MTD M2

NOTES

Cutting speed variation

V=\

General purpose machines, used for a range of workpiece sizes and materials call for a much wider
variation in rotary speeds (N) (RPM)

Stepped variation

Provides a limited number of fixed rotary speeds

Stepless variation

Can provide infinite number of speeds, within the maximum and minimum values

For example, the speed can have any value between 159 to 212 RMP, in a stepless variation

Stepless variation is necessary when there is a wide variation in the hardness of the workpiece
material.

Stepped variation: Ray diagrams

Graphical representations called ray diagrams (or speed charts) can be conveniently used for
designing rotary stepped drives.

They show the input source as a single point which is connected to the points for rotary output
speeds (N), by lines similar to the rays emanating from a light source.

Figure shows the ray diagram for the previous example, where the input source is an electric motor,
running at 750 R.P.M
Here the minimum RPM is 159.1 and maximum is 212.2, there are two steps between them which is
represented in the figure

A wide variety of gearboxes utilize sliding gears or friction or jaw coupling.

The selection of a particular mechanism depends on the purpose of the machine tool, the frequency
of speed change, and the duration of the working movement.

The advantage of a sliding gear transmission is that it is capable of transmitting higher torque and is
small in radial dimensions.

Among the disadvantages of these gearboxes is the impossibility of changing speeds during running.

Clutch-type gearboxes require small axial displacement needed for speed changing

The extreme spindle speeds of a machine tool main gearbox Nmax and Nmin can be determined by
Stepped and stepless output

Need for providing variation in rotational movements

The variation of the speed of spindle is necessary because

1) To machine jobs of same materials but having different diameters of job

2) To machine jobs of different materials
3) To use cutting tools of different shapes and compositions
4) For removing material at various cross-sectional areas of chips requiring different amount of
power such that:
a) Tool life is kept approximately constant,
b) Material is removed at approximately constant power input for different cutting
conditions requiring different torque at the output
5) Cost of machining should be low

Constraints for speed (RPM)

there are two constraints

1) Power constrains
2) Tool life constraints
1) Power constraints
The power output at the spindle is given by

2) Tool life constraints

Cost consideration for selecting speed and feed rate in machine tool

A machining operation should be conducted at such values of cutting parameters (speed, feed, depth
of cut etc.) that ensures the minimum cost price of the machined component.

The machining cost is expressed by the equation:

𝑪 = 𝑪𝒎𝒕 + 𝑪𝒏𝒑𝒕 + 𝑪𝒕𝒄 + 𝑪𝒕

The provision for regulating the spindle rpm and feed rate is an essential requirement of machine
tools to ensure economic machining of work pieces of different materials and sizes by cutting tools of
different shapes and composition.

VARIOUS LAWS OF STEPPED REGULATION

What should be the criterion for choosing the discrete steps between two extreme available values
n1 and n2 of the spindle rpm.

For choosing the discrete values of spindle rpm, there are four cases from which the most suitable
law of speed range distribution is chosen
For the same number of stages and same extreme values of speed in rpm, there are number of ways
to take intermittent steps.

The various steps of rpm values will have different operational characteristics

A. RPM VALUE IN ARITHMETIC PROGRESSION

An arithmetic progression is a sequence of numbers such that the difference of any two
successive members is a constant.
If the initial term of an arithmetic progression is n1 and the common difference of successive
members is a, then the nth term of the sequence is given by
n1=n
n2=n1+a
n3= n1+2a
nz = n1 + (z - 1) a
Points to be noted for AP

1) Suppose the machining of the work piece of diameter 212 mm is started.

2) For a cutting speed of V= 20 m/min, the value n1 = 30𝑟𝑝𝑚 will correspond to the optimum
cutting. Before speed changes to next rpm i.e., n2 = n1+a= 61.4 𝑟𝑝𝑚 one must remove
108.3mm of metal from the work piece diameter.
3) This required 11 passes assuming a permissible depth of cut 5mm
4) During all passes except the first one, the machining is uneconomical as the actual cutting
speed would be less than the permissible value.
5) On the other hand, in changing over an rpm value of n11 = 344𝑟𝑝𝑚 𝑡𝑜 n12 = 375𝑟𝑝𝑚 one
has to reduce the work piece diameter only by 1.6mm though one can actually remove more
than this allowance in one pass.
6) So, for arithmetic progression, at high-speed range some values of speed steps are
redundant,
7) Whereas in the low rpm range there is clearly a need to add steps between the calculated
values.

In order to make the machine performance equally feasible in the whole range, the lower rpm values
of rpm should be brought still closer while high rpm values can be widening a little

So, the arithmetic progression does not permit economical machining at large diameter ranges

Application:

Stepping speeds according to arithmetic progression are used in Norton gearboxes or gearboxes with
a sliding key when the number of shafts is only two.

B. RPM VALUES IN GEOMETRIC PROGRESSION

General purpose machines have to use different rotary speeds for different workpieces.
As the R.P.M. of the spindle varies inversely with the workpiece (cutting) diameter, it is
convenient to organize the intermediate rotary speeds in a geometric progression.
In this arrangement, the next, higher rotary speed is a constant multiple of the preceding
speed.
The multiple is called 'Step (progression) ratio' (ϕ). If the minimum rotary speed is ‘n' R.P.M.,
the higher speeds will be as below:

n1=n,
n2=n1ϕ,
n3= n2ϕ =n1ϕ2,
For No. of speeds = z
nz=nz-1ϕ = n1ϕz-1
POINT TO BE NOTED FOR GEOMETRIC PROGRESSION

A) Before the change over from a speed n1 = 30𝑟𝑝𝑚 to n2 = 37.5𝑟𝑝𝑚, an allowance of 42mm
must be machined from work piece diameter. For the maximum depth of cut 5mm, this
allowance may be removed in four to five passes.
B) In changing over from n11 = 300𝑟𝑝𝑚 𝑡𝑜 n12 = 375𝑟𝑝𝑚 one has to take the depth of cut of
2.1mm which can be easily accomplished in one pass.
C) It is seen that in order to make the machine performance equally feasible in the whole range,
the lower rpm values of rpm should be brought still closer while high rpm values can be
widen a little.

Geometric progression gives smaller increments at lower rotary speeds, and bigger steps at higher
rotary speeds. This is very convenient and economical, due to the following reasons:

a) The cutting diameter decreases with each cut which progressively decreases the actual linear
cutting speed (v).
b) General purpose machines have to use different rotary speeds for different workpieces. As
the R.P.M. of the spindle varies inversely with the workpiece (cutting) diameter, it is
convenient to organize the intermediate rotary speeds in a geometric progression.
c) In this arrangement, the next, higher rotary speed is a constant multiple of the preceding
speed
C. RPM Values in harmonic progression
Harmonic progression is developed from the idea that diameter range served by each rpm of
the progression is equal
 POINT TO BE NOTED FOR HARMONIC PROGRESSION

1) It is observed from the table below that in order to change the speed from n11 = 183
𝑟𝑝𝑚 𝑡𝑜 n12 = 375 𝑟𝑝𝑚 the work piece diameter must be reduced from 35 mm to 17
mm.
2) On a slender work piece of 35mm, a large depth of cut cannot be taken as this would
lead to deformation of the work piece.
3) If 2mm assumed as a permissible depth, the total allowance will be machined in four to
five passes
4) It may be concluded that in Harmonic progression the RPM values in high range are too
wide apart making this range uneconomical.

GEAR BOXES FOR MACHINE TOOLS

Requirements of Gear Boxes for Machine Tools:

a) Provide adequate spindle speeds

b) Transmit desired power
c) Provide smooth silent operation of the transmission and accurate rotation of the spindle
without vibrations.
d) Simple construction in respect of total number of shafts, gears, clutches, bearing and control
system components.
 e) Ease of carrying out preventive maintenance and to make the adjustments in bearing
clutches etc. by taking care of easy access.

The gear box may be built either into the spindle head (or head stock) or be designed as a separate
unit

Gear boxes designed integral with spindle head provide a more compact spindle drive, are easy to
assemble.

However, in these, vibrations from the gear box may be transmitted to the spindle gear boxes and
also heat produced in the gear box may heat the spindle head.

In the case of gear boxes with a divided drive, the gear box and spindle head (head stock) are
designed as separate units and the gear box is linked to the spindle head through some type of
transmission such as belt transmission. In these gear boxes the heat produced in the gear box by
friction losses and vibrations are not transmitted to the spindle head.

DESIGNING OF SPEED BOX

SELECTION OF RANGE RATIO

The following information's are required for stepped drive design

A. The highest output rpm, nmax

B. The lowest output rpm, nmin
C. The number of steps Z into which the range between nmax and nmin is divided
D. The number of stages in which the required number of speed steps are to be achieved

After selecting proper value of Rv and Rd, the range ratio Rn is determined.
Typical values of Rn for some machine tools are given in table.
Rn value of general-purpose machine tool are high- as a variety of cutting tools of different shapes
and composition are used

Rn value is small in For Grinding machine - range Rd <2

Rn value for the special purpose machines is also low- less variation in tools
For machine tools rpm constitutes a Geometric progression (G.P.)

WHY GP: BETTER DESIGN FEATURES

A) rpm can be obtained by mounting new gear pairs on the shaft every time (practically not
feasible as it is time consuming, and we will have a large non-productive time)
B) Speed steps in gear box can be obtained through group transmission between a number of
shafts. This can be achieved if rpm value lies in geometric progression. This is due to the
following features of G.P.
WHY G.P.? CONSTANT LOSS OF ECONOMIC CUTTING SPEED IN THE WHOLE RPM RANGE IN G.P.

Loss of economic cutting speed= The difference between the actual cutting speed and optimum
cutting speed
SELECTION OF VALUES OF COMMON RATIO, Ф

The standard value of ф is established from the following two main considerations:

First condition:

a) In machine tool drives two speed motors are often used; the ratio of the two speeds
generally equal to2 (e.g., motors have rpm values of 3000 and 1500, or 1500 and 750, etc.)
b) If the spindle rpm values constitute geometric progression for the lower rpm of the motor,
then according to the property of geometric progression, the spindle speeds should increase
two times when the motor speed is switched to higher one.
c) This means that if there is a spindle rpm value of nx, then after a certain number of steps R1
there must occur a spindle rpm value=2nx

d)

Second Condition:
The geometric progression should be developed by keeping the standards of preferred numbers and
preferred series. The geometric progression should then satisfy the condition.

The geometric progression should be developed by keeping the standards of preferred numbers and
preferred series
The factor between two consecutive numbers can be the 5th, 10th, 20th, or 40th root of 10 (approx.
1.58, 1.26, 1.12, and 1.06, respectively). These are called R5, R10, R20 and R40.
The factor between two consecutive numbers can be the 5th, 10th, 20th, or 40th root of 10 (approx.
1.58, 1.26, 1.12, and 1.06, respectively). These are called R5, R10, R20 and R40.

ADVANTAGE OF PREFERRED NUMBER

Preferred Numbers are an important tool which minimize unnecessary variations in sizes.
The complete range is covered by minimum number of sizes, which is advantageous for both
producer and customer.

With the acceptance of standardization, there is need to keep the standard sizes or dimensions of
component in discrete steps.
With the acceptance of standardization, there is need to keep the standard sizes or dimensions of
component in discrete steps.

The sizes should be spread over wide range and at the same time, they should be spaced properly.
e.g., diameters are to be standardized between 10mm to 25mm, then sizes should be 10mm,
12.5mm, 16mm, 20mm, and 25mm. This lead to use the geometrical series known as preferred
series.

It includes R5, R10, R20, R40, R80 series and each series has a series factor.

SELECTION OF VALUES OF COMMON RATIO, Ф (Conclusion)

a) For particular value of range ratio

b) The number of speed steps increases with a reduction in the value of ф.
1) It is desirable to select a small value of ф so that the loss of economic cutting speed and
hence, productivity loss is low.
2) But a large number of speed steps make the drive complicated and expensive.
c) Proper value of ф must be selected to make the balance
d) The most commonly used values of ф are 1.26, 1.41, and 1.58
e) Lower values complicate the drive (ф=1.12& 1.06), better to use stepless drive
f) Large values (ф= 1.78 & 2.0) lead to large production loss. They are rarely used in special
machine tools

The large value of ф is used on small –sized machine tools whereas small values of ф are used on
large-sized machine tools.
DESIGNING THE LAYOUT OF A MECHANICAL DRIVE

Speed transformations from the input to the output shaft are obtainable through
a) A cone pulley driven head stock using belts and gear
b) A geared headstock using tumbler gears, or change gears or sliding clusters or clutched gears

Cone pulley drive

Advantages of cone pulley drive given bellow them:

1) Simple in design and Low investment

2) Noiseless and smooth running which is particularly useful in finishing operations
3) High mechanical efficiency due to less friction loss.
4) Rubberized belt drives can absorb shocks due to overload. For this reason, most of the
machine tools have at least one belt drive in the drive belt
5) Particularly no influence on the dimension and the size of the electric motor.
6) Cheaper where the motion is transmitted over a relatively long distance.

However, cone pulley has following limitations

1) Large number of steps are not available

2) Rate of production is slow through loss in speed structure
3) Handling time for setting a speed is more
All geared head stock

A single pulley all geared headstock is often preferred to cone pulley drives because of the following
advantages in spite of their initial cost.

a) A great increase in output power due to high initial belt speed

b) Quick speed changes obtainable by levers
c) Saving the floor space
d) Large life to the driving delt because shifting is eliminated

REQUIREMENT FOR ALL GEARED HEAD STOCK

 1) Should have sufficient speed changes.
2) Should be obtained without stopping the machine if possible.
3) Any speed should be obtained without passing through the intermediate speeds.
4) Only gears required for power should be engaged at a time.
5) Least possible gears, shafts and levers are used
6) To prevent interference when shifting gears, the difference between pitch diameters of
adjacent gears on the same shaft or in the sliding cluster should be at least 4 teeth.
7) Same module should be used as far as possible
8) Axial length of gear train is the shortest when gear cluster is made sliding. Sliding cluster
should not have more than 3 gears.

ARRANGEMENT OF SPEED CHANGING IN ALL GEARED DRIVE:

1. Sliding Key Method

2. By tumbler gear

The tumbler gear is swung by an arm while the input gear is slide along shaft II to mesh with any
desired gear in the gear cone in shaft I. then the tumbler gear is swung back and locked in position.

This system is also used in feed drives.

 3. By using plate or claw clutches

Here two sets of speeds are obtained once by engaging the clutch, and another time by disengaging
the clutch

4. By using clusters
Here a set of gears slide on the shaft to engage another set of gears one at a time so as to
provide a number of output speed.

The methods of speed change with cluster gears or clutched drives are used for spindle
drives when main power is transmitted.
SPEED STRUCTURE DIAGRAM
The drawback of structure diagram is that it does not indicate the actual rpm of the intermediate
points or actual gear ratios and is only an indicative of connective patterns.

Structure diagrams are always shown in bilateral fashions and can be either open (O) or crossed (X)
type.

Basic Rules

1) Each arrow must connect follow-up arrows until the output stage are arrived.
2) At the output level, one and only one arrow must connect an output point. Never, should
two or more arrows lead to one output point. However, any number of arrows (preferably
not more than three) can be generated from an input point.
3) All output points must be connected by arrows.
4) Never, an arrow should end up beyond the bounds of the required output r.p.m. at the final
stage.
5) Arrow that stands for a particular connection (gearing) must be drawn parallel when
repeated for another set in the same stage
 RAY DIAGRAM

For quantitative assessments of speed layouts, structure diagrams are converted into ray
diagrams
The Ray diagram indicate exact locations of speeds and input-output points.

In last example: four speed 2x2 layout of open type (admissible structural diagram)

It can be converted into 15 ray diagrams.

The input point varies from lower speed to the upper speeds

1,2,6,7,11, or 12 will require very long connection from motor input (i.e., very high transmission
ratio)

The smallest connecting link at input stage will be for 4, 9, and 14. Hence they are the preferred ray
diagram.

However, the selection of best ray diagram (or optimised ray diagram) is subjected to several
constraints (we will read it in subsequent sections)
DECISION MAKING FOR THE BEST RAY DIAGRAM OF GEARBOX

The gearbox of derived speed requirements requires that it must be the optimum design with
respect to

a) Size

b) Number of gears, shafts levers etc.

c) Cost (size is kept small to minimize the cost, they are interrelated)

Size is dependent on the following rules:

(i) Ray restriction

(ii) Stage restriction
(iii) Shaft size minimization
D = diameter of shaft in cm