MACHINE TOOLS

WEEK 1
Machine Tools, Basic Concepts and
Classifications

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Weekly Subjects and Related Preparation Studies

Week Subjects Related Preparation

1 Machine tools, basic concepts and classifications Lecture Notes Part 1

2 Constructive structures of machine tools and elements Lecture Notes Part 2
3 Drive systems and mechanisms in machine tools Lecture Notes Part 2
4 Functions of lathe Lecture Notes Part 2
5 Working principles of lathe and its mechanism Lecture Notes Part 3
6 Working principles of drilling machine tool and its mechanism Lecture Notes Part 3
7 Working principles of milling machine tool and its mechanism Lecture Notes Part 3
Working principles grinding and superfinish machine tool and their
8 Lecture Notes Part 4
mechanism
9 Midterm 1
Working principles of broaching and planing machine tools and their
10 Lecture Notes Part 5
mechanism
11 The functions, working principles and mechanisms of gear benches Lecture Notes Part 6
12 Saw cutting machine tools and their mechanism Lecture Notes Part 7
13 Numerical controlled machine tools - general principles Lecture Notes Part 8
14 Machine tools for micro and nano machining and smart machine tools Lecture Notes Part 9
15 Final
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Recommended English Books
M.P. Groover PRINCIPLES OF MODERN John Wiley.

MANUFACTURING

Helmi A. Youssef, MACHINING TECHNOLOGY: CRC Press, 2008

CRC Press,
Hassan 2008
El-Hofy MACHINE TOOLS AND OPERATIONS

P.H. JOSHI MACHINE TOOLS HANDBOOK: TATA McGRAW-HILL

PUBLICATION, 2007
DESIGN AND OPERATION

N.K. MEHTA MACHINE TOOL DESIGN AND TATA McGRAW-HILL

PUBLICATION, 1999
NUMERICAL CONTROL

G.C. SEN PRINCIPLES OF MACHINE TOOLS New Central Book

Agency, 2011
A.BHATTACHARYYA
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Recommended Turkish Books
Erhan ALTAN LECTURE NOTES / DERS NOTLARI

Faruk AKÜN MACHINE TOOLS (VOL 1-2)/ İTÜ Yayınları,

TAKIM TEZGAHLARI (CİLT 1-2) 1973-1978
MUSTAFA AKKURT MACHINING SCIENCE AND TECHNOLOGY, Birsen Yayınevi,
CNC MACHINE TOOLS AND PRODUCTION 2009
AUTOMATION /
TALAŞ KALDIRMA BİLİMİ VE TEKNOLOJİSİ
CNC TAKIM TEZGAHLARI VE ÜRETİM
OTOMASYONU
H. Oktay BODUR MACHINE TOOLS / Birsen Yayınevi,
TAKIM TEZGAHLARI 1984

Faruk MENDİ DESIGN OF MACHINE TOOLS / Gazi Kitapevi, 1999

TAKIM TEZGAHLARI TASARIMI
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Evaluation and Exams
 One midterm (8th week)
(effectiveness of the midterm is 30%)

 Two quizzes
(effectiveness of each quiz is 10%)
 One homework
(effectiveness is 10%)
Details about the content of the homework will be given in
following weeks.
 One final exam (effectiveness is 40%)
 Reset Exam
 MACHINE TOOLS
Description of Machine Tool

It is a machine for shaping or machining

metal or other rigid materials, usually
by cutting, boring, grinding, shearing or
other forms of deformation. Machine
tools employ some sort of tool that does
the cutting or shaping.
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What is machine tool?
Power driven machine which is capable of
producing various shapes in metal by using
various sources.

Power driven machine which is capable of

producing various shapes in metal by cutting
away the surplus material (called chip) using
sharp cutting tool.
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What is machine tool?
Machine tools are machines that
give special forms to the materials in
desired shapes and tolerances.

These can be metal forming,

machining, welding, casting machines
or plastic processing machines, non-
traditional manufacturing machines
etc.
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History of Machine Tools

As a device of production, the use of machine

tools has begun since history of humanity.
However, with the beginning of the Industrial
Revolution in Europe (I. Industrial Revolution)
at the beginning of the 19th century, machine
tools showed a rapid development with their
current meaning.

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History of Machine Tools

The most significant developments in manufacturing

methods are observed in the “Industrial Revolution” which
developed in England after 1870. With the industrial
revolution, societies are oriented towards a rapidly
expanding mechanization. Within this period, technological
inventions gradually increased the production, while the
physical effort spent on production was gradually reduced.
In particular, the inventing of steam engine is a
technological revolution in the manufacturing industry. In
this period, manpower was replaced by machines.

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History of Machine Tools

Towards the end of 19th century, the principles of manufacturing

technologies were introduced and serial manufacturing (2nd
Industrial Revolution) started.

The great development in the field of machine tools started with the
introduction of numerical controlled (NC) machine tools in the
1950s. First of all, CNC (computer numerical control) and then DNC
(direct numerical control) machine tools were developed by
equipping these NC machine tools with computers. Thus, production
at the optimization level was performed.

At this stage, robot systems were started to be used (3rd Industrial

Revolution) to create robot factories (unmanned factories) by using
software including CAD/CAM systems as well as equipment.

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History of Machine Tools

Industrial revolutions throughout history;

1. Steam machine used in mechanical machine tools to use

the steam power efficiently. – INDUSTRY 1.0
2. Production line development by Henry Ford's production
line design and starting the use of electricity in mass
production. – INDUSTRY 2.0
3. Programmable machine tools caused mechanical and
electronic technologies to be replaced by digital technology
in production in the 1970s. – INDUSTRY 3.0
4. Industry 4.0 is an industrial strategy plan that is expected
to start the 4th Industrial Revolution. – INDUSTRY 4.0

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 MACHINE TOOLS
CLASSIFICATION

Machine tools/machines can generally be classified into 6 main

groups;

1. Machine tools in casting methods (squeeze casting machines

etc.)
2. Machine tools in forming methods (presses, rolling machines,
etc.)
3. Machine tools that are used in the processing of plastic materials
(extruders, etc…),
4. Machine tools that are used in the material processing with
physical and chemical methods (non-traditional methods).
5. Machine tools in welding methods
6. Machine tools in machining methods
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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

A- According to the geometrical shapes of

the workpieces
B- According to the number of the
workpieces
C- According to the functions of the
machines
D- According to the types of control
 CLASSIFICATION OF MACHINE TOOLS IN MACHINING
According to the
According to
Geometrical According to the According to the Types
the Number of
Shapes of the Functions of the Machine of Control
the Workpiece
Workpiece
Machining cylindrical
Simple Lathes Manual
surfaces
Machining flat Mechanical
Universal Milling machine tools Automatic
surfaces NC

Making holes Production Drilling machine tools

Machining profiles Special Shaper/planer

Transfer Sawing machine tools

Numerical
Grinding machine tools
controlled

Modular Broaching machine tools

Super finish machine tools

Gear cutter machine tools

Thread cutter machine tools

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

According to the geometrical shapes of workpieces.

1. Machine tools for machining cylindrical surfaces (lathes)

2. Machine tools for machining flat surfaces (milling machines,

shapers, planers)

3. Machine tools for making holes (drilling machines)

4. Machine tools for machining profiles (milling machines,

hobbing machine tools)

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

According to the number of workpieces

1. Simple Machine Tools

2. Universal Machine Tools (general purpose)
3. Production Machine Tools (special purpose)
4. Special Machine Tools (limited purpose)
5. Transfer Machine Tools
6. Numerical Controlled Machine Tools
7. Modular Machine Tools

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

1. Simple Machine Tools

These kinds of machine tools have only one shaft.

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 MACHINE TOOLS
CLASSIFICATION OF MACHINE TOOLS IN MACHINING

2. Universal Machine Tools

These machines can be used for many aims. The
capacity and the efficiency of these machines are low,
the amortized value is high and the necessity of
qualified workers are the disadvantages of these
machines.

They can be used for almost any type of application,

but the speed of production is very low.

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 MACHINE TOOLS
CLASSIFICATION OF MACHINE TOOLS IN MACHINING

2. Universal Machine Tools

Universal Milling Machines
Universal Turning Machines
spindle chuck tool-post tail-stock tail-stock wheel

lead-screw
carriage wheel carriage cross-slide wheel
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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

3. Production Machine Tools

These machines are used only for special application
or aim. These machines provide the work to be done
in a short time without the necessity of qualified
worker. These kind of machines can be used for bulk
production in small scales.

Slightly more productive than general purpose

machine tools and are used for production purposes.

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 MACHINE TOOLS
CLASSIFICATION OF MACHINE TOOLS IN MACHINING

3. Production Machine Tools

Capstan/Turret Lathes

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

4. Special Machine Tools

These machines can be used for special aims and

these machines are more economic and have high
efficiency.

They are specially made for mass production and

are designed for particular application.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

4. Special Machine Tools

They are used for highly automated production
processes, where the production rate is very high.
They are least flexible.
Example: automated lathes

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

5. Transfer Machine Tools

 Transfer machine tools can have one station or multi station.

In general, these machines have several stations for
performing various machining processes and these stations
are designed in a special range of next to each other. These
machines are for the net shape bulk production and generally
automatic.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

5. Transfer Machine Tools

 Workpieces are fed into the machine and automatically
indexed from station to station. Each station simultaneously
performs a different operation on the workpiece and they exit
the machine as a partially or completely finished unit.
Standard transfer machine systems consist of multiple,
sequential mechanical components, such as machining heads,
transfer devices, indexing tables, and work.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

5. Transfer Machine Tools

 Workpieces are held by stationary or traveling fixtures and
indexed in a circular or linear path. In the course of a cycle,
components pass through each work station undergoing
specific machining operations. The indexing table turns either
vertically or horizontally and supports both continuous and
intermittent movement. When combined with an automated
transfer line for part feeding, transfer machines amplify
production rate.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

5. Transfer Machine Tools

 They are used in the mass production of metal parts for a
variety of industries, such the automotive and industrial
machinery industries. Custom systems exist for
manufacturing discrete components.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

6. Numerical Controlled (NC) Machine Tools

NC: is a first generation numerical controlled machine tool. It is a
hardware based machine tool rather than software. There is no
programming flexibility. For each part, it cannot be easily performed for
purpose.
CNC: is a second generation numerical controlled machine tool. In these
types of machine tools, a flexible system is provided by software.
Depending on the machine features and using special codes (such as
G00, G03, M04, M08), the part program is written and transferred to the
machine tool.
DNC: is a third generation numerical controlled machine tool. These
machines are connected directly to the host that performs the
production in the enterprise and the program transfer is on-line.
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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

6. Numerical Controlled (NC) Machine Tools

 These machine tools can be used to machine complex geometrical parts in high
amount. The manufacturing time is short and the efficiency is high.
 The demand of fixturing, controlling and measurement equipment is low in NC
machine tools.
 Numerical controlled machine tools (NC, CNC, DNC) should not be only used for
mass production purposes.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

6. Numerical Controlled (NC) Machine Tools

 The usage of numerical controlled machine tools for complex and few parts
provides advantage and economy.
 The parts can be machined in high quality with these machine tools. The cutting
speed increases as the number of axes increases.
 The best example is the usage of these machines is mold production shops.

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

7. Modular Machine Tools

 Machining of the stationary workpiece by rotating tools

 High manufacturing quality with simultaneous operations

 Customized equipment due to modular design

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Comparison of Machine Tools

Simple Universal Production Special Machine Transfer Numerical Modular

Machine Machine Machine Tools Tools (limited Machine Controlled Machine
Tools Tools (special purpose) purpose) Tools Machine Tools Tools
(general
purpose)
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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

7. Modular Machine Tools

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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

According to the functions of the machines

• Lathes
• Drilling Machine Tools
• Milling Machine Tools
• Shaper / Planer / Slotter
• Grinding Machine Tools
• Sawing Machine Tools
• Broaching Machine Tools
• Gear Cutter Machine Tools
• Super Finish Machine Tools
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CLASSIFICATION OF MACHINE TOOLS IN MACHINING

According to the types of control

Manual Automatic

Mechanical

NC

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BOUNDARY DIAGRAM OF MACHINE TOOLS

From the cutting tool-workpiece-process trio;

In a broad sense, A MACHINE TOOL consists of the kinematic system
which provides the motions required for the process, the part and the
tooling systems required for mounting and demounting of workpiece and
cutting tool, the auxiliary systems such as the lubrication, cooling, chip
disposal, lighting etc., and the body system carrying all these systems.

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BOUNDARY DIAGRAM OF MACHINE TOOLS

Tooling
Part System
System

Material
Machined
Energy Workpiece Cutting Tool
Part
Information

Kinematic
System
Auxiliary
Systems
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Relative Motions

Shaping/cutting in the machine tools is the results of relative

motions created between the workpiece and the cutting tool.

In this respect, motions can be divided into three groups;

(1) Main (cutting) motion,
(2) Feed motion and
(3) Auxiliary (adjustment) motion.

Various machining methods are presented by performing

these motions with the cutting tool and/or the workpiece.

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