13 Machine Tool Power Drives

Learning Objectives
The content of this chapter would
enable the readers to:
" Understand the
necessity and
power drives in machine tools. functions
of " Estimate
maximum torque, speed and power
State the definitions of machine tool requirement before selecting the rated power
drive. power and speed for the power sources and
ing the design
Classify, characterize and select power sources entire power drive system for the given
for different machine tools. machine tool.
Acquire knowledge which will help to select Know and exploit the basic
and design the power drive systems for dif advantages, limitations and scoperequirements,
of applica
ferent machine tools. tion of hydraulic drive in speciic machine
tools.

13.1 Introduction
Machine tools need adequate power to accomplish chip formation and
etc. while machining. All machine tools are provided with some power sources overcome friction, inertia forces,
and also kinematic
to transmit power and motion from the
power sources to the moving job and tool. Several types ofsystems
sources of different rated capacities and characteristics are available from power
which
sclected depending upon the machining requirements of the machine tool concerned. the appropriate one is to be
While designing the power drive system and selecting power
tool, the total maximum torque, speed and power requirement sources (e.g., motors, etc.) for any machine
need to be assessed taking all the possible
factors into account. This obviously requires knowledge and experience of machining
electro-hydraulicdrives have few advantages as wellas limitations. Selection, design andtheories. Hydraulic or
application of such
drives become essential and also economically viable for some machine tools such as heavy
duty grinding
machines, broaching machines and even horizontal drilling and boring machines. Machine tool designers,
hence, essentially need to be aware of the types, characteristics and the standard rated capacities of the
power sources which are feasible and available. They should also know how to estimate the maximum forces,
various
torque, speed and power that may be required by the concerned machine tool.

13.2 Power Sources Used in Machine Tools

Any machining work essentially needs relative motions and cutting power for che desired tool-work interac
tions. AI machine tools must possess one or more power sources to provide such cutting power and tool
work motions.
448 Machining and Machine Tools

Machine tooldrives actually refer to the source(s) of motion, torque and power and the kinematic system(s)
machining work.
that transform and transmit those motions and power to the tooland work for necessary
Machinc tool drive also includes the system that is used to regulate speed and feed.
Machine tool drives may be one of the following typcs:
motor(s)
1. Electro-mechanical type drives: These are more common where main source(s) is electrical
several mechanisns.
from which power and motions are transmitted to the tool and work through elec
2. Electro-hydraulic type drives: They are common where power and motions are derived from
trical motor(s) and transmitted through several hydraulic systems.
3. Combination of electro-mechanical and electro-hydraulic drives.
Electro-mechanical type machine tool drives comprise generally of electrical motor(s) and a number of indepen
of
dent or interdependent kinematic chains of several mechanisms. Electro-hydraulic drives usually consist
1. one or more hydraulic power packs, each comprising a suitable hydraulic pump such as vane pump,
strainer, foot valve
radial piston pump, etc. being driven by an electric motor and the allied reservoir,
and a relief valve.
2. hydraulic motor or actuator, generally piston-cylinder system.
3. a hydrauliccircuitry comprising several valves for transmitting and regulating pressure, force and
travelling speeds and directions.
Some heavy duty and precision machine tools such as broaching machines, grinding machines, etc. are
designed to have both mechanical and hydraulic drives. Electrical motors are most widely used as power
sourcels) in machine tools. Motors of different types and sizes are used depending upon the type and
application of the machine tools. Machine tool drives, in terms of tool-work motions, are further classi
hed as:
1. stepped drive or stepless drives.
2. positive type drives or non-positive type drives.
The differences and examples of all such possible machine tool drives have been presented in Chapters
12, 14 and 15.
The types of electricmotors, which are generally used for electro-mechanical drives in machine tools, are
as follows:
1. For stepped drives
(a) induction motors having only one or two fixed speeds.
2. For stepless drives
(a) variable speed induction motor with frequency converter.
(b) DC motors.
(c) Ward-Leonard system of motor-generator-motor set.
3. For NCand CNC machines
(a) stepper motor.
(b) AC and DC servo motors.
In induction motors, the speed of the spindle N is obrained as
x60
N, = rpm (13.1)
Np
 Machine Tool Power Drives 449

where f is the frequency (Hz) and N PE

is the number of efective pairs of magnetic poles. In some induction
motors, NPP can be changed from 4 to 2 giving two speeds.
In clectro-hydraulic drives, generally robust and powerful AC motors are
used to run the pumps of the
hydraulic power packs.

13.3 Estimation of Power Requirement for Machine Tool Drives

Machine tool drives need power
1, to provide cutting power for chip formation (separation).
2 to overcome friction forces and power consumed at the sliding
3.
surfaces.
to overcome inertia forces.
4. for auxiliary motions and work.
5. to accommodate dynamic and overload factors.
For instance, the maximumn power requirement (U) from the motor in a centre lathes
from
may be estimated

U= cmax +Ufmax + Utmax ]xfa x fal

(13.2)

where U is the maximum power required for machining; P, V, is the cutting power required; PV,is the feed
power required; Ua is the maximum friction power; Uima is the maximum inertia power;ff are dynamic
and overload factors (in the order of 1.0 to 1.25); and n., n. are the electrical and mechanical efficiencies of
the entire drive systems. Now the maximum power required for machining is given by

Ucm=(P,V+PV max (13.3)

However, while selecting and purchasing the motor, its rated power must be standard, available and not less
than U, estimated. The kinematic systems for transforming, transmitting and regulating motions in different
machine tooldrives have been schematically shown and explained in Chapters 1416 and 21.

13.4 Hydraulic Drives in Machine Tools

Hydraulic drive is employed in some machine tools requiring noiseless smooth operation and heavy forces
during tool-work interactions. Hydraulic drive is generally incorporated for tool or work-feed motions. High
speed rotary motions are attained by electric motors as usual. For hydraulic drive, a machine tool needs use of
one or more hydraulic power pack, where basically an oil as hydraulic fuid is pressurized by a pump-motor set
and that high pressure Auid, after desirably regulated bya relief valve, is used to drive one or more hydraulic
motors, preferably linear type such as piston-cylinder system. Usually the piston moves in stationary cylin
ders to move the table or any slide with the tool or the workpiece. Occasionally the piston remains stationary
and the cylinder holding the tool or the job moves as in hydraulic copying lathe (Fig. 21.24, Chapter 21).
Figure 21.23 schematically shows atypical hydraulically driven machine tool where the rotating drill is moved
at stepleslyvarying feed rate. The hydraulic Auid at high pressure raised by pump and regulated by relief valve
is passed into the piston-cylinder type hydraulic motor via direction control valve. The speed of travelof the
450 Machining and Machine Tools

piston (i.c. tool-fred rate) is regulated by a throtle valve assisted by pressure educing valve. The relarive
advantages of hydraulic drive are:
1. Smooth operation.
2. Precision (stepless) speed control.
3. len jerk. vibration and noise.
4. Handly needs separate lubrication.
5. Lesser wear and tear.
6. Easier connections by Aexible tubings.
In spite of such merits, wide application of hydraulic drive in machine tools is constrained for the following
reasons:

1. Necds more Aoor spacec.

2. Chances of leakage of Auid, which not only causes inconveniences and hazards but also affects feed
rate control.
3. More difhculties in repair and maintenance.
Hydraulic drives are preferably and often essentially used in some machine tools which need high strength
and rigidity and stepless precision control of feed motions without jerk and noise under heavy cuts (such as
heavy duty precision grinding machines, broaching machine and heavy duty boring machines).

13.5 Solved Problems

PROBLEM 1
If the frequency () is 50 and the number of effective pairs of magnetic poles
the spindie speed. (N) is 2, then calculate
Solution: The spindle speed is given by
x60 50 x 60
N
Np 2 = 1500rpm

PROBLEM 2
An induction motor is to be sclected while designing a
conditions:
centre lathe to be used under the following
(a) max. valuec of the main cutting force, P = 800 N
(b) mak. valuc of cutting velocity, V = 240 m/min
(c) fcod-power required (P V) = 10 %of cuting power
d) power necded to oveIcome fricions (U) = 15% of cuing power
(e) poweI ncoded to oveIcOme incrtial force (U) = 5% of cuting foce
) overuad fackor,f = 1.50
dynamic facLOr, f = 1 20
(h) cfhcicncics uf che clecurical systen, , =0.95
() chcicncy of che uehanical syateiaa. =099
 Machine Tool Power Drives 451

Determine the standard rated power of that motor to be purchased from the market.
Solution: The value of maximum total power is given by

where the curting power U, equals P V Here,

U,(max) = 800x 240 Nm/min = 3200 Nm/sec = 3.2 kw
So, maximum power required for machining only (U) is given by
U=(P+PV).,=3.2 + 0.1+ 3.2 =3.52 kW
Therefore,

U,= (3.52+0.15x3.2 +0.10 x3.2)1.25 x1.2 =9.47 kW

0.95 x 0.90

The nearest higher standard power available is 11kW. Therefore, for the present lathe, a 11 kW induction
motor has to be used.

SUMMARY
The necessity and functioning of power drives in
machine tools have been briefly pointed out. The
definition of machine tool power drive is also
stated. The power sources being used in machine
tools have been classified. The characteristics and
applicability of those types are also mentioned. The
principles of selection of type and rated capacity
of power sources, which are feasible and available
in market, depending upon the machining require
ments have been briefly discussed. It is also simply
demonstrated how the maximum power require
ments are assessed. This is essential and important
while designing the power drive system of any
machine tool specified for any particular range of
work.
Hydraulic or electro-hydraulic drives are often
preferably employed in some machine tools. The
basic principle, requirements, relative advantages,
limitations and applicability of such hydraulic drives
have been briefly included in this chapter for the
benefit of the readers and practicing engineers. Next
to power drive, the most important part of any ma
chine tool its kinematic structure. This has been
dealt in the next chapter.

MULTIPLE CHOICE QUESTIONS

[Answers are provided in the CD]

1. A machine tool drive deals with (c) Regulation of tool-work motions
(a) Power requirement (d) All of the above
(b) Transmission system
452 Machining and Machine Tools

2. Machine tooldrive cannot be (c) Vane pump

(a) Electro-mechanical type (d) Radial piston pump
(b) Electro-hydraulic type 7. Ward-Leonard system of motor-generator
(c) Pneumatic types motor set up is used in some lathe for
(d) Combination of clectro-hydraulic and (a) Stepped drive
clectro-mechanical (b) Stepless drive
3. Machine tools having stepped drive (spindle (c) Any of the above
speed) are powered by (d) None of the above
(a) DC motor 8. Hydraulic drive is used in broaching machine
(6) Induction motor for
(c) Servo motor (a) Stepless cutting velocities
(d) Stepper motor (b) Stepless feed rate
Servo motors are used for feed drives of (c) Stepped curting velocities
(a) Hydrauliccopying lathe (d) Stepped feed rates
(b) Broaching machine 9. In hydraulically driven broaching machine the
(c) CNC milling machine cutting velocity is varied by regulating
(d) Capstan lathe (a) Relief valve
5. In some machine tools, hydraulic drive is used (b) Foot valve
for (c) Throttle valve
(a) Stepped drive (d) Presure reducing valve
(b) Stepless drive 10. Application of hydraulic drive in machine
(c) For both of the above tools is constrained or limited due to
(d) None of the above (a) More floor space required
6. The pump, which is not used in hydraulic (b) Chances of leakage of fuid
drive of any machine tool, is (c) More difficult maintenance
(2) Gear pump (d) All of the above
(b) Centrifugal pump

REVIEW QUESTIONS
1. What are the functions of machine tool devices?
2. How can machine tool drives be classified?
3. Whar type of power sources are generally used
in diferent machine tool drives?
4. How are machine tools provided with stepless
drives?
5. Describe briely the principle of Ward-Leon
ard system used to provide stepless drive in
machine tool.
6. How can speod be changod in induction motor?
7. Sate the advantages and limiations of hydraulic
drive over mechanical drive in machine tools.
8. What factors need to be considered while
selecting motor for any machine tool
drive?
9. How is the power of the main motor of any
centre lathe and any drilling machine select
ed for purchase?
10. Describe briefly with the help of suirable
diagram the construction and working of
hydraulic-feed drive of any machine tool.