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LECTUR'E~03: FORMS-OF;KINEMAIIC.
. ,

STRUCTURE IN MACHINE TOOts· 7

DR. NIKHIL R. DHAR

Professor, IPE Department
BUET

Role of Kinematic Structure in Machine Tools

• The desired formative and the auxiliary motions (along with power) of the tool-
wnrk in machine tools are derived from the power source (S) with the help of a
number of kinematic chains (KC). Each of the tool-work motions need a
separate and usually different kinematic chain which is comprised of a number
of mechanisms or devices connected in series. For example, the kinematic chain
that derives job rotation from the main motor in a centre lathe is comprised of a
:/-: belt-pully system, a clutch, a speed gear box and the spindle which are
f;ii,, connected in series. Again, the gear box itself is made of number of
1¢; mechanisms. The kinematic chains usually accomplish:
\~
;r}
• Transfer of motion (and power) from the source(s) to the tool and work
• Transformation of motion;
IIJ rotation to rotation (different speed)
lll rotation to translation (and often vice-versa) or oscillation
II direction of motion
Ii splits one speed into number of speeds (rpm)
~ r. N. R. Dh~r, Professor, De[Jaitment oflndustrial and Production Engineering, BUET I I 78/3 ~

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The overall system of all the kinematic chains taken together in a machine
tool is called kinematic structure of that machine tool. This is schematically
depicted as follows (Fig.14). In the figure, Si denotes power source (i=l ,2 ..),
II KCi denotes kinematic chains (i=l,2 ... ), mij denotes mechanisms and Mi
denotes motions (i=l,2 .. ). Mathematically the relations can be expressed as
'
KC\= ~:>11U=1,2,3 .......) sources (S)
(motO<S)
kinemaUc chains
KC,
1001-work
moUons (M)
I

KS = 2:KC;(i=l,2,3.......)= LLmlj @-----1~ - ----(3)

j i j

Where,S power sources &-I~ ·-·-·--cfil

KC kinematic chains ~KC3

m mechanisms &-- ·-·-·---·-DD

M motions
KS kinematic structure
@---I mn1 mn2 mn3 mn4

Fig.14: Constitution of kinematic structure of machine tools

-
t!-}')i Dr. N. R. Dhar, Professor, Department oflndustrial and Production EnRineering, BUET I I 78/32

Different forms of Machine Tool Kinematic Structure

It is known that the kinematic structure of any machine tool consists of all its
kinematic chains which with the help of series of several mechanisms
transmit power and motions from the power sources, after desired
transformations, to the tool and work. Kinematic structure of any machine
tool may be broadly classified into three types depending upon the nature of
interconnections of the kinematic chains, as follows:
Elementary (Kinematic) Structure: This is the simplest type of kinematic
structure where all the kinematic chains are independent and hence the
number of kinematic chains is equal to the number of power sources and
also obviously equal to the number of tool-work motions. This kind of
structure can be symbolically denoted as Eii where, E stands for
elementary, the first i stands for number of power sources and second i
stands for number of kinematic chains (KCs). The value of i may be
1,2,3.. .. ..

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l .,:ll Dr. N. R. Dhar, Professor, Department of Industrial and Production [Link], BUET I I 78/4g

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Complex (Kinematic) Structure: This is very common kinematic

structure where all the kinematic chains (KCs) are interconnected or
interdependent, and hence, the number power sources is only 1 (one)
irrespective of number of kinematic chains.
• Complex structures are symbolically expressed by C1j, where, j =
2,3,4 ...... .. indicating number of kinematic chains.
II Compound (Kinematic) Structure: It is actually combination of E and
II C type structures. Here, some of the kinematic chains (KCs) are
independent and some are interdependent.
• Compound structures are symbolically expressed as Kij• where,i is
the number of power sources (i = 2,3,4 ...... ) and j is the number
i) of kinematic chains (KCs) G= 3,4,5 .. .... ). For example, K23 =
1.·, C12 + E11
I ~ 1[ Dr. N. R. Dhar, Professor, Department of Industrial and Production Engineering, BUET I I 1s141 /

Different Tvpes of Kinematic Structures in Machine Tools

Elementary Structures (Eii): One typical application of E22 is shown in Fig.15.
The cutting motion and the feed motion, imparted to the job and the tool
respectively, are provided from two individual motors by two independent
Kinematic chains. Such lathes are used when the feed rate needs precision ,
control by DC or stepper motor independent of cutting velocity.
r-----~~~
L _ BP
_ ________
C SGB .J

BP - belt and pulley C - clutch 5GB - speed gear box FGB • food gonr box

Fig. I 5: Kinematicchains for the tool-work motions in centrelathe

Other examples of Eii structure
E11 -for broaching machine usually having only one motion (tool) by only one
Kinematic chain and one power source.
: .,, Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/4~

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I E4cfor 3-axis CNC milling machine, where the spindle rotation and the three
feed motions are provided by four independent sets of power source and
Kinematic chain
Complex Structure (Cli): Fig.16 visualizes a typical C12 type complex
Kinematic structure of a centre lathe where the two Kinematic chains are
interdependent and derives the cutting motion and the feed motion from only
one motor.

BP · bell and puDey C • dutch SGB • speed gear box FGB • feed gear bolC
Fig.16: Typical complex Kinematic structure of type C12 for centre lathe

-!-~ Dr. N. R. Dhar, Professor, De artment oflndustrial and Production En ineerin , BUET 78/431

Some lathes have provision for simultaneous longitudinal and cross feed
for the tool for turning taper etc. The Kinematic structure of such lathe
would be C13 type as indicated in Fig.17, where three kinematic chains,
producing rotation of the job and two feed motions of the tool are
interconnected havim1 onlv one nower source.
CM

Fig. I7: Typical complex kinematic structure of type C13 for Centre lathe
Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/4~

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Fig.18 visualizes another application of C13 structure in Hobbing Machine

while cutting the teeth of straight toothed spur gears. There are three tool
work motions needed; cutting motion, CM (tool rotation) Indexing motion,
IM (gear blank rotation) and tool (hob) feed motion, FM.
I

Fig. I 8: Kinematic structure (C 13) of Hobbing Machine

78/45]
! _.;_, Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , SUET

All these three motions are derived from a single motor by three
interconnected kinematic chains;
(i) Motor KC 1 rotation of tool (hob), CM
(ii) Tool rotation KC 2 indexing motion IM of blank c,
(iii) Blank rotation KC 3 tool feed motion FM
where, KC 1 -c 1 - C2 - SGB - C3 - C4
KC 2 - C4 - C5 - D - !GM - C6
KC 3 - C6 - FGB - C7 - feed screw
SGB, 1GB and FGB are the speed gear box, indexing gear box and feed gear
box respectively. The nodal points indicated by C1, C2, C3 etc. are also some
mechanisms. D is a summation (differential) mechanism. Actually, the
kinematic structure of Gear Hobbing Machines is C14 type having another
interdependent kinematic chain needed for cutting the teeth of helical gear.
1-.~ Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , SUET 78/4~

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Compound Structure (Kij): An application of a simple type compound Kinematic

structure, K23 is schematically shown in Fig.19. Here the Kinematic chains
providing work feed (rotation) motion and the tool feed motion are interdependen~
and ~onnected to a motor, Ml and thus constitute C12 structure. Grinding motion
provided by another motor, M2 can be taken as E11 . Thus combination of C12 and
E11 results in the compound structure K23 =C 12+ E11 . Similarly, kinematic structures
like Ess, C1s and K24 also exist and used in different machine tools.
WFM

.
C - clulch
BP - belt pulley
Fig. I9: Compound kinematic structure of type K
Dr. N. R. Dhar, Professor, De artment oflndustrial and Production En ineerin , BUET 78/4~

Mechanisms used in Machine Tool Kinematic svstems

• Mechanisms are generally referred to the devices or systems that are used for
transformation of motion from one form to another desired form and / or
transmission of motion from one point to another desired point.
• For example, screw-nut system is a very common mechanism that enables
transformation of rotation (of the screw) into translation or linear motion (of
the nut). Belt pulley system, with open belt and two pulleys of same
diameter, is another common mechanism which only transmits rotation from
one point to another point. The following classes of mechanisms are most
widely used in machine tools:
Mechanisms for transmission of rotation and its transformation w.r.t.
speed, direction and axis of rotation i.e. Rotation to Rotation.
Mechanisms for transformation of rotation to translation or
reciprocation; i.e. Rotation to Translation.
Differential mechanisms for summation of two or three motions into one.
@( or. N. R. Dhar, Professor, Department of Industrial and Production Engineering, BUET I I 78/4~

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Mechanisms for Transforming Rotation to Rotation: These mechanisms

refer to those elementary mechanical units that are used to change
rotation in respect of one or more speeds, direction, location of action and
axis of rotation. Such mechanisms are further classified as;
Stepped Drive or Stepless Drive
Ii Non-positive Drive or Positive Drive
1: Stepped Drive and Stepless Drive: Stepped drives refer to having a
discrete number and values of speeds (rpm) as output from a given input
speed i.e. if input speed is N1, output speed(s), N0 will be N 1, N2, N3 -----
-- N0 • Whereas stepless drive refers to deriving any speed Ni as output
within a range, say NL (lowest) to Ng (greatest), from a given single input
speed, N1, i.e., for N1, N0 = Ni where NL~ Ni~ Ng
-
- Dr. N. R. Dhar, Professor, Department oflndustrial and Production Engineering, BUET I I 78/4~

Fig.20 schematically presents the basic difference between stepped drive and
stepless drive. However, stepped drives have wider use in conventional
machine tools. Stepless drive helps in using the desired optimum speed.
inpul (speed), N1 ( 1 Ni 7~ 1------- -

stepped driver stepless driver

Fig.20: Difference between stepped drive and stepless drive
Non-positive Drives and Positive Drives: The drive, where there are chances
of slip and non-constancy of transmission ratio, is considered non-positive,
viz. belt-pulley drive, friction roller drive etc. Whereas, positive drive refers
to revention of sli and consistent transmission ratio viz. ear drives.
! .o, Dr. N. R. Dhar, Professor, De artment oflndustrial and Production En ineerin , BUET I 78/Stj

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I The best example is wide application of belt (mostly V-type and often flat type) and
pulley (step or cone type) system in machine tools. The main advantages are:
• safety, by slipping at overloading
• easy transmission over longer distance
prevention of transfer of vibration from the motors to the machine tool.
•
The major limitation of such drive is chances of slip and undesirable change in
I
transmission ratio. Hence non positive drives, are avoided where motions need to
Ir,
be synchronized as in rotations of the gear blank and the cutter in Hobbing
Machine. The best example of positive drives are a follows:
• Chain and sprocket system
Gearing system for transmission as well as transformation of rotation between;
• parallel shafts
non parallel shafts whose axes, if extended, intersect
non parallel and non intersecting shafts

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~!~l Dr. N. R. Dhar, Professor, Department of Industrial and Production EngineerinQ, BUET I I 78/51[

--

Stepped Speed Drives

Feed Gearboxes: Feed gearboxes are designed to provide the feed rates
required for the machining operation. The values of feed rates are
determined by the specified surface finish, tool life, and the rate of material
removal. The classification of feed gearboxes according to the type of
mechanism used to change the rate of feed is as £ lows:
Feed gearboxes with pick-off gears: Used [Link]i.....-_;,....r:==::i
in batch-production machine tools with
infrequent changeover from job to job, such
as automatic, semiautomatic, single-
purpose, and special-purpose machine
tools. These gearboxes are simple in design
and are similar to those used for speed
[Link] shown in Fig.21.
Fig.21: Pick-off Gears
Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78l5zj

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Feed gearboxes with sliding gears: These gearboxes are widely used in general-
purpose machine tools, transmit high torques, and operate at high speeds. Fig.22
shows a typical gearbox that provides four different ratios. Accordingly, gears
Z2, Z4, Z6, and Z8 are keyed to the drive shaft and mesh, respectively, with gears
z,, Z3, Z5, and Z7, which are mounted freely on the driven key shaft. The sliding
key engages any gear on the driven shaft. The engaged gear transmits the
11
motion to the driven shaft while the rest of the gears remain idle.
11
The main drawbacks of such feed boxes are the power loss and wear occurring
due to the rotation of idle gears and insufficient rigidity of the sliding key shaft.
Feed boxes with sliding gears are used in small and medium-size drilling
machines and turret lathes.
Norton gearboxes: These gearboxes provide an arithmetic series of feed steps
that is suitable for cutting threads and so are widely used in engine lathe feed
gearboxes as shown in Fig.23
i 9 Dr. N. R. Dhar, Professor, Deoartment oflndustrial and Production EngineerinQ, BUET I I 781531

I\:,
l , 13
z,,,, z, z. z,

t z,
8
. z.
!'j

I
z, ,. z. z,
Fig.22: Feed gearboxes with sliding gears

Yoke

Driven " sliding

gear gear
Sliding gear
Fig.23: Norton gearboxes

,,.,.,-: Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/5~

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Mechanical Stepless Drives:

Toroidal and Reeves Mechanisms: Fig.24 shows the Toroidal and Reeves
variable speed transmission, which consists of a pair of pulleys connected
by a V-shaped belt; each pulley is made up of two conical disks.
These disks slide equally and simultaneously along the shaft and rotate
with it. To adjust the diameter of the pulley, the two disks on the shaft are
1, made to approach each other so that the diameter is increased or
decreased.
I!
The ratio of the driving diameter to the driven one can be easily changed
and, therefore, any desired speed can be obtained without stopping the
machine.
Drives of this type are available with up to 8:1 speed range and IOhp
capacity

Dr. N. R. Dhar, Professor, Deoartment of Industrial and Production EnQineering, BUET I I 781551

t.40YernMlof <OM ~
n, = constant n, = constant

(a) (c) Mwemeni ol cont puleys

Fig.24: Toroidal stepless speed transmission: (a) n2 < n1 Fig.24: Toroidal and
(b) n2 = n1and (c) n2 >n1 Reeves Mechanisms

Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/5§

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. -.
Positive. . Infinitelx V:aria. bl e Drive · F " 25 c,_,
a pos1t1ve torque tran . . · 1g. shows
consists of two h . sm1ss1on arrangement that n _ Sh,aftl _ _ •

consists of a . c am wheels, each of which -

- -- .......
«- -
- ..
the shafts in ftt'r o'. co~es t~at are movable along

I I
5rwlofl ll - • • - •
e axial d1rect 10 n - 5,clr,r, - '
The teeth
• of• th e c h am
· wheels are. connected by a
spec1a
et 1 cham · B Y rotating. the screw, the levers
g h . moved thus changing the location of the
c a1~ pulleys, and hence the speed of rotation
pr_ov1des a speed ratio of up to 6 and is available (b)n 2 <n 1
(a) n2 > n 1
with power rating up to 50 hp.
The _use of infinite variable speed units in Fig.25: Positive infinity
variable drive
ma~hm_e tool drives and feed units is limited by
their higher cost and lower efficiency or speed
range .
181,1,
Dr. N. R. Dhar, Professor, Deoartment of Industrial and Production En"ineering, BUET 1
r

Electrical Stepless Speed Drive: Fig.26 shows the Leonard set, wh ich consists
of an induction motor that drives the direct current generator and an exciter ( E) .
The DC generator provides the armature current for the DC motor, and the
exciter prov ides the field current; both are necessary for the DC moto rs t hat
drive the machine tool.
The speed control of the DC motor takes place by adjusting both the annature
and the field voltages by means of the variable resistances A and F, respecti vel y.
de motor
Machine
tool

Fi .26: Leonard set electrical ste less s Jeed drive

@[or. N . R. Dhar, Professor, D~ artmcnt of Industrial and Production Eng ineering. OUET

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• Byandvarying the resistance A, the tenninal voltage of the DC generator

hence the rotor voltage of the DC motor can be adjusted between
zero and a maximum value.

• The Leonard set has a limited efficiency: it is large, expensive, and

noisy.

• Nowadays, DC motors and thyrestors that pennit direct supply to the

DC motors from an alternating current (AC) mains are available and,
therefore, the Leonard set can be completely eliminated.

• Thyrestor feed drives can be regulated such that the system offers
infinitely variable speed control.

I@_~,)! Dr. N. R. Dhar, Professor, Deoartment oflndustrial and Production Engineering, BUET I [ 78/52
...,...

Hydraulic Stepless Speed Drive: The speeds of machine tools can be

hydraulically regulated by controlling the oil discharge circulated in a
hydraulic system consisting of a pump and hydraulic motor, both of the
vane type, as shown in Fig.27.
This is achieved by changing either the eccentricity of the pump eP or the
eccentricity of the hydraulic motor em or both.
The vane pump running approximately at a constant speed delivers the
pressurized oil to the vane type hydraulic motor, which is coupled to the
machine tool spindle.
To change the direction of rotation of the hydraulic motor, the reversal of the
pump eccentricity is preferred.
Speed control in hydraulic circuits can be accomplished by throttling the
quantity offluid flowing into or out of the hydrocylinders or hydro motor.

-
© Dr. N. R. Dhar, Professor Deoartment oflndustrial and Production Engineering, BUET
I I I 78/6g

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Pressure gauge
Hydraulic pump
eccentricity ep

Oil
-=- reservoir
Fig.27: Hydraulic Stepless Speed Drive
--;· Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET [ 78/6]

• TheHas
I
advantages of the hydraulic systems are as follows:
a wide range of speed variation
I
Changes in the magnitude and direction of speed can be easily
perfonned
I Provides smooth and quiet operation
I Ensures self-lubrication
I Has automatic protection against overloads
I
The major drawback to a hydraulic system is that the operation of the
hydraulic drive becomes unstable at low speeds. Additionally, the oil
1, viscosity varies with temperature and may cause fluctuations in feed
'
A
and speed rates

-
~ll Dr. N. R. Dhar, Professor, Department of Industrial and Production Engineering~ I 78/6~

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I Plan:tary. Transmission: Fig.28 shows a planetary transmission with bevel gears

th~t .1s widely used in machine tools. Accordingly, any two members may be the
dnvmg members, while the third one is the driven member. The differential
contains central gears Z1 and Z4, and satellites Zi and Z3 (an additional wheel)
rotated by worm gear 2. The differential can operate as follows :
I Z4 is a driving member, the carrier is a driven member, and worm gear 2 is
·.
I" stationary.
The carrier is a driving member, gear Z4 is a driven member, and worm gear 2
• is stationary.
Gear wheel Z1 is a driving member (rotated by worm gear 2), gear wheel Z4 is
•
"' a driven member, and the carrier is fixed.
The carrier is a driving member, so is gear Z1, and gear wheel Z4 is a driven
• member.
Gear wheels Z and Z4 are driving members and the carrier is a driven member.
• 1

@j Dr. N. R. Dhar, Professor, Deoartment of Industrial and Production En,dneering, BUET I I 78/63]

The principal relationship between axes speed is described by Willis formula,

with Z2 = Z3 and Z1 = Z4, as follows:
i = II~ - 110 = Z2 z, = - I
111 - no Z4Z3
where ; = conversion ratio
11 = speed of carrier rotation
11" n = rotational speeds of Z1 and Z4, respectively.
0

The minus sign in the previous

equation indicates that gear wheels
Z1 and z~ rotate in opposite
X

direction when the carrier is

stationa1y.
Fig.28: Planetary Transmission

Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/6~

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Gearing svstems tor Transtormatlon and Transmission of RotaUon

eN t
le
~j
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~1~1!~fffil z
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IJillillllll!jJ!U ~W!fflll l}})J»»rm{I z,,.c:.,,. z
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H
[ 78/6]
I" I~ Dr. N. R. Dhar, Professor, Deoartment of Industrial and Production Engineering, BUET ]

Stepless Drive: For best machining economy, the speed (rpm) of rotation of the blank
(in turning) or the cutter (m illing, drilling etc.) need to be optimized considering the
tool-work materials, tool geometry, environment, machine capacity and the tool I work
diameter. But this calculated optimum speed (rpm) may not be available in step drive.
For instance, if in a turn ing operation, the optimum job-speed comes up to be 890 (say)
rpm the nearest lower and higher spindle-speeds available (in case of stepped drive) in
that lathe may be 625 rpm and 900 rpm, then the operator is compelled to take 625 rpm
and thereby huge amount (about 30%) of loss in MRR i.e., productivity and hence in
economy will occur. Such losses can be overcome by stepless drive. This is more
essential in case of costly heavy duty and modern CNC machine tools.
However, non positive stepless drives like cone pulley and friction rollers etc. are not
.· used in machine tools. Even positive type stepless drive like PIV (positively infinity
variable) drive are also not used now-a-days in any machine tool. Presently the benefits
of stepless drive for both speed and feed are attained by using variable speed
(frequency) AC motors, DC or AC servomotors etc.

$)1 Dr. N. R. Dhar, Professor, Dceartment of Industri al and Production Engineering, BUET _J I 78/6~

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Mechanisms tor Transforming Rotation to Translation

• Fig.29 shows the various types of mechanisms are used in different machine tools
for transforming rotary motion into linear or translator motion, especially to attain
controlled tool/work cuttin motions and feed ·;;,;;;;;;;;~====~;;=!
motions.
Mechanlslms for converting rolalion to translelion
Ecoentnt meehanlsm
mechanlslm lllustrallon

Screw• nut system ~ ·nu,u [Link] levef

mechanism

Rack and pinion

com-camronowcr
/ ~
Crank· connecUng rod \' .,.,M.,,,.,...,.,.r;;;:;;;:i.~=
(a)plaleeam
1//4

Whitworth mechanlsm (b}Cyllnc!ncaltam

Fig.29: Different mechanism for transforming of rotary motion into linear motion
78/6]
Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET

Screw-nut System: Typical applications of this mechanism in machine tools are;

Lathes - cross feed and longitudinal feed (using halfnut) of the tool(s)
• Shaping and Planing machines - feed motions of the work-table and tool(s)
• respectively.
Drilling machines - vertical positioning of the radial arm and drilling head
• in radial drilling machine
Milling machines - job feed motions; longituqinal, cross and vertical.
• Grinding machines - positioning or feed motions (cross and vertical) of the
• workpiece
CNC machine tools - tool or work feed motions, preferably by re-circulating
1..-
• balls type screw-nut system
Rack-pinion System: Rack-pinion mechanisms are also used in machine tool
Kinematic system. Some common applications are;
Lathe - longitudinal travel of the carriage over the bed .
-•
~ j,ll Dr. N. R. Dhar, Professor, Department of Industrial and Production EnQineerinQ, BUET I I 78/6~

--
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I Drilling machine-feed travel of the drilling spindle

I Planing machine-reciprocation of the large table with the workpiece
I
Small surface grinding machine-longitudinal reciprocation of the worktable
Crank and Connecting Rod Mechanism: These mechanisms are often used to
' produce reciprocating motion of the cutting tool from rotary motion, in
slotting machine, gear shaping machine etc. where stroke length need to be
large. This system is simple and inexpensive but resilient and do not have
quick return effect.
Eccentric Mechanism: This mechanism, similar to crank and connecting rod
mechanism is used in power saw machine and gear shaping machine
requiring more rigidity but shorter stroke length.
Oscillating Lever Mechanism: This mechanism having quick return effect is
very commonly used in shaping machine.
1-,

'.l i1f Dr. N. R. Dhar, Professor, Denartment oflndustrial and Production Engineering, BUET I
[ 78/~

Whitworth Mechanism: This is very similar to oscillating lever mechanisms

but provides longer stroke length and consistent quick return effect
irrespective of stroke length.
Cam and Cam-follower System: These mechanisms are generally used in
semi-automatic and automatic (fixed or hard automation) machine tools e.g.
single spindle and multi spindle automatic lathes to provide short length
linear tool travels from rotation of the cam shaft(s). The following types of
cams are generally used in automatic (fixed type) lathes
Plate Cams - disc type eccentric cam, disc type with desired peripheral
• profiles, mostly archemedian spiral (for constant feed rate)
Cylindrical Cams: Typical applications are in single spindle lathe for
• feeding the radially moving tools and to operate the single revolution
clutches for turret indexing and changing spindle-speed and in swiss type
automatic lathe for headstock travel.
-
Ilt'lf Dr. N. R. Dhar, Professor, Department of Industrial and Production Engineering BUET I
,
I 7817g

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Lobe Cams: These are nothing but small steel plates, which can be
easily replaced and shifted to desired positions on the periphery of a
rotating drum. Such cams are typically used to control the movements
of the cutting tools in multi-spindle automatic lathes.
Wedge Cams: It is like a taper rod or plate which is made to
reciprocate by a rotating system and produces in the follower small
oscillatory motion synchronized with the other tool-work motions.
The relieving motion of the cutter (or the blank) in gear shaping
machines is an example of application of such wedge cams.
Several other mechanical devices or mechanisms are also used in some
1I,•f machine tools such as, Telescopic shaft and universal joints, Over
running clutch, Single revolution clutch, Ratchet and paul and Geneva
mechanism
m [ 78/7]

-
Dr. N. R. Dhar, Professor, Deoartment of Industrial and Production En2ineerin2, BUET l

Power sources used in Machine Tools

Any machining work essentially needs relative motions and cutting power
for the desired tool-work interactions. All machine tools must possess one or
more power sources to provide such cutting power and tool-work motions.
Machine tool drives actually refer to the source(s) of motion, torque and
power and the kinematic system(s) that transform and transmit that motions
and power to the tool and work for necessary machining work. Machine tool
drive also includes the system that is used to regulate speed and feed.
Machine tool drives may be one of the following types:
II Electro-Mechanical Type - more common where main source(s) is
electrical motor(s) from which power and motions are transmitted to the
tool and work through several mechanisms.
Electro-mechanical type machine tool drives comprise generally of
electrical motor(s) and a number of independent or interdependent
kinematic chains of several mechanisms.
•~ Dr. N. R. Dhar, Professor, Department of Industrial and Production En 2ineerin 2, BUET I I 78/7~

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1 Elect~o-Hydraulic Type - where the power and motions are derived from
electrical motor(s) and transmitted through several hydraulic systems. Electro-
hydraulic drives usually consist of
1 one or more hydraulic power packs, each comprising of a suitable hydraulic
pump like vane pump, radial piston pump etc. being driven by an electric
motor and the allied reservoir, strainer, foot valve and a relief valve
• hydraulic motor or actuator, generally piston-cylinder system
• a hydraulic circuitry comprising several valves for transmitting and
j

regulating pressure, force and travelling speeds and directions

1
Some heavy duty and precision machine tools like broaching machines,
grinding machines etc. are designed to have both mechanical and hydraulic
drives. Electrical motors are most widely used as power source(s) in machine
tools. The motor of different type and size are used depending upon the type
and application of the machine tools.
Combination of Electro-Mechanical and Electro-Hydraulic Drives

Dr. N. R. Dhar, Professor, Deoartment oflndustrial and Production Engineerinl!, BUET I [ 78/TI]

Machine tool drives, in terms of tool-work motions, are further classified as,
Stepped drive or stepless drive
• Positive type drive or non-positive type drive
•
The types of electric motors, which are generally
used for electro-
mechanical drives in machine tools, are:
• for stepped drives
induction motors having only one or two fixed speeds
I
•
for stepless drive
variable speed induction motor with frequency converter
• DC motors
• Ward-Leonard system of motor-generator-motor set.
I
for NC and CNC machines
• stepper motor
• AC and DC servo motors
•
@[ Dr. N. R. Dhar, Professor, De~artment oflndustrial and Production Engineering, BUET l I 78/7~

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Estimation of Power Requirement for Machine Tool DriVes

I Machine tool drives need enough power
to provide cutting power for chip formation (separation)
• to overcome friction forces and power consumed at the sliding surfaces.
1 to overcome inertia forces
•
1
for auxiliary motions and work
to accommodate dynamic and overload factors.
11
For instance, the maximum power requirement, Um from the motor in a centre
II lathes, may be estimated from
= [U cmax + ufinax + ulmlr< l X fd X fol
um
Tie x 11m
Where, Ucmax = maximum power required for machining = ( P,Vc + PxVr) max
P,Vc = cutting power required, PxVr = feed power required
Urmax= max. friction force, Uimax= max. inertia force
fd, f = dynamic and overload factors (in the order of 1.0 to 1.25)
11 1101 = electrical and mechanical efficiency of the entire drive systems.
and e, m [ 78/~
f ;ll Dr. N. R. Dhar, Professor, Department oflndustrial and Production Engineering, BUET I
.....

Hydraulic Drive in Machine Tools: Hydraulic drive is employed in some machine

tools requiring noiseless smooth operation and heavy forces during tool-work
interactions. Hydraulic drive is generally incorporated for tool or work feed
motions as shown in [Link].
For hydraulic drive, a machine tool needs
use of one or more hydraulic power pack,
where basically an oil as hydraulic fluid is
pressurized by a pump-motor set and that
high pressure fluid, after desirably
regulated by a relief valve, is used to drive
one or more hydraulic motors, preferably
linear type like piston-cylinder system.
-
Occasionally the piston remains stationary
and the cylinder holding the tool or the job
moves as in hydraulic copying lathe. Fig.30: Principle of hydraulic copy turning

. Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET 78/7~

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Fig.31 shows a typical hydraulically driven machine tool where the rotating
drill is moved at stepless varying feed rate. The hydraulic fluid at high
pressure raised by pump and regulated by relief valve is passed into the
piston-cylinder type hydraulic motor via direction control valve. The speed of
travel of the piston i.e, tool-feed rate is regulated by a throttle valve assisted
by pressure reducing valve. ,,....,,.,.,_,

10:.noij

Fig.13: Circuitry and

kinematic system of
hydraulically driven
machine tool

Dr. N. R. Dhar, Professor, De artment of Industrial and Production En ineerin , BUET

Relative Advanta~es of Hydraulic Drive are:

smooth operation
precision (stepless) speed control
I less jerk, vibration and noise
I hardly needs separate lubrication
I lesser wear and tear
I easier connections by flexible tubings
In spite of such merits, wide application of hydraulic drive in machine tools is
constrained for the follow reasons:
I needs more floor space

.
chances of leakage of fluid, which not only causes inconveniences and hazards
but also affects feed rate control
more difficulties in repair and maintenance.
Hydraulic drives are preferably and often essentially used in some machine tools
which need high strength and rigidity and stepless precision control of feed motions
without jerk and noise under heavy cuts; such as heavy duty precision grinding
machines, broaching machine and heavy duty boring machines.
f -o,] Dr. N. R. Dhar, Professor, Department of Industrial and Production Engineerin_~
--

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