11 Introduction to Machine Tools

Learning Objectives
The contents of this chapter would enable the readers to:
Express the exact roles of machining and " List the elementary machining operations gen
machine tools in manufacturing. erally carried out in the conventional machine
Define machine tools, identify their common tools.
features and state the functions of their major Identify the major aspects associated with
Components. machine tools.
Visualize the basic configurations of the pri
mary machine tools.

11.1 Introduction
Finishing by machining through gradual material removal from blanks started about thousand years ago.
For instance, logs of irregular sizes and shapes were machincd to produce cylindrical rods with the required
dimensional accuracy and finish for specific advantageous applications. The machining was done by sharp
edged stones as cutting tool and employing reasonable tool-work motions and energy manually.
Need for strong and hard materials, such as various metals and alloys; innovation; development: and grow
ing demand for rapid production and good product quality result in improvement of design, development
and wide use of machine tools starting from centre lathes, drilling machines, shaping. planing and sloring
machines, milling machines and so on. With time and demand several other machine tools such as boring
machines, gear shaping and hobbing machines, broaching machines, etc. have also come up.
The common features of all such conventional machine tools include (a) firm holding of the job and the
tool, (b) kinematic system to transfer motions and power from the power source(s), mostly electric motors, to
the job and tool and () che strong and robust body structure. Anumber of machine tools are used to accom
plish different types of machining operations - turning, drilling, boring, shaping, milling, etc. - to produce
cylindrical surfaces, Aar surfaces, contour surfaces and parting, slitting, slotting, grooving,etc. Machine tool
engineering covers several aspects: planning, design, manufacture, installation, inspection, operation and
maintenance of machine tools. Allsuch points have been briefily highlighted in this chapter.

11.2 Definition and Role of Machine Tool

With the rapid and vast developments in science and technology, innumerable techniques and processes
of manufacturing products, of various materials, configuration and precision have been innovated and
420 Machining and Machine Tools
removal and
- forming, joining
incorporated." All these processes are grouped into four major categoricsmachining
by and grinding by which
rgeneratie.The removal process in manufacturing is accomplished
accuracy and surface finish for proper functioning,
jobs are semi-finished or finished to desired dimensional Preforming like casting, forging, rolling, etc.
improved performance and longer service life of the products. engineering products need machining after pre
cannot provide such accuracy and finish, hence most of the powerful and robust machines called machine
torming. Machining and grinding inevitably require use of come
tools. Therefore, without machine tools not only several engineering components but also other machines and
industries and socio-economy are extremely depen
cquipments cannot be produced. Hence, manufacturingseveral ways0; one comprehensive definition is:
dant on machine tools. Machine tool can be defined in to pro
machine tool is a non-portable and poweroperated device or system of devices in which energy is espendedblank(s)
A removing excess material from the preformed
duce jobsofdesired dimension and finish by machining, that is, work surface at contolled speeds and feeds.
the
in the form of chips with the help of cutingtool(s) moved past
and Their Functions
11.3 Major Components of Machine Tools
machine, etc.) essentially comprises some major
Any machine tool (e.g., lathe, drilling machine, milling
components as common features such as:
1. Devices for holding the blank and the cutting tool(s) properly and firmly.
workpiece.
2. Devices for providing motions and power to the tool(s) and the and power from the power source(s)
3. Kinematic system for transforming and transmitting the motions
to the tool(s) and workpiece.
4. Automation and control systems.
quite strongly, rigidly and safely.
5. Heavy structural body to support and accommodate those systems
between the workpiece and the
Machining in any machine tool needs proper contact and relative motions cutting power from the power
tool. The firmly held tool and the workpiece receive the desired motions and the number of mechanisms. The
drive of the machine through a kinematic system comprising various types and
slide along the guides provided on
cutting tool or workpiece may be mounted on a table, which is made tocomprises
the machine tool body. The robust structural body of the machine tool a base, bed, column, legs,
machine tool are firmly
etc. depending on the type and size of the machine tool. The base or columnsof the guides to enable
grouted on a proper foundation. The bed and columns of the machine tool are provided with
the slides holding the work or tool move in desired directions. Besides this, a machine tool essentially also
too-work motions.
possesses systems of varioustypes for manual or automatic control of the

11,4 General Configuration of Common Machine Tools

and Their Uses
11.4.1 Centre Lathes
Lathes, especially centre lathes, are most widely used in machine shops for their versatility. General con
figuration of centre lathe is shown in Fig. 11.1. The major components and their functions in acentre lache
are as follows:
1. Headstock: This heavy housing, being mounted on the bed at its left end, receives power and motion
from the motor and transmits the same to the workpieces through a clutch, speed gear box (SGB)
 Introduction to Machine Tools 421

Tool post Job(rod) Tailstock

Tool
Headstock
SGB

www
FGB +
Rack
-Feed rod
Leadscrew
Bed
Carriage

Figure 11.1 | Configuration and salient features of centre lathe.

and the spindle contained in the headstock housing, Thus, the headstock enables rotating the work
piece at different speeds as required.
2. Tailstock: This relatively smaller body can be shifted and fixed at any location on the lathe bed coaxi
ally with the headstock. The main functions of the tailstock are to provide support to long and heavy
workpieces and often hold and move some cutting tools for operations like driling, reaming, etc.
3. Carriage: This heavy part with a number of mechanisms and parts in it is made to slide along the
lathe bed. The carriage firmly holds the tools and moves it at different feed rates. The carriage derives
motions usually from the spindle through a feed gear box (FGB) and a feed rod or lead screw.
4 Bed: This rigid bulky horizontal beam stands firmly on two legs or columns. On the bed, the head
stock remains bolted, the tailstock is shifted and clamped and the carriage slides.
5. Work-tool holding devices: The blanks are usually mounted in berween centres or chucks, whereas
curting tools are generally held in the tool post which is mounted on the saddle. Tools are also offen
held in the tailstock quill.
The common and frequent uses of cenre lathes include the following:
1. Turning, which is of rwo types external and internal. These can be furher subdivided into straight,
taper, stepped, contour.
2. Facing, chamfering, grooving, parting, etc.
3. Centering, drilling, reaming, boring, etc.
4 Thread cutting: external and internal.
5. Knurling,
done in
Some of these operations are schematically shown in Fig. 11.2. Several other operations can also be
centre lathes using suitable attachments.

11.4.2 Shaping Machine

their
The general configuration of shaping machine' is shown in Fig. 11.3. The major components and
functions in a shaping machine are as follows:
Ram: This salient part is made to reciprocate horizontally along a fixed guide and provides the cut
ting motion to the tool being mounted in front of the ram.
 422 Machining and Machine Tools

Grooving Forming Threading

Turning Facing

External

Internal

Figure 11.2 Some common machining operating done in centre lathe.

motions to the
2. Bed: This heavy rigid body moves slowly along the horizontal guides to provide feed
blank mounted on the bed.
main driving
3. Housing (body) with base: This hollow but rigid large structure accommodates the
mechanisms and provides support to the moving ram and the bed. mechanisms.
change
4. Power drive: It is the source of power and motion with spced and feed
Shaping machines are generally used for machining lat surfaces in different planes, grooving, splitting, etc.
of shaping machines has now-a-days been limited to
Because of poor productivity and process capability, useindustries.
only piece production and maintenance work in small

Clapperbox Ram
Tool
Job
Housing
Vice
Power drive

Bed

Base

Figure 11.3 Configuration of shaping machine.

11.4.3 Planing Machine

The general configuration of planing machine is shown in Fig. 11.4. Paning machines also do almost the
same type of machining operations as done in shaping machines. However there are some differences; the
major ones are as follows:
 Introduction to Machine Tools 423

-Frame

Tool.
Job
Table
Power
Bed drive

Base

Figure 11.4 |General configuration of planing machine.

1. In planing, the table with the job reciprocates to impart cuting motion and the tool moves slowly
for the feed motion unlike in shaping machine.
2. Planing machines are usuallymuch larger and heavier than shaping machines and are used for large
jobs and heavy duty work.

11.4.4 Drilling Machine

Drilling machines are used!' mainly to produce straight cylindrical holes in solid bodies with the help of
drill bits. Drilling machines widely vary in configuration and size. Figure 11.5 typically shows configura
tion of a commonly used column type drilling machine. Drilling machine (column type) comprises the
following:
1. Column: A long hollow but rigid vertical structure which stands on its base and provides support to
theother components.
2. Drilling head: This box type body accommodates the power drive and the gear boxes to adjust speed
and feed.
3. Spindle: This rod-like component is rotated and axially moved along with the coaxially mounted
drill to impart both cutting motion and feed motion to the tool.
Drilling machines of different sizes and configurations are used
1. Mainly for creating or enlarging straight cylindrical holes.
2. Ocasionally for boring, counter boring, counter sinking, etc.
3. Often for cuting internal threads in objects like nuts using suitable attachments.

11.4.5 Milling Machine

The general coniguration of typical knee type conventional milling machinewith horizontal arbour is
shown in Fig. 11.6. Its major parts are as tollows:
1. Milling arbour to hold and rotate the cutter.
424 Machining and Machine Tools

Drilling Feed
head Speed gear
gear box
box

Spindle
Column
Drill

Bed

Base

Figure 11.5 | Configuration of a typical drilling machine.

Ram

Cutter
job

Speed
gear
Feed box
gear
box

Base

Flgure 11.8 | Contiguration of atypical drilling machine.

 Introduction to Machine Tools 425

Surtacing Slotting Grooving Slitting Forming

Figure 11.7 Some common milling machines.

2. Ram to support the arbour.

3. Machine table on which job and job holding devices are mounted to provide the feed motions to
the job.
4. Power drive with speed and feed gear boxes to provide power and motions to the tool-work.
5. Bed which moves vertically upward and downward and accommodates the various drive
mechanisms.
6. Column with base which is the main structural body to support other parts.
Milling machines are also quite versatile and can do several operationssuch as:
1. Making Aat surfaces in different planes.
2. Grooving, slitting and parting.
3. Helical grooving.
4. Forming 2-D and 3-D contoured surfaces.
Figure 11.7 shows some of theaforesaid milling operations. More detailed discussions with several illustra
tions are provided in the subsequent chapters.

11.5 Major Aspects of Machine Tools

The major aspects of machine tools engincering and their functional interrelations are indicated in
Fig. 11.8. Amachine tool manufacturing industry first makes a proper planning and critically decides,
after thorough survey of the market demands and socio-economy, the category, type, capacity, precision,
automation, etc. of machine tools they will manufacture. After selection, the machine tools are designed
and then manufactured accordingly. Atdifferent stages and completion of manufacture, cach prototype is
inspected and tested. The customer or the users first select from these manufactured and available machine
tools according to their need and satisfaction. Afrer purchase, the machine tool is mounted and installed on
a suitable foundation. Before regular use or operation, the machine tool has to be properly commissioned
and tested. During and after operations, the performance of that machine tool is assessed mainly in terms
of productivity and product quality. If the performance is not sarisfactory, the causes are analysed and the
experts prepare a list of corrective measures to be undertaken by the operator, maintenance section or even
designer and manufactures of that machine, immediately or later for desirably good or better performance
of that machine tool.
 426 Machining and Machine Tools
Foundation and installation
Design Manufacture Selection

Testing
Operation

Maintenance Assessment

Modification/
Corrective measure Analysis
improvement

Figure 11.8 Major aspects associated with machine tools.

SuMMARY
The roles of machining and machine tools in
manufacturing industries and on socio-economy
have been highlighted. A reasonable definition of
machine tool has been provided. AIl the conven
tional machine tools possess some common features
and components for serving specific purposes. This
has been briefly addressed. The general configura
tion, major parts and their features and purposes
have been presented with respect to some primary
machines: drilling machine and milling machine.
The elementary machining operations that are car
ried out in these machine tools are also illustrated.
The general applications of the different classical
machine tools have been mentioned here.
Machine tool engineering has obviously become
a great concern in manufacturing and a feld of pro
fessional interest of several sections of people. The
major aspects and the interactive modules of activi
ties that are associated with machine tool engineer
ing have been highlighted in this chapter. The actual
work done in machine tools through generation of
geometrical surface by using Generatrix, Directrix
and tool-work motions is discussed in the next
chapter.

MULTIPLE CHOICE QUESTIONS

[Answers are provided in the CD]

1. Machine tool helps manufacturing products (c) Do not deal with any energy
by (d) Both produce and use energy
(a) Joining process 3. The machine that can be called machine
(b) Metal forming process tool is
(c) Removal process (a) Stamping machine
(d) Regenerative process (b) Shearing machine
2. Machine tools (c) Rolling machine
(a) Produce energy (d) All of the above
(b) Utilize energy (e) None of the above
 Introduction to Machine Tools 427

4. While machining, the workpiece rotates in

(a) Lathes
(b) Drop forging
(c) Hot rolling
(b) Drilling machines (d) Machining
(c) Shaping machines 8. The operation that cannot be done in lathes is
(d) Milling machines (a) Enlarging cylindrical hole
5. While machining, the cutting tool always (b)
rotates in
Internal thread cutting
(c) Parting
(a) Centre lathes (d) Knurling
(b) Shaping machines (e) None of the above
(c) Planing machines 9. The oldest machine tool is
(d) Milling machines (a) Lathe
6. The process which cannot be called preform
(b) Shaping machine
ing is (c) Planing machine
(a) Rolling (d) Milling machine
(b) Forging 10. Flat surfaces are not produced in
(c) Machining (a) Lathe
() Welding (b) Drilling machine
7. Maximum dimensional accuracy and surface
(c) Shaping machine
finish can be achieved by (d) Milling machine
(a) Sand casting

REVIEw QUESTIONS
1. How can 'machine tool' be defined? What
socio-economic roles are played by machine
tools for the industries and the nation?
2. Name the major components common to all
conventional machine tools and the functions
of those components.
3. Show by simple diagrams the various ma
chining operations that are generally done in
lathes.
4. State the locations and functions of the head
stock, tailstock and carriage in centre lathes.
5. How are planing machines different from
shaping machines?
6. By sketching a simple line diagram ofa drilling
machine, visualize the location and position of
the tool, workpiece, base, spindle, column and
motor in that machine.
7. Show by line diagram, a milling machine and
visualize its ram, column, bed and tool-workpiece
mounted in that machine.
8. Show by suitable diagrams some (at least five)
common machining operations that are con
ducted in milling machines.
9. Where and how the cutting tool and he
workpiece are mounted in shaping machine
and planing machine?
10. Describe briefly, with the help of a block dia
gram, the major aspects that are associated
with machine tools engineering,. Also show the
inter-connections amongst those aspeCts.