Birla Institute of Technology and Science Pilani, Hyderabad Campus

Second Semester 2015-2016

MF F341 DESIGN OF MACHINE TOOLS
Open Book
Test 2 09.04.2016
60 minutes 20%weightage
Answers should be crisp and to the point, Vague or incomplete answers will not get ANY credit

Q1. What are the different types of thick film and thin film lubrication methods used in the machine
tools? [4]

Q2. Design a guide way for a heavy duty lathe machine, considering following specifications and
conditions:
Maximum cutting forces Px= 120 kgf, Py= 130kgf, Pz= 300 kgf
Weight of the carriage, tool post, and tool with other assembly parts = 16 Kgf
Select the maximum permissible value of pressure [pmax] for heavy duty machine tool
operating at low sliding velocity. For the average [pav] to maximum [pmax] pressure relation,
assume that the tool post is mounted on the carriage such that the reactional forces are exactly
acting at the center of the carriage. Hence, xA/L=0.
The horizontal distance from the tip of the tool to the center of the nearest guideway is 30 cm.
The center to center distance of the guide ways is 100 cm. The axis of workpiece supposed to
locate at 60 cm height (vertical) from the centers of guideways.
The length of the carriage cannot be more than 20 cm because of other dimensional
constraints.
Determine the face lengths (a, b, c) for the guide ways. Determine the pulling force (Q) for the
carriage, if the coefficient of friction between the guideway and carriage is 0.2. Also make a
schematic diagram of the guide way with tool and work piece, mentioning all dimensions and
forces/reactions acting. [9+4+3]

Q3. Compute average pressure, maximum shearing stress and pitch error for a lead screw of lathe
machine. The lead screw is double start ACME thread. The various parameters are, Minor
diameter=44mm, major diameter=46mm, Pitch=8 mm, Effective diameter=45 mm, Length of
nut=120 mm, Px=50 kgf, Py=60 kgf, Pz=120kgf, coefficient of friction between the thread and the
nut=0.1, coefficient of friction between the guide and carriage=0.2, weight of carriage = 40 kgf.
[For steel E=2105 kgf/cm2, G=1.6105 kgf/cm2] [10]

Q4. For a lathe machine, the maximum permissible error in diameter during the turning operation is
0.12mm. It is desired to find out the effect of only spindle on the dimensional errors. The
minimum allowed stiffness values of the headstock and tailstock is 4000 kgf/mm, and 2500
kgf/mm respectively. Compute the maximum permissible cutting force in radial direction (Py)
subject to the dimensional accuracy stated earlier. What will be the minimum dimensional error
in diameter corresponding to this cutting force component? [10]

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