Introduction to Machine Tool Drives

and Mechanisms
 Machine Tool – Definition,
 Classification of Machine Tools
 Working and Auxiliary Motion & Parameters
 Calculation of Machining Time
 The Design of Machine Tool
 Machine Tool Drives

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 Machine Tool – Definition
 Machine tool is a system of devices in which energy is expended to
produce jobs of desired dimension and finish by Machining. i.e removing
excess material from the workpiece in the form of chips with the help of
cutting tool moved past the work surface at controlled speed and feeds.
 Machine tool is a machine that imparts the required shape to a workpiece
with the desired accuracy by removing metal from the workpiece in the
form of chips.
 Precision machine device is defined as a piece of equipment with one or
more moving parts whose accuracy determines the quality of the device
 The required dimensions and forms of parts are usually obtained by one or
more of the following methods:
 Casting of modern metal in a mold
 Joining of parts by welding or similar methods
 Forging, stamping or other forming processes
 Machining

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 Machine Tool – Definition
 Machine tool does not always apply force and motion to the
tool, but sometimes applies them to the material to be cut,
 Machine tool usually does not including such power tools as
– cutoff saws, shears, punch presses, routers, and the like
• Because , they do not machine metals by “cutting
chips”
 True machine tools also provide:
– Means for accurately controlling the tool to take as deep
or as shallow a cut.
– Means for applying this action consecutively in the
direction needed to obtain the desired finished shape.
– Means for interrupting this action whenever necessary,
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 Machine Tool – Definition
Examples of precision machine devices include:
 MACHINE TOOLS
 Lathes  Coordinate Measuring Machines
 Shaper  Production Equipment
 Drilling Machines  Presses
 Milling Machines  Mechanical watches
 Grinding Machines
 Planer  Etc…
 Sawing Machine
 Gear Cutting Machine
 Broaching Machine

 Machine tool is a mechanism for applying

force and motion to a cutting instrument
called a tool
 Objectives of machine tools are:
i. To produce surface
ii. To trace formed curves
iii. To provide a finish to a given surface
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 Classification of Machine Tools
Machine Tools

General purpose Semi-automatic

Automatic (CNC)
(Manual) (NC)

 By the degree of automation into:

 By the degree of specialization into:
(i) Machine tools with manual control,
(ii) Semi-automatic machine tools, and (i) General-purpose machine tools—which can
(iii) Automatic machine tools. perform various operations on workpieces of
 By weight into: different shapes and sizes,
(i) Light-duty machine tools weighing (ii) Single-purpose machine tools—which can
up to 1 t, perform a single operation on workpieces of a
(ii) Medium-duty machine tools particular shape and different sizes, and
weighing up to 10 t, and (iii) Special machine tools—which can perform a
(iii) Heavy-duty machine tools weighing single operation on workpieces of a particular
greater than 10 t. shape and size.
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 Working and Auxiliary Motion
in Machine Tools
 Working Motion: Motions which are essential to impart the required
shape to the workpiece.
1) Drive motion or Primary cutting motion
2) Feed motions
 Auxiliary Motion: Motions that do not participate in the process of
formation of the required surface but are necessary to make the working
motion fulfill their assigned function (i.e.; clamping and unclamping of
the workpiece, idle travel of the cutting tool to the position from where
cutting is to proceed, changing the speed of drive and feed motions,
engaging and disengaging of working motions, etc.).
 In general-purpose machine tools, most of the auxiliary motions are executed
manually. On the other hand, in automatic machines, all auxiliary motions are
automated and performed by the machine tool itself. In between these two
extremes, there are machine tools in which the auxiliary motions are automated
to various degrees, i.e., some auxiliary motions are automated while others are
performed manually. 6
 Working and Auxiliary Motion
in Machine Tools
 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
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 Working and Auxiliary Motion
in Machine Tools
 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

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 Parameters Defining Working
Motions of a Machine Tool
 Cutting Speed: Distance travelled by the work
surface in a unit time with reference to the cutting
edge of the tool. It is usually expressed in m/min.
 Feed: Distance advanced by the tool for each
revolution of the workpiece. expressed in mm/rev.
 Depth of Cut: Perpendicular distance between the
machined surface and the unmachined surface or the
previously machined surface expressed in (mm).

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 Parameters Defining Working
Motions of a 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 10
Working Motions for a Lathe
Machine Tool

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Working Motions for a Lathe
Machine Tool

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Working Motions for a Lathe
Machine Tool

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Working Motions for Reciprocating
Primary Cutting Motion

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Working Motions for Reciprocating
Primary Cutting Motion

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Calculation of Machining Time

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Calculation of Machining Time

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Calculation of Machining Time

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Calculation of Machining Time

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Calculation of Machining Time

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Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting
Motion

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Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting
Motion- Shaper

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Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting
Motion- Shaper

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Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting
Motion- Shaper

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Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting
Motion- Shaper

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 Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting Motion- Shaper

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 Calculation of Machining Time
Working Motions for Reciprocating Primary Cutting Motion- Shaper

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Calculation of Machining Time

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Calculation of Machining Time
Working motions for Milling and Drilling

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Calculation of Machining Time

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Calculation of Machining Time

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Calculation of Machining Time

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 The Design of Machine Tool
Machine tool design: It deals with the design considerations of the machine
components and the machine as a whole.
Machine tool components: Any machine tool (e.g., lathe, drilling machine,
milling machine, etc.) essentially comprises some major components as common
features such as:
1. Devices for holding the blank and the cutting tool(s) properly and firmly.
2. Devices for providing motions and power to the tool(s) and the
workpiece.

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 The Design of Machine Tool
3. Automation and control systems.
4. Kinematic system for transforming and transmitting the
motions and power from the power source(s) to the tool(s)
and workpiece.
5. Machine tool structures: Heavy structural body to support
and accommodate those systems quite strongly, rigidly and
safely. The types of machine tool structures includes:
i. Beds and bases – sub assemblies are mounted
ii. Housings – individual units are assembled eg speed box,
spindle head
iii. Supporting and moving work piece / cutter – table, carriage,
tailstock etc.

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 The Design of Machine Tool
• The machine tools aspect was very bound by:
– their structure and
– function,
– artistically and
– intellectual conceptions of the epoch.
• The machine tools design is the result of the shape modeling in the
report with functional role.
• In the machine design,
– the shape like an essential characteristic are created for to
–
respond to an aim in
Aesthetic aspect
the using of the user
– Functional requirements
– Ergonomics
• Machine tools design must respect the basic principles of the
design:
– the proportion, the rhythm, the symmetry and the contrast
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The Design of Machine Tool
The putting in proportion for a milling
machine

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 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

1. Safety can be achieved by following measures:

2. Shielding the rotating parts and moving parts of machine tools by
hoods and guards
3. Protecting the workers from chips, abrasive dust and coolant by
means of screens, shields etc.
4. Providing reliable and fool proof clamping for the tool and work
piece
5. Providing reliable earthing of the machine
6. Providing devices for safe handling of heavy work pieces
7. Precluding the accidental pressing of push buttons and handles
8. Providing blocking devices which preclude simultaneous
engagement of conflicting transmissions
9. Providing limit switches for machine tool members and devices
for overload protection
 Safety And Ease Of Operation
(Continued)
 Ease or convenience of operation:
 Switches and handles should be located
within reach of operator
 Force and torque required to operate the
knobs, handles and hand wheel should be
such that fatigue of operator is minimized
 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.
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
Design for Precision
 Productivity
Productivity of a metal cutting machine tool can be expressed as
1
Q .
t c  t no
Where tc = machining time
tno = nonproductive time such as job and tool handling time, time of
idle travel, set up time, inspection time and unscheduled delays
η= 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
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
Engineering Design Process
Applied To Machine Tools

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Engineering Design Process
Applied To Machine Tools

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 Next Lecture:
Machine Tool Drives

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