Q 1) Write a short note on Vibration of machine tool and dynamic rigidity.

Ans. Machining operations of a machine tool are directly affected by vibrations. These vibrations
affect the machining accuracy, productivity and life of the machine tool. To achieve higher
accuracy and productivity and life of the machine tool, vibrations in machine tool must be
controlled. For analysis of dynamic behaviour of machine tool, rigidity and stability are two
important characteristics.
Machine tool vibrations may be divided into three basic types: 1. Free or transient vibration
2. Forced vibration
3. Self excited vibration (chatter)
Effects of vibrations: 1. Variation of chip thickness, penetration rate, cutting speed, etc
2. Poor surface finish of the work piece.
3. Dimensional accuracy of job is also affected. This is mostly due to chatter vibration.
Chatter marks are proof for the effect of vibration on the work piece.
Causes of vibrations in machine tools: 1. Inhomogeneous work piece material
2. Hard spots or a crust in work piece leads to free vibrations.
3. Discontinuous chip removal results in fluctuation of the cutting thrust. The breaking
away of a built-up edge from the tool face also impart impulses to the cutting tool
Electric motors produce both rectilinear and torsional vibration. Rectilinear vibrations are due to
a non- uniform air gap between the stator & rotor, asymmetry of windings, unbalance, bearing
irregularities; misalignment with driven shaft. Forced vibrations induced by rotation of
unbalanced member affect the surface finish & tool life. This can be eliminated by careful
balancing or by self centring. Rotating components should be placed in position where effect of
unbalance is less.
Gear induced vibration are due to production irregularities, assembly errors, or distortion of
mesh caused by deformation of shafts, bearings and housing under transmitted load. All gear
faults produce non-uniform rotations which affect the surface finish & tool life. Belt drives are
used as filters to suppress high frequency vibration, can induce their own forced vibration. Any
variation in effective belt radius change belt tension and belt velocity
Machine-tool chatter: - chatter is a self-excited vibration which is induced and maintained by
forces generated by the cutting process. It effects surface finish, tool life, production rate and

also produces noise. Chatter resistance of a machine tool is usually characterized by a maximum
stable (i.e. not causing chatter vibration) depth of cut.
Machine-tool chatter is essentially a problem of dynamic stability. A machine tool under
vibration-free cutting conditions may be regarded as a dynamical system in steady- state motion.
Systems of this kind may become dynamically unstable and break into oscillation around the
steady motion
The vibration behaviour of a machine tool can be improved,
1. By reduction of the intensity of the sources of vibration.
2. By enhancement of the effective static stiffness and damping.
3. By appropriate choice of cutting regimes, tool design, and work-piece design.
Q 2) Discuss in brief the functions of Machine Tool Structures and their requirements.
Ans. Machine tool parts, such as beds, bases, columns, box-type housings, over arms, carriages,
tables, etc. are known as structures. The structures, depending upon their function, may be
broadly divided into the following three groups.

Group 1: - beds and bases, upon which the various subassemblies are mounted;
Group 2: - box type housings in which individual units are assembled, e.g., speed box
housing spindle head, etc.; and
Group 3: - parts that serve for supporting and moving the work piece and cutting tool,
e.g. table, carriage, knee, tail stock, etc.

Machine tool structures must satisfy the following requirements:

1. All important mating surfaces of the structures should be machined with a high degree of
accuracy to provide the desired geometrical accuracy;
2. The initial geometrical accuracy of the structures should be maintained during the whole
service life of the machine tool; and
3. The shapes and sizes of the structures should not only provide safe operation and
maintenance of the machine tool but also ensure that working stresses and deformations
do not exceed specific limits; it should be noted that the stresses and deformations are
due to mechanical as well as thermal loading.
The design features that provide for ease of manufacture, maintenance, etc. are peculiar to each
structure and will, therefore, be discussed separately for different structures. However there are
two common features which are fundamental to the satisfactory fulfilment of above requirements
for all structures. These are:
1. Proper selection of material, and
2. High static and dynamic stiffness.

Q 3) What are the various functions of guide ways? Discuss in brief types of guide ways.
Ans. The basic function of guideways is to ensure that the machine tool operative element
carrying the work piece or cutting tool moves along a predetermined path, which is generally a
straight line, as in lathe, drilling, boring machines, etc. or circular as in vertical turret lathes and
boring mills, The major requirements that the guideways must satisfy are:
1.
2.
3.
4.
5.
6.
7.

High accuracy and surface finish of guideway surfaces,

High accuracy of travel, which is possible only when the deviation of the actual path of
travel of the operative element from the predetermined normal path is minimum,
Durability, which depends upon the ability of guideways to retain the initial accuracy of
manufacturing and travel,
Low value of frictional forces acting on the guideway surface to ensure less wear,
Minimum possible variation of the coefficient of friction,
High rigidity, and
Good damping properties.

Based upon the nature of friction between the contacting surfaces of the guideways and
operative element, guideways can be classified as:
1.
2.

Guideways with sliding friction - known as slideways, and

Guideways with rolling friction - known as anti-friction ways.

Depending upon lubrication conditions at the interface of contacting surfaces, the friction
between the sliding surfaces may be described as dry, semi-liquid and liquid. Dry friction occurs
when there is no lubricant between the sliding surfaces. This is rarely if ever, encountered in
machine tools.
Whenever a body slides with respect to another body and there is a lubricant between the two,
the sliding body tends to rise or float due to hydrodynamic action of the lubricant film (Fig.
4.1).
The hydrodynamic force Q may, in general, be represented by the expression: Q=Kb.V

(4.1)

Where, Kb = a constant that depends upon the geometry of the sliding surfaces,
wedge angle , parameters of the lubricant film and viscosity of the lubricant.
v = sliding velocity

Fig. 4.1 Schematic diagram of a slider

If the weight of the sliding body is G, the resultant normal force acting on it is
N = Q - G (4.2)
It is evident from Eq. (4.1) that as the sliding velocity increases, the hydrodynamic force also
increases. As long as Q < G, the sliding body rests on the stationary body and the friction
conditions are of semi-liquid type; under these conditions the two bodies are partially separated
by the lubricant film, but partially experience metal-to-metal contact. When Q> G, the resultant
normal force on the sliding body begins to act upwards and the body floats. The sliding
surfaces are now completely separated by the lubricant film and their interface experiences liquid
friction. The slideways in which a permanent lubricant layer separating the sliding surfaces is
obtained due to the hydrodynamic action are known as hydrodynamic slideways. At low sliding
speeds, a permanent lubricant layer between the sliding surfaces can be obtained by pumping the
liquid into the interface under pressure, high enough to lift the sliding body. Such slideways are
known as hydrostatic slideways.