Department of Mechanical Engineering

Faculty of Engineering & Technology

Manav Rachna International Institute of
Research & Studies
Faridabad (Haryana)

Subject: Design of Machine Tool

Subject Code: BME-DS-725
Second Year – Eighth Semester
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Academic Session: Jan 2021 – June 2021
Course Outcomes:

After completion of this course the students will be able to

BME-DS-725.1 Define the basic concepts and state the general requirement of
Machine tools.

BME-DS-725.2 Understand modern design techniques, they can choose the

suitable drive as per the motion requirement i.e. rectilinear motion, periodic
motion, linear motion etc.
BME-DS-725.3 Familiar about the gearing diagram of lathe, milling, drilling.
The students will know about the various gear drives, gear boxes, gear ratio, load
carrying capacity and their applications.
BME-DS-725.4 Analyze machine tool dynamics, dynamic and elastic system of
machine tool, dynamics of cutting forces and tool chatter.
BME-DS-725.5 Evaluate dynamic performance, cutting forces and tool chatter.
BME-DS-725.6 Develop, modify and design the various machine tools.

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Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad
Syllabus

Part-A
Unit 1: Introduction
General requirements to machine tools, Machine tool design recommendations,
Classification of motions to shape surface, Machine tool drives for rectilinear
motion, Periodic motion, reversing motion etc.
Unit 2: Kinematics of Machine Tools
Kinematics or gearing diagram of Lathe, drilling Machine, Milling Machine
etc. Main drive and feed drive, principles specification of Machine tool.
Unit 3: Design of Kinematics Scheme
Methods to determine transmission ratios for drives,. Development of
Kinematics scheme, minimum of transmission transmission groups,
Determination of number of teeth on gears.

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Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad
 Part-B
Unit 4: Speed and Feed Boxes
General requirement Design of gear trains, speed boxes types, speed changing
devices Feed boxes characteristics of feed mechanism, types of Rapid traverse
mechanisms, variable devices.
Unit 5: Spindle Design and Spindle Bearings
Main requirement, Materials and details of spindle design, Spindle bearings,
bearings, types of bearings and their selections, Bearing Materials BED,
COLUMNS, TABLES AND WAYS; Materials, typical constructions and
design.
Unit 6: Machine Tool Dynamics
Dynamic performance, dynamic and elastic system of Machine, tools.
Dynamics of cutting forces, tool chatter.

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Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad
 Syllabus

Text Book:
1. Sen and Bhattacharya, Machine Tools Design., CBS Publishers
2. N.K. Mehta Machine Tool Design, Tata Mc Graw Hill.

Reference Book:
3. N. Acherkan Machine Tool Design, Four Volumes,.Mir Publishers.,
4. S.K. Basu and D.K. Pal, Design of machine tools, Oxford and IBH 51

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Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad
 Lecture Plan
Lecture No. Topic

1
Introduction to machine tool
2 Introduction to machine tool

3 Requitements to machine tools , machine tool design recommendations

4 Classification of motions to shape surface

5 Machine tool drives

6 Machine tool drives
7 Kinematics or gearing diagram of Lathe machine

8 Kinematics or gearing diagram of Lathe machine

9 Kinematics or gearing diagram of drilling Machine

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 Lecture Plan
Lecture No. Topic

10
Kinematics or gearing diagram of drilling Machine
11 Kinematics or gearing diagram Milling Machine

12 Kinematics or gearing diagram Milling Machine

13 Main drive and feed drive , Principles specification of Machine tool.

14 Methods to determine transmission ratios for drives

15 Methods to determine transmission ratios for drives
16 Development of Kinematics scheme

17 Minimum of transmission transmission groups

18 Determination of number of teeth on gears

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 Lecture Plan
Lecture No. Topic

19
General requirement Design of gear trains
20 Speed boxes types

21 Speed changing devices, Feed boxes

22 Characteristics of feed mechanism,Types of Rapid traverse mechanisms

23 Bearings,Main requirement, Materials and details of spindle design

24 Bearings,Main requirement, Materials and details of spindle design
25 Spindle bearings,

26 Types of bearings and their selections,Bearing Materials

27 Machine Bed, Materials, typical constructions and design

8 Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad

 Lecture Plan
Lecture No. Topic

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Machine COLUMNS, Materials, typical constructions and design
Machine TABLES AND WAYS; Materials, typical constructions and
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design

30 Machine guide ways Materials, typical constructions and design

31 Tool chatter

32 Tool chatter
33 Dynamic performance of machine Tools
34 Dynamic and elastic system of Machine, tools

35 Dynamics of cutting forces

36 Revision

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 Lecture No. Topic

1&2
Introduction to machine tool

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 Introduction to machine tool

1)A machine tool is a power driven device in which

energy is utilized in deformation of material for shaping,
sizing, or processing a product to a desired accuracy by
removing the excess material in the form of chips.

2 They have an in-built arrangement that facilitates the

use of various types of detachable cutting tools that can
be changed to suit the task at hand, and removed for
replacement or resharpening, after wear.

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 Introduction to machine tool

What is Machine &Machine tool ?

 MACHINE TOOLS can regenerate themselves

(as compound to other machines)

 Machine : will do only a particular work like

sewing machine, washing machine and it cannot
make its own parts.

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 Introduction to machine tool

Types of Machine tools

• Lathe
• Planner, shaper
• Milling machine
• Drilling , tapping and reaming machines
• Broach , saw
• Grinders and polishers
• Gear and thread cutting machines

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 Introduction to machine tool

Basic elements of machine Tool

 Work holding devices:- To hold the workpiece in the correct orientation to
achieve the required accuracy.
 Tool holding device:- to hold the cutting tool in the correct position with
respect to the workpiece and provide enough holding force to counteract the
cutting forces acting on the tool. e.g tool post.
 Work motion mechanism:- to provide the necessary speeds to the
workpiece for generating the requisite surface e.g head stock
 Tool motion mechanism:- to provide the various motions needed for the
tool in conjunction with workpiece motion in order to generate the different
surface profiles as desired e.g carriage
 Support structure:- to support all the mechanisms as shown above and
maintain their relative position with respect to each other and also for
relative movement between the various part to obtain the requisite part
profile and accuracy. e.g bed

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 lathe machine

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 Planner and shaper

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 Milling

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 Drilling

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 Essential requirements of a machine tool

a) Low cost- the initial cost of the machine tool as well as the cost of production
should be low.
b) High accuracy- the machine tool should be capable of producing high quality
products at highest possible speed.
c) High useful life- the machine tool should render a trouble free service while
retaining its accuracy for longer period.
d) Low maintenance cost- the maintenance of machine tool should be easy and
maintenance cost should be low.
e) Reliability – the machine tool should retain accuracy over a period of its life.
f) Ease of operation- it should be easy to operate the machine tool.
g) High production capacity- it is defined as the ability of machine tool to machine
a definite number of workpiece in unit time.
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 OBJECTIVE OF MACHINE TOOL

1) PRECISION :- means accuracy with which a job can be

manufactured on a machine tool. it depends on static stiffness

and strength of the machine tool.

2) Productivity :- means the volume of material removed per minute

from the work piece.it depends on the dynamic stiffness of the

machine tool.

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 Selection of machine tool

• The type of product required

• Degree of accuracy required

• Amount of metal to be removed

• Size of the work piece

• Quantity of product required.

21 Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad

 CHARACTERISTICS OF MACHINE TOOL

• It should be powerful.

• It should be capable of operating at high speed.

• It should be rigid.

• It should be durable.

• It should be safe in operation.

• It should have good lubrication facilities.

• It should be simple in design.

• There should be safety and convenience of control.

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 Purpose of machine tool

Machine tools are generally used for two purposes:

1) To produce certain forms

2) To produce finished surfaces

The form of surfaces produced depends upon the shape of the cutting

tool and the relative path of motion between the cutter and workpiece.

The relative motion also known as working motion, between cutter

and workpiece can obtained either by motion of workpiece or cutting

tool or by a combination of both.

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 Classification of Machine Tools

Machine
Tools
General Semi-
Automatic
purpose automatic
(CNC)
(Manual) (NC)

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 Classification of Machine Tools

1) Machine tools can be classified according to size: light duty

(weighing less than 1 ton), medium duty (1 to 10 tons), and heavy
duty (above 10 tons)
2) According to the method of actuation: manually operated, semi-
automatic, and fully automated.
3) Purpose: general purpose machine tools, which can be used for
a wide variety of operations, on a range of sizes of workpieces,
and special purpose machine tools, for specific operations, on a
limited range of workpiece sizes and shapes.

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 Classification of Machine Tools

4) Types of motions used for removing material.

Rotary cutting machines rotate workpiece (turning lathes, capstans,
turrets, autos), or the cutting tool (drill, milling cutter, grinding wheel),
or both (cylindrical grinder).
Linear cutting machines remove material by moving the tool
(shaping, slotting), or the workpiece (planning, surface grinding), in a
straight line.
In both the types of machine tools, linear motion is used for moving
(feeding) the workpiece or the tool, to mate (engage) them for
material removal.

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Department of M.E./ F.E.T./ Manav Rachna International University/ Faridabad
 Selection of machine Tool depends upon

• The type of product required.

• Amount of metal to be removed.

• Size of workpiece

• Quantity of product required.

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 Procedure to design machine tool

• Decide material for structure

• Decide manufacturing process such as
a) Casting
b) Fabricated
Type of structure
c) Open
d) Closed
• Force acting on structure which can cause bending and twisting
• Take into account weight of structure, weight of work piece etc.
• Nature of vibrations to be generated during work piece.
• The structure should have sufficient stiffness and strength.
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 Classification of Motion in machine Tool
In order to obtain the required shape on the work piece it is necessary that the cutting tool should move in the
particular manner with respect to the work piece.
There are two types of Motions in a Machine Tool.
a)Working motion
b) Auxiliary motion
Working Motion:- in machine tools the working motions are powered by an external source of energy such
as electrical or hydraulic. The process of chip removal is effected by the working motion of machine tool
which are transmitted either to the cutting tool, or to the work or to both simultaneously.
Working motions of a machine tool are of the following types:-
a) Primary cutting motion or drive motion
b) feed motion
Both primary cutting motion and feed motion is specified by speed or feed rate.
Primary cutting motion:- it provides for cutting the chip from the blank at the cutting speed equal to the
velocity with which the chip leaves the work. The most commonly used types of primary cutting
motions are of two types:
Rotary primary cutting motion (rotary motion may be transmitted either to the work as in the lathe group of

29 machine tool or the tool as in grinding machine, drilling machine, milling machine.)
 Classification of Motion in machine Tool
Resiprocating primary cutting motion:- This type of motion is used in shaper, planer, slotter,
powerhacksaw and broaching machine. In such machines tools the cutting cycle consists of a working stroke
during which the tool cuts the chip and the idel or return stroke during which the tool or work returns to its
initial position. The speed of return stroke should be kept higher than that of working stroke in order to reduce
the non productive time in machining.
Feed Motion:- The rate of feed or speed of the feed motion is substantially less than the cutting speed.

Auxiliary Motion:- the auxiliary motion do not take part in the process of formation of the required surface
but are none the less necessary to make the working motions to fulfil their assigned function.
The various types of auxiliary motions in machine tools are as follows.
 Engaging and dis-engaging of working motions
 Changing the speed of drive and feed motion
 Clamping and unclamping of work piece
The auxiliary motions may be carried out manually or they may be automated in automatic machine tool.

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 Working motions for some machine tools

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 Working motions for some machine tools

1) For lathe and boring machines:-

Drive motion- rotary motion of workpiece
Feed motion – translatory motion of cutting tool in the axial or radial
direction.
2) For drilling machines:-
Drive motion- rotary motion of drill
Feed motion- translatory motion of drill
3) For milling machines:-
Drive motion – rotary motion of cutter
Feed motion- translatory motion of the work piece.
4) For shaping, planing and slotting machines:-
Drive motion- reciprocating motion of cutting tool
Feed motion- intermittent translatory motion of workpiece.
5) For grinding machines:-
Drive motion- rotary motion of grinding wheel
Feed motion- rotary as well as translatory motion of the work piece.

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 Machine tool drives

 Machine tool drives are used to transmit motion from power

source to the operative element of the machine tool.
 The general requirement for the machine tool drives is that they
should have provision for regulating the speed of travel of the
operative element.
 The transmission system for cutting and feed motions constitute
drive and are obtained by a chain of higher pair.

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 Classification of Machine tool drives
Machine tool drives may be classified as electrical, mechanical or
hydraulic and as stepped or stepless.
In all drives, the motive power is provided by an electric motor. This
power is transmitted to the spindles, slides, tables etc. in such a
manner that the movement of the motor shaft is transformed
through the drive elements into the required cutting and feed
motions.
The ideal drive should possess the following characterstics.
1) It should be able to provide the necessary range and number of
cutting speeds and feed rates.
2) Cutting speed and feed rate changes should be obtained
without interrupting the machining operation.
3) Power loss in the drive should be minimum.
4) The drive should be compact
5) Full power should be available at all working speed.
Stepped drives provide only a finite number of output speed.
Stepless (or infinitely variable) drives are ideal because they are
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capable pf producing speed ranges with infinitely fine steps.
 Classification of Machine tool drives

According to:-
Source of power
Transmission system
Nature of motion produced
The machine tool are universally driven by electric motors and
further transmission is obtained by any of the following methods.
a) Mechanical drives using belts, gear trains, chains, leadscrew
and nut etc.
b) Hydraulic drive
c) Electrical drive.

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 Classification of Machine tool drives

In mechanical drives the transmission of motion from external

source to the operative source to the operating element can take
place through mechanical elements such as gears, belts, chains
etc.
Mechanical drives may be stepless type or stepped type but
hydraulic drives and electrical drives are invariably stepless in
nature.
Mechanical transmission is used for transmitting rotary as well as
translatory motion to the operative element.
Hydraulic transmission is used in machine tool for providing rotary
as well as translatory motion.
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 Selection of drives

Depend upon the following factors:-

 Surface finish and accuracy desired
 Production time
 Simplicity of design with respect to maintenance, repair and
control.
 Power to weight ratio.
 Optimum efficiency.

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 Types of drives

1) Individual drive
2) Group drives

Individual drive:- if a machine or machine tool is driven by its own prime mover (motor, diesel
engine etc) then it is called as individual drive.
There is considerable economy of power for driving any machine.
In case of motor failure, a particular machine remain idle and this doen’t affect the working of other
machines.
Give a better look and there is practically no chance of any accident.
Power loss are small.
Replacement of belt takes very little time
Layout is very simple
Gives a wide speed variation and better control of speed range.

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 Types of drives

Group drives

1) If one motor or prime motor rotates a number of machine tools by the help of main shaft, then
it is called as group drive.
2) This type of drive can be seen only in old machine shop.
3) The motor is fixed to the floor and its power is transmitted to the main shaft.
4) The main shaft transmits the power to various machine tools through counter shaft and loose
and fast pulleys.

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 Mechanical drive

In a mechanical drive the transmission of element will depend upon

the type of conversion needed between the drive shaft and the
driven shaft.
1. Conversion of rotary motion into rotary motion:-
The following transmission elements are used to convert rotary motion of
the drive shaft (input shaft) to the rotary motion of the driven shaft (output
shaft)
a) Belt drives:- in such drives a pulley is mounted on the drive shaft and
another on the driven shaft and the motion is transmitted from the
drive pulley to the driven pulley with the help of belt.
b) Chain drives:- Roller chain and silent chain are employed in machine
tool drives. The direction of the rotation of the driving sprocket and
driven sprocket is same.
c) Toothed gearing:- toothed gearing serves for transmitting motion
between parallel , intersecting and crossed shafts. straight tooth and
helical tooth spur gears are used to connect parallel shaft. For
intersecting shaft , straight or spiral bevel gear are used and for
crossed shaft, worm gearing is used.
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 Belt drive

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 Chain drive

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 Toothed gear

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 Mechanical drive

.
2. Conversion of Rotary motion into rectilinear
reciprocating motion :-
The following kinematics links are used to convert rotary
motion into rectilinear motion .
a) Rack and pinion – if the pinion is rotated on the driving
shaft the rack will travel in straight line. For one revolution
of the pinion the travel of the rack will equal the number of
teeth on the pinion.

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 Mechanical drive

.
b) Worm and rack – upon rotation of the worm the travel
of the rack takes place.

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 Mechanical drive

c)
.
Screw and nut – rotation of a screw fixed in an axial direction will
cause a nut held against rotation to travel in a straight line along the
screw . If on the opposite the nut is fixed axially and rotated the screw
will travel axially when it is held against rotation.

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 Mechanical drive

d)
.
Slider and crank – the number of strokes per min of the slider crank
mechanism equals the speed in rev/min of the driving crank.

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 Mechanical drive

.
3. Mechanisms for periodic (intermittent ) rotation :-

Periodic rotation mechanisms include a stop with pin

a) Ratchet device combined with crank or crank
mechanisms
b) Geneva mechanisms.

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