shorter life of the bearings.

• Over-preloading may increase accuracy but decrease running property

• How to preload: 1] Mounting the bearing on tapered shaft. Or on a sleeve that can expand →
Inner ring expands → preloading [Mandrel type] 2] Using a interference fit for outer ring 3]
Purchasing a bearing with outer ring preshrunk.

4.2 Rizvi’s Suggestions:

• Why bearings are preloaded

• How preloading is done

• How to realize that sufficient preloading is done

• Problems of over-preloading

4.3 Previous Years’ Questions:

1. What do you mean by pre-loading of bearing? How does pre-loading of bearing increase the
machining accuracy?

2. What is the purpose of preload in ball bearing? How is it applied?

3. What are the components of an ideal roller bearing?

4. What are the advantages end disadvantages of a journal bearing?

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5 Introduction to Machine tools [Nafis Sir]
5.1 At a glance:

• 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".

• 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.

5.2 Previous Years’ Questions:

1. How can machine tools be classified? What socio-economic roles are played by machine tools
for the industries and the nation? Explain briefly.

2. Describe the advantages and application of CNC machines.

3. What are the requirements of a machine tool?

4. Describe the importance of CNC machine tool compared to a traditional one?

5. Name the major components common to all conventional machine tools and explain the functions
of those components.

6. Describe briefly with the help of block diagram, the major aspects that are associated with
machine tools engineering. Also show the inter connections amongst those aspects.

7. What are the requirements Of a Machine tools?

8. What are the challenges those create the need for NC machine tools?

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6 Grinding Machine
6.1 At a glance:

• Grinding machine (aka grinder) ≡ power tools or machine tools: used for grinding.

• Grinding ≡ Type of machining using an abrasive wheel as the cutting tool.

• Grinding: Working Principle: Each grain of abrasive on the wheel’s surface cuts
via shear deformation
−−−−−−−−−−−−−−−→ small chip from the workpiece

• Operations performed by grinding machines are 31] Grinding of (a) external and internal
cylindrical surfaces, (b) tapered and complex-shaped surfaces, (c) flat surfaces, (d) screw threads,
(e) gear teeth 2] Cutting off blanks 3] Sharpening cutting tools

• Type of Grinding Machines 3 Cylindrical g/m, Centre-less g/m, Internal g/m, Surface g/m,
Special purpose g/m.

Cylindrical
Grinder:
Used for
generating
external
cylindrical
surfaces.

Cylindrical
grinder with
plung-cut
principle:

25
Internal
grinders:

Planetary
grinders:

Surface
grinders
with rect-
angular
table:

26
Surface
grinders
with re-
volving
table

Vertical
spindle sur-
face grinders
with rect-
angular
table:

27
Vertical
spindle sur-
face grinders
with re-
volving
table:

28
Motions of cylindrical grinding m/c

• Cylindrical grinding machine’s movements: Workpiece is mounted between the centers of the
workhead and tailstock which are placed on the swiveling plate of the work table.

1. Principle movement -rotation of the grinding wheel

2. Circular feed -rotation of the workpiece

3. Longitudinal feed - straight reciprocating movement of the work table.

4. Cross feed(infeed) - intermittent radial displacement of the wheelhead per stroke of the
table

5. 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.

• Rotation of grinding Wheel:

• motor M2 → V-belt drive 112

147 → Rotation of grinding wheel

• Circular feed or rotation of the workpiece:

• Variable d.c. motor M1 → V-belt transmission → Spindle

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•

•
63 63
𝑆 𝑤 𝑘 = 𝑛𝑚 .0.985 · 𝜋𝑑 𝑤
130 168
• Cross feed/infeed mechanism

• 1] Rapid positioning movement of the wheelhead relative to the leadscrew 2] Hand-controlled, 3]

Automatically-controlled continuous and intermittent, 4] Periodical cross feed of the wheelhead
magnetic clutch C1 being engaged
• Hand-controlled cross feed: Handwheel(1) −−−−−−−−−−−−−−−−−−−−−−−−→ Bevel gear 39/39 →
vertical shaft → worm gearing 2/40 → Infeed screw-and-nut transmission → Wheelhead.

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 magnetic clutch C1 being disengaged
• Rapid positioning movement: Hydraulic motor M3 −−−−−−−−−−−−−−−−−−−−−−−−−−→
a pair of cylindrical gears 35/35 → bevel gearing 39/39 → Infeed leadscrew

•
magnetic clutch C2 engaged
• Automatically controlled intermittent feeds: Hydraulic motor M4 −−−−−−−−−−−−−−−−−−−−→
clutch C1 engaged
Worm gearing 1/50 → Handwheel −−−−−−−−−−−−−→ Bevel gearing 39/39 →
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,

31
 stopping the motion of worm gearing 1/50.

Hydraulic Drive in Cylindrical Grinding M/C

• 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; contin-
uous 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

Surface Grinding M/c:

• General 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.

Centerless grinding M/c

• Why Used: External and internal surfaces of cylindrical parts having no central holes can be
ground on centerless grinding machines:

• Through-feed centerless grinding: 3 Grinding Wheel (1), Regulating Wheel (2), Workpiece
(3), Work-rest blade (4).

32
•

• Working Principle: Grinding Wheel removes stock allowance → Regulating Wheel imparts to
the workpiece rotation (circular feed), and longitudinal movement (Axial Traverse feed)

• Axial traverse feed: Setting the regulating wheel or the work rest blade at an angle 𝛼 to the axis
of the grinding wheel → Axial traverse feed.

• For rough grinding 𝛼 = 1.5◦ to 6◦ , For finish grinding 𝛼 = 0.5◦ to 1.5◦ .

• 𝑆 𝑤 = 𝑣 2 sin 𝛼 Where, 𝑆 𝑤 = Axial Traverse feed, 𝑣 2 = Peripheral speed of regulating wheel.

• To obtain a true cylindrical surface of the workpiece: Workpiece’s axis should be set above the
centre of the grinding and regulating wheel by an amount of about 0.15𝑑 𝑤 to 0.25𝑑 𝑤 , But ≯ 10
to 12 mm (to avoid vibration)

• In plunge cut grinding: The axes of the grinding and regulating wheel are set parallel to each
other → Workpiece supported on the work-rest blade is only rotated (No axial traverse feed) →
The cross feed (infeed) is effected as the movement of the grinding or the regulating wheel by a
precision feed screw in a direction perpendicular to the Workpiece axis.

• Center Line Disposition:

33
6.2 Previous Years’ Questions:
1. Short Notes: (c) Functions of hydraulic drive in cylindrical grinding machine

7 Microfinishing [Nafis Sir]

7.1 At a glance:

• Microfinishing Machines: Intended for final machining of workpieces.

• Most widely used machines are: Lapping, Honing, Superfinishing

• Lapping: 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

• 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

Lapping: Motion:

• Rotation of Lap 2:

34
• Motor → V- belt drive → worm gearing 4/40 cardan shaft II → V-belt drive →
Spindle 5 → Lap 2 rotates

• Rotation of Lap 1:

• Motor → V- belt drive → shaft III → Worm gearing 4/40 → sleeve 8 rotates →
Lap 1 rotates

• Lapping can be applied to flat surface and cylindrical surface.

• For lapping flat surface: forced oscillation is imparted to the retainer and for lapping cylindrical
surface: retainer is kept motionless so as to avoid a camber of the workpiece ends.

• Flat Surface: Motion to Retainer

35
 •
Clutch 9 engaged
• Motor → ShaftIII → Worm gearing → Cylindrical Gears −−−−−−−−−−−−→ Shaft I →
Disc 7 → Crank pin 3 → Forced oscillation on retainer

• For cylindrical surface 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.

7.2 Previous Years’ Questions:

1.

8 Gear Shaper [Nafis Sir]

8.1 At a glance:

Videos

• Watch: Different types of gear manufacturing processes: Generating and Form Cutting : Shap-
ing, Hobbing, Milling, Gashing, Broaching

• Watch: Gear Hobbing and gear shaping

36
Form Cutting Vs Generating:
• Cutting gears : 2 types : Form Cutting , Generating
• Form Cutting ≡ Each Tooth space is cut by a cutter. Cutter shape is identical with gear tooth
space. Slow Process. e.g. Milling
• Generating ≡ cutting tool edges take a series of successive positions relative to the gear tooth
profiles → cut the gear tooth. e.g. Rack type cutter, gear hobs and rotary shaping cutters.

Movements in a typical Gear shaper:

•
• I- Reciprocating movement of the cutter [Up and down]
• II-Gear blank rotation
• III-Circular feed of the cutter
• IV-Radial infeed
• V-withdrawal movement of the cutter
• We studied I,II,III motions only.

Reciprocating motion of cutter:

• Reciprocation Motion of cutter flow chart: Motor → Belt-pully → Shaft-I → Link Gear, 1
→ Gear Cutter Reciprocation Up and Down

Here,
𝑣 𝑚 = Mean cutting speed, m/s
𝑣 𝑚 =(2𝑙) × 𝑛 𝑛= double strokes per second
𝐷1 𝑙 = stroke length = 𝑏 + 𝑐 Where, 𝑏 = gear blank
𝑣 𝑚 =(2𝑙) × 𝑛𝑚 facewidth, 𝑐 = cutter overhead
𝐷2
𝑛𝑚 = motor rps

37
Rotation of cutter: Circular feed 𝑆 𝑐 mm/double stroke

• 2 types: Coarse feed, fine feed

• Coarse feed:

• Fine feed:

38
 •
• Coarse feed equation:
50 80 15 𝑎 50 50 50 39 39 1
1 𝜋𝑚𝑧 𝑐𝑡 = 𝑆 𝑐
80 70 30 𝑏 50 50 50 39 65 90
• Fine feed equation:
50 80 15 𝑎 𝑐 50 50 39 39 1
1 𝜋𝑚𝑧 𝑐𝑡 = 𝑆 𝑐
80 70 30 𝑏 𝑑 50 50 39 65 90
• Here, 𝑚= module of gear cutter, 𝑧 𝑐𝑡 = tooth no. of gear cutter

Rotation of gear blank: Indexing motion

39
 • Kinematic equation:
1 90 65 39 50 21 21 𝑎 1 𝑐 1 32 1 1
=
𝑧 𝑐𝑡 1 39 39 50 21 21 𝑏 1 𝑑1 40 120 𝑧
• 𝑎1 𝑐1
𝑏1 𝑑1 = 𝑧𝑐𝑡
𝑧

• Here, 𝑧 = no. of teeth of gear blank

Mechanism for cutting helical gears:

• Cutter = rotary gear shaper cutter with helical teeth
• Helical guideways mounted on a ram slide. 𝑙Helical Guidways = 𝑙cutter tooth [lead, 𝑙 = Axial travel for
one single complete helical revolution about the pitch diameter of the gear.]
• Guideways 3 1] Movable part secured to the cutter spindle, 2] Stationary part mounted in the
hub of worm z=90 [kinematic diagram er worm gear ta]
• Stationary part rotates with worm wheel.
• Movable part receives a forced additional rotation together with the cutter spindle.

Gear Hobbing Methods:

• Gear hob: removes materials from the gear blank to produce cylindrical gears.
• Working Principle (Movements): Gear hob has two motions: 1] rotates (I) 2] Straightly moves
(II). Gear Blank has 1 motion. rotates

•
• Working Principle: Gear blank is cut with the cutting edges of gear hob as if the gear blank is
in mesh with a moving rack
• How to produce spur gear with Hobber: Given, Spur gear no. of teeth 𝑧 and face width 𝑏. 1]
Blank should make 𝑍/𝑧 revolutions during one revolution of 𝑍 start hob. 2] Straight movement
is imparted to the hob to extend the form of the teeth along the gear face width 𝑏

40
 • How to Set up Gear hobber: Firstly, hob axis is horizontal. One of the hob teeth is set at the
center of work table in order → Obtain correct profile of the tooth.

• For Spur gear: Hob axis is to be at an angle of 𝛿 with the gear blank face at the lead angle 𝜆 of
the hob thread i.e. 𝛿 = 𝜆

• For Helical Gear: Hob axis is to be inclined at an angle of 𝛿 = 𝛽 ± 𝜆 Here, 𝛽 = helix angle of
the gear to be cut,𝜆 = lead angle of hob thread

• + : for different helix hands of of the gear to be cut and the hob

• - : for the same hands

8.2 Assignment:
Assignment Math:

• If for a specific tool-workpiece combination, maximum cutting speed is 100 m/min. Which one
of the motor rpms (940/1440) should we select? Assume that facewidth of the gear blank is 90
mm and over travel of the cutter is 10mm. Here, 𝐷 1 =200mm and 𝐷 2 =400mm

Solution:
– 𝑙 = 𝑏 + 𝑐 = 100 mm
– for n = 940 rpm, 𝑣 𝑚 = 2𝑙𝑛 = 2𝑙𝑛𝑚 × 𝐷2 = 94 m/min < 100 m/min [Acceptable]
𝐷1

– for n = 1440 rpm, 𝑣 𝑚 = 2𝑙𝑛 = 𝐷2 = 144 m/min [Not acceptable]

2𝑙𝑛𝑚 × 𝐷 1

• What will be the circular feed if a=b=c=d=50, 𝑧 𝑐𝑡 =42 and m=10 mm.

Solution:
– 1 50 80 15 𝑎 𝑐 50 50 39 39 1
80 70 30 𝑏 𝑑 50 50 39 65 90 𝜋𝑚𝑧 𝑐𝑡 = 𝑆 𝑐
𝑎𝑐
– 𝜋𝑚𝑧 𝑐𝑡 420𝑏𝑑 = 𝑆𝑐
– 𝑆 𝑐 = 𝜋 = 3.1416 mm/ double stroke. [𝑆 𝑐 = circumferential movement of gear cutter]

8.3 Previous Years’ Questions:

1. Discuss the features of multiple-tool shaping cutter head.

2. What are the motions involved in gear shaper? Explain them briefly.

3. What are the motions involved and cutter setting mechanism for cutting helical gear in gear
hobber? Explain with necessary sketches.

41
 4. What is strain back effect? How does it affect the cutting tool? How does the clapper box save
the cutting tool?

5. Write short notes on the following: b) Gear shapering machine

9 Installation and Acceptance tests of Machine Tools [Nafis Sir]

9.1 Previous Years’ Questions:
1. Briefly explain the effect of holes on the rigidity of a machine tool structure.

2. Discuss the different acceptance tests in details.

3. Describe briefly the maintenance activities required for longer service life of a machine tool.

4. Mention the requirements of a machine tool control?

5. Write short notes on the following (a) Machine tool tests and accuracy checking

10 Regulation of speeds and feed Rates [Saimon Sir]

10.1 Previous Years’ Questions:
1. Why is stepped regulation of speed and feed commonly used in traditional machine tools? What
are the laws of stepped regulation? Which law is the best among those? Give proper reasoning
behind your selection.

2. What are structural diagrams? Mention the criteria for selecting the best structural diagram.

3. A lathe is designed for machining aluminium workpiece of up to 500 mm diameter and mild
steel workpiece of upto 300 mm diameter. Both HSS and cemented carbide tools are used.
Determine the diameter of the smallest workpiece which maybe machined on this lathe if the
permissible cutting speed of the HSS-mild steel pair = 50 m/mm, that of the carbide- aluminium
pair 1500 m/mm and R = 75. [Ans. 𝐷 𝑚𝑖𝑛 = 6.67mm (Al-C) and 4mm(HSS-MS)]

4. If 𝑛1 = 15, 𝑛 𝑧 = 450 and z = 12, find the spindle speeds according to GP series and AP series.
(𝜙, n and z have their usual meanings) .

5. Mention the kinematic advantages of GP series.

6. What is the aim of speed and feed regulation? How maximum and minimum cutting and feed
speeds are obtained?

7. State the basic functions of the kinematic structure of machine tools. Also explain the functional
principle of each kinematic chain in the kinematic structure of any machine tools.

8. Explain how can you determine the maximum and minimum cutting and feed speeds.

9. If 𝑛1 = 10, 𝑛 𝑧 = 480 and 𝑧 = 12, find the spindle speeds according to GP series and AP series.
(𝑛1 , 𝑛 𝑧 , and 𝑧 have their usual meanings)

42
 10. Draw the economic ray diagram for a 6-speed gearbox and show the individual transmission
ratios.
11. Draw the saw diagrams for AP, GP and LP series. Which one is the best among these three and
Why?
12. Write down the structural formula for Z = 18. Draw four ray diagrams for Z= 18. Also calculate
the speeds, if input speed is 1200 rpm and 𝜙 = I .41 .
13. What do you understand by formative capacity? that, maximum relative loss Of formative
capacity remains constant for geometric progression series.

11 Volume of Gearbox, its Strength and Mass Moment of Inertia [Sai-

mon Sir]
11.1 Previous Years’ Questions:
1. Prove that, for a given design horsepower, volume of a gear box is directly proportional to the
number of teeth and Inversely proportional to the speed Also prove that, if module is constant,
kinetic energy is proportional to the cube diameter and directly proportional to the speed.

12 Machine Tools Gear Drive System [Saimon Sir]

12.1 Previous Years’ Questions:
1. Prove that, the number of teeth of adjacent gears must differ by at least four to avoid collision
between gears.
2. Show that, the difference in the number of teeth of adjacent gears of a cluster must be at least
four to avoid collision.
3. Prcwe that the difference in the number Of teeth Of adjacent gears Of a cluster must be at least
4. (Assume that all gears have the same module).

13 Infinitely Variable Drive System for Machine Tools [Saimon Sir]

13.1 At a glance

Stepped drive Vs. Stepless drive:

• Stepless drive:

• Advantages of Stepless drive: Possible to attain optimum cutting condition. Important in

reduction of handling time, because speed, feed can be changed without stopping the machine.
Constant cutting speed can be obtained for stepped shaft and irregular contour. Improved tool
life and better surface quality. Drives of friction type run more quietly than gear or chain drives.

43
Classification:

Friction Drive:

• Single Disc Friction Drive

• Double Disc Friction Drive

• Friction Drive using Cones

Heynau Drive:

Wuelfel Kopp Tourator:

13.2 Previous Years’ Questions:

1. Explain the working principle of the following variators using suitable diagrams: (i) Svetozarov
variator (ii) Wulfel Kopp Tourator

2. Explain the mechanisms which transform rotary motion into translation motion in various
machine tools. State the relative merits and demerits of stepped drive over stepless drive in
respect of transmission of motion and power in machine tools.

14 Hydraulic Drive [Saimon Sir]

14.1 At a glance

Hydraulic Fluid properties:

via pressurized oil
• Hydraulic Drive −−−−−−−−−−−−−→ transmit power.

• Hydraulic Fluid ≡ Power transmitting fluid e.g. pressurized oil, water.

• Bulk Modulus ↑ More power transmission [Fluid should be incompressible]

• Oil viscosity ↑ Film can maintain → lubrication → less wear → good

44
 • But, if viscosity ↑↑ pressure drop in pipe lines ↑

• If viscosity ↓↓ leakage problem + more wear due to insufficient lubrication.

• Viscosity index = 90. suitable. [Viscosity Index: (0-100) signifies how viscosity changes with
temperature. low viscosity index → more change in viscosity for temp. change. High viscosity
index → less change in viscosity for temp. change]

• Stable chemical composition → should not change property too much.

• Low moisture content [moisture → Surface corrosion. + reduced oil film thickness = bad
lubrication]

• Low coefficient of thermal expansion

• Low air inclusion [Air inclusion → incompressibility ↓ less power transmission]

Advantages and disadvantages of Hydraulic drive

• Advantages: Relatively small (e.g. aeronautical industry), Simple and smooth speed reversion
(e.g. Grinding m/c table), Infinitely variable speed and feed, Programmed control and overload
protection, Self lubricating effect

• Disadvantages: High production cost, Leakage reduces the efficiency, Not easy to repair

Pump Classification:
• Pump 3 Constant delivery, Variable delivery

• Constant Delivery [Delivery rate and direction = fixed] e.g : Gear Pump, Screw Pump

• Variable Delivery [Delivery rate and direction can be changed by changing arrangement] 3 Axial
arrangement, Radial Arrangement

• Axial Arrangement e.g. : Axial Piston Pump

• Radial Arrangement e.g. : Vane pump, Radial Piston Pump

45
Gear Pumps

• Gear Pump:
meshes with
• Working Principle (Rotation of gear): Electric Motor → gear 1 (Driving) −−−−−−−−−→
gear 2 (Driven) [in general, gears: 2; if 3, then middle gear is the driving gear].

oil
• Working Principle (Oil Squeezing and pumping): Suction side −−→ fills up the tooth gap →
Carried by the rotation of the gears → Meshing of tooth → Oil is squeezed out of the tooth gap
→ Pumped to the delivery side.

• If no backlash and the good fitting between the teeth and the housing → leakage loss ↓ [Backlash
≡ Tooth space − Thickness of engaging tooth (see figure)]

• Problem: A tooth completely seals a tooth gap of the mating gear before the whole amount of
oil in the gap is squeezed out → Resulting small amount (about 10%) of high pressure oil {
rough running of the pump.

• Solution: Relieving channel. Pressurized oil can escape through it to the delivery side.

• Quieter running condition ← by helical or herringbone gears.

d+2m

d-2m

Delivery and Power rating of gear pumps:

46
 • During one rev of gear rotation, 1 gear delivers a volume,

1
𝑉≈ × ring volume
2
1𝜋
= [(𝑑 + 2𝑚) 2 − (𝑑 − 2𝑚) 2 ]𝑏 [Here, ring area= white area in the figure] (1)
24
1𝜋
= 4 · 𝑑 · 2𝑚 · 𝑏
24

• Here, 𝑑 = pitch dia of gear. 𝑚 = module, 𝑏 = face width, 𝑑 + 2𝑚 = outer circle dia, 𝑑 − 2𝑚 =
inner circle dia

• Rate of delivery for two gear pumps:

𝑄 = 2𝑉𝑛
1𝜋
=2 4 · 𝑑 · 2𝑚 · 𝑏
24
(2)
= 2𝜋𝑑𝑚𝑏𝑛
𝑑 2 𝑏𝑛 𝑑
= 2𝜋 [Here,𝑚 = ]
𝑇 𝑇

• Here 𝑛 = Revolution per unit time, 𝑇 = no. of tooth.

• Power developed by the pump: 𝑊¤ 𝑝 = 𝛾𝑄𝐻 = 𝑝𝑄

• 𝑝 = pressure developed by the pump. 𝐻 = Head developed by the pump.

• Power rating of the motor required for pump: 𝑊¤ 𝑚 = 𝑝𝑄

𝜂 𝑣 𝜂𝑚

• Here, 𝜂 𝑣 = Volumetric efficiency ≈ (0.7, 0.8), 𝜂 𝑚 = Mechanical Efficiency ≈ (0.7, 0.9)

Screw Pump:

• Screw Pump 3 right and left threaded shafts.

• Working Principle: Almost same as gear pump. Oil moves in the axial direction. No oil
squeezing. No turbulence.

• Merit: Pump all types of fluids and slurries

• Merit: Well balanced and noiseless

• Merit: Long service life.

• Demerit: They have low volumetric and mechanical efficiencies.

• Demerit: Manufacturing cost of precision screw is high.

47
Vane Pump:

• Vane Pump: A kind of Variable delivery pump.

• Vane Pump 3 Radial slots and Rectangular vanes (1), Rotor (2), Housing (3), Fluid Entry (4),
Bore (5), Fluid Exit (6),

• Rotor (with a fixed axis) is placed eccentrically in the Bore of a pump body

• Working Principle (Movement): Prime Mover → Rotor → Rectangular vanes reciprocate

along the radial slots.

• Working Principle (Suction and delivery): When space between 2 successive vanes increases→
Suction. And when space decreases → Oil squeezed out.

• Problem: If there is no vane between inlet and outlet at some point during operation time →
Some oil will go straight towards delivery

• Solution: Distance between the inlet and outlet of the pump should cover at least two vanes.

• Volume of supply depends on eccentricity

• Advantage: Light in weight and compact.

• Advantage: Volumetric and overall efficiencies are high.

• Advantage: Discharge is less sensitive to changes in viscosity and pressure variations

• Advantage: Their vanes are self-compensating for wear and vanes can be replaced easily.

• Limitations: Vanes are subjected to side wise thrust.

• Limitations: High accuracy required to manufacture.

• Limitations: Frictional loss (Efficiency 0.7-0.75)

• Limitations: They are not suitable for abrasive liquids.

48
14.2 Previous Years’ Questions:
1. Explain the working principle of infinitely variable hydraulic drive. What are the advantages
and disadvantages of using such drive?

2. Discuss the working principle of a gear pump with suitable diagram. How can you calculate the
theoretical flow rate and power requirements of a gear pump?

3. Describe briefly with the help of suitable diagram the construction and working of hydraulic-feed
drive of any machine tool.

4. What type of power sources are generally used in different machine tool drives? State the
advantages and limitations of hydraulic drive over mechanical drive in machine tools.

5. With a neat sketch give a brief description, how a vane pump of external supply type works.
What is the effect In supply rate if your the eccentricity Of the housing?

6. How can you increase the speed of return stroke during the operation of a hydraulic cylinder?

7. Briefly how a hydraulic tracer control unit works.

15 Guideways [Saimon Sir]

15.1 At a glance

Classification of guideways

• Guideways ≡ Track along which something moves.

• Guideway 3 2 types: 1] Slideway 2] anti-friction way

• Slideway ≡ Guide ways with sliding friction

• Anti friction way ≡ Guide ways with rolling friction

• Slideway 3 Closed, Open [Based on resisting normal force]

• Closed Slideway: Can resist opposite normal force; Open Slideways: Can’t resist opposite
normal force

• Slideways 3 Flat, Vee, Dovetail, Cylindrical [Based on shape of x-section]

49
 • Slideways 3 Surrounding, Surrounded [Based on surrounding]
• Surrounding Slideways = Slideways surround rigid portion: Surrounded Slideways = Slideway
is surrounded by rigid portion [Slideway is stationary while rigid portion is moving along it]

•
• [Hatched = slideway, Blank = rigid portion]

Clearance Adjustment
• Clearance ↓↓ → Excessive frictional force
• Clearance ↑↑ → Non Uniform travel
• Clearance changes due to wear
• Some Device → adjust clearance periodically.

Materials for Slideways:

• GCI (Gray Cast Iron): Commonly used
• GCI + Ni + Cr → wear resistance ↑ bending strength ↑
• Flame Hardening { surface hardness ↑
• Desired properties for slideways: wear resistance (surface hardness should be high. ∵ friction
→ wear), Bearing + Bending strength (Load of rigid body → bearing stress + bending stress),
Damping capacity (≡ Absorb mechanical energy → dissipate as heat), Heat Capacity (Temp.
should only increase a little bit with heat gain), Environmentally neutral (don’t react with any
coolant/lubricant), cost ↓
• Why Plastic can be useful material for slideways: Anti-corrosive, Anti-scoring (doesn’t cut a
groove into rigid material), Friction ↓ → Wear ↓. Plastic Low Cost + Easy fabrication, pressure
can be given uniformly from rigid body.
• Problems with Plastic as a material for slideways: Surface hardness ↓ suitable for Low Pressure,
Poor thermal conductivity → Thermal Distortion, Absorbing oil → tend to swell, low speed
range.

50
 cause
• Wear ←−−−− material properties, surface roughness, pressure on slideways, sliding velocity,
working life, dirt and chip accumulation.

Hydrostatic Slideways:
supplied
• Hydrostatic slideways ≡ High pressure oil −−−−−−→ between the two mating parts. Moving
is replaced by
element → floats over a fluid film. Metal-to-metal contact −−−−−−−−−→ fluid shear type friction.

• Working Principle:
oil
Pump −−→ Control valves → Restrictor R: Pressure reduction from 𝑝 to 𝑝 𝑟 →
pockets of slideways → Clearance ℎ between the slideway surfaces: Here, oil pressure = 𝑝 1

• Load carrying capacity, 𝐹 = 𝛼 × 𝐴𝑝 1 Where, 𝛼 = oil pressure drop factor[ 21 , 31 ], 𝐴 =

projected area, 𝑝 1 = Oil pressure
d𝐹
• Rigidity of the slideways, 𝐾 ≡ −
dℎ
• Advantages: 𝐹,𝐾 ≠ 𝑓 (Sliding velocity). No metal to metal contact → No stick slip (Stick slip
≡ spontaneous jerking motion that can occur while two objects are sliding over each other). .
Little wear of the sliding elements and thus longer life. Oil forces dust and chips out of the
bearing area. Oil leakage also facilitates heat dissipation. High machining precision. Good
damping property (absorb mechanical energy).

Pneumatic Slideways

• Pneumatic ≡ operated by high pressure air.

• Working Principle: High Pressure air → filter → Pressure regulating Valve →

Pockets of slideways

51
 •

Anti-friction guideways

• Anti-friction guideways: Rolling members inserted between guideways → Nature of friction=

rolling [instead of sliding]

• Limited travel Anti-friction guideways: A type of anti-friction guideways: Rolling members in

a cage.
𝑙
• Cage length should be, 𝑙 𝑐 = 𝑙 𝑔 − Where, 𝑙 𝑔 = length of Guideways (stationary), 𝑙 = length of
2
moving member.
𝑙
• Maximum limit of the movement of moving member = = 𝑙𝑔 − 𝑙𝑐
2

• Advantages: Low friction 𝑓rolling < 𝑓sliding . Less stick slip (jerking) effect. Highly accurate
movement. Uniform slow motion is possible. Less wear and considerably long service life.
Operation without external lubrication.

• Drawbacks: Cost high, ∵ requires finished and hardened rolling elements. Waviness of the
surface → inaccuracy of motion ∵ the contact is at a point or along a line. The rolling elements
lags behind the sliding member (𝑣 sliding = 2𝑣 rollers ) (See Figure). → Recirculation is needed
if travelling distance is long. [Recirculation ≡ rolling elements move continuously through a

52
 circuit, or path. Where non-recirculating bearings have limited travel, recirculating bearings
have unlimited travel, constrained only by the length of the rail or shaft guideway.]

Recirculating Ball Nut

• Use of Lead screw: Problem: friction and backlash.

• Solution: Recirculating Ball-nut-screw

• How (Load carry): Balls roll between the flanks of screw thread and nut thread → transmitting
load from one flank to the other → Friction problem solved

• How (Recirculation): Balls roll in the helical channel of the thread form, leave the screw at one
end and return through an axial channel in the nut and re- enter the nut at the other end forming
a closed loop in the operation. [see figure for understanding]

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Difference between Flat, Vee, Dovetail, Cylindrical Slideways:

Subject Flat Vee Dovetail Cylindrical

Manufacture Simple Relatively Easy
costly to
Manufacture
Self do do
Adjusting
Dirt Accu- do When
mulation surrounded,
prevents
Clearance Adjustment Simple difficult to
required Clearance adjust
adjustment
Lubricant Poor When Poor
Retention Surrounded,
can’t retain
Constraint Constrained Theoretically
in all fully
directions constrained
Others Saddle is Easy Require Low rigidity
well traverse and small space, as fixed at
supported accurate Can stand two ends
guiding vertical
upward
force
Uses High Medium and Cross slides Column
supporting small lathe. in lathe. drilling
force on Planer Milling machine.
long machine machine Over-arm of
slideway. tables. milling
Bigger Saddles and machine.
machine tool knees Tailstock
with high sleeve
force

15.2 Previous Years’ Questions:

1. Why are the clearances between slideways components required to be adjusted? Explain the
mechanism of clearance adjustment in dovetail slideways with suitable diagrams.

2. Explain the design of slideways for wear resistance by analyzing the forces acting upon the
slideways surfaces.

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3. Briefly mention the advantages and limitations of antifriction slideways.

4. What are the types of slideways? Which factors must be considered for the selection of material
of a slideway.

5. Explain the design of slideways for stiffness by analyzing the forces acting upon the slideways
surfaces.

6. What are the advantages of a hydrostatic slide way?

7. Briefly explain the design of slideways for wear resistance by analyzing the forces acting upon
the slideway surfaces.

8. How do you modify the following design as shown in Fig. 3(a) for Clearance in dovetail
slideways? Write down the reasons behind your modification.

9. With neat sketches, show the cross-sectional view of surrounding and surrounded type flat, vee,
dovetail and cylindrical type slideways.

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