GENERAL PRINCIPLES OF

MACHINE TOOL DESIGN

PROF. A.B.PATEL
Machine Tool Classification
By degree of automation
i. Manual control
ii. Semiautomatic
iii. Automatic
By weight
i. Light duty ------up to 1 ton capacity
ii. Medium duty---from 1 ton to 10 ton capacity
iii. Heavy duty ----greater than 10 ton capacity
By degree of specialization
i. General purpose
ii. Single purpose
iii. Special purpose

Working And Auxiliary Motion In
Machine Tools
1. Primary cutting motion
2. Feed motions
For lathe and boring machines
Drive motion- rotary motion of work piece
Feed motion- translatory motion of cutting tool in axial and
radial direction
For drilling machines
drive motion- rotary motion of drill
Feed motions- translatory motions of drill
For milling machines
Drive motion- rotary motion of cutter
Feed motion- translatory motion of work piece


Working And Auxiliary Motion In
Machine Tools (continued)
For planing, shaping and slotting machines
Drive motion- reciprocating motion of cutting tool or
work piece
Feed motion- intermittent translatory motion of work
piece or tool
For grinding machines
Drive motion- rotary motion of grinding wheel
Feed motion- rotary as well as translatory motion of
work piece
Parameters Defining Working
Motion Of Machine Tool
The working motion of the machine tool are defined
numerically by their velocity.
The velocity of primary cutting motion or drive motion is
known as cutting speed
The velocity of feed motion is known as feed.
The cutting speed is denoted by v and measured in units
m/min
Feed motion is denoted by s and measured in following units:
1. mm/rev in machine tools with rotary drive motion, e.g. lathe,
boring machine etc.
2. mm/tooth in machine tools using multiple tooth cutters, e.g.
milling machine
3. mm/stroke in machine tools with reciprocating drive motion, e.g.
shaping and planing machine and
4. mm/min in machine tools which have a separate power source
for feed motion, e.g. milling machine
Parameters Defining Working Motion Of
Machine Tool (continued)
In machine tools with rotary primary cutting motion the cutting speed
is determined by
v = .d.n/1000 m/min
where d= diameter of work piece in mm (as in lathes) or cutter (as
in milling machines)
n= revolution per minute of the work piece or cutter
In machine tools with reciprocating primary cutting motion, the cutting
speed is determined by
v = L/(1000.T
c
) m/min
where L = length of stroke, mm
T
c
= time of cutting stroke, min
If the time of idle stroke in minutes is denoted by T
i
the number of
strokes per minute can be determined by:
n = 1/ ( T
c
+ T
i
) and T
i
< T
c

If K = T
i
/T
c
then n = K/{T
c
(1+K)}
and v = n.L(K+1)/(1000K) m/min
Parameters Defining Working Motion Of
Machine Tool (continued)
The feed per revolution and feed per stroke are related
to the feed per minute by:
s
m
= s.n
where s
m
is feed per minute
s= feed per revolution or feed per stroke
n= number of revolution or strokes per
minute
Feed per tooth in multiple tooth cutters and feed per
revolution are related by: s= s
z
.Z
where s= feed per revolution
s
z
= the feed per tooth of cutter
Z= number of teeth on the cutter
Machine Tool Performance Criteria
Safety
Ease of operation
Accuracy
Precision
Dependability
Production capacity
Productivity
Producibility
Material required to manufacture
Production cost
Level of operating expenses
Appearance


Safety And Ease Of Operation
Safety can be achieved by following measures:
a. Shielding the rotating parts and moving parts of machine tools by
hoods and guards
b. Protecting the workers from chips, abrasive dust and coolant by
means of screens, shields etc.
c. Providing reliable and fool proof clamping for the tool and work
piece
d. Providing reliable earthing of the machine
e. Providing devices for safe handling of heavy work pieces
f. Precluding the accidental pressing of push buttons and handles
g. Providing blocking devices which preclude simultaneous
engagement of conflicting transmissions
h. Providing limit switches for machine tool members and devices for
overload protction

Safety And Ease Of Operation
(Continued)
Ease or convenience of operation:
a. Switches and handles should be located
within reach of operator
b. Force and torque required to operate the
knobs, handles and hand wheel should
be such that fatigue of operator is
minimized
c. Display should be at proper height and
color
Accuracy
The accuracy of a machine tool depend on the
following parameters:
a. Accuracy of guiding elements such as guide ways,
power screws affects the geometrical accuracy
b. Kinematic accuracy is controlled by velocities of two or
more forming motions. It depends on the length of
kinematic train. The short kinematic chain improves
the accuracy of components
c. Increasing rigidity improves accuracy
d. Accurate measuring devices will ensure accuracy of
dimensions.
Productivity
Productivity of a metal cutting machine tool can be expressed as


Where t
c
= machining time
t
no
= nonproductive time such as job and tool handling time,
time of idle travel, set up time, inspection time and unscheduled
delays
= factor that accounts for stoppages for maintenance and
breakdowns
Productivity of a machine tool can be improved by
a. Cutting down machining time
b. Cutting down nonproductive time
c. Carrying out simultaneous operations
d. Improving reliability of the machine tool
.
1
no c
t t
Q

Producibility Or Simplicity Of
Design
Simplicity of design results in ease of
manufacture and operation. This can be done
by:
a. Using standard components
b. Using standardized subassemblies
As a rule general purpose machine tools are
more complex. Special purpose machine tools
are simple in design and can be used for mass
production. Before deciding design
specifications one should restrict one self to
reduce complexity of design
Cost Of Manufacturing And
Operation
Cost of manufacturing a machine tool is
determined by complexity of design. Cost of
manufacture can be brought down by:
a. Simplifying the design
b. Using standard components and
subassemblies
c. Reducing the weight by proper design and
selecting stronger materials
d. Selecting proper method of manufacture
( casting, forging, fabrication etc.)
Appearance

Good appearance of machine tool influences the
mood of operator
This enhances the operators productivity
Different colors are selected for different usage
Light grey, blue and green colors are more
predominant
Covers and hoods are given streamlined shapes
and sharp curves and bends are avoided
Bibliography
Machine Tool Design And Numerical
Control
By
N.K.Mehta
Tata McGraw-Hill Publishing Company
Ltd. New Delhi