IPE 431
Machine Tools
Course conducted by
Rashik Ahnaf
Lecturer, Dept. of IPE, BUET
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Chapter – 5
Functional Principles of Machine Tools
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Basic Definitions of Machine Tools
• Machine: A device which is used to transform the shape of any material as per
requirement by some mechanism but can not do so without any tool.
• Tool: A device which is also used to transform the shape of any material but it can
do so without any machine like hammer, Screw driver, file, saw etc.
• Cutting Tool: Cutting tool, as the name suggests, is a material, generally harder
than the workpiece material, used for cutting the material, removing excess
material in the form of chips. Example: Lathe tool, Milling cutter, Drill bit etc.
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Basic Definitions of Machine Tools
• Machine Tool: A machine tool is a non portable and power operated device or
system of devices in which energy is expended to produce jobs of desired
dimension and finish by machining i.e. removing excess material from the
preformed blank(s) in the form of chips with the help of cutting tool(s) moved
past the work surface at controlled speeds and feeds. Example: Lathe, Milling
machine, Drilling machine, Shaper
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Major Components of Machine
Tools
• Holding Devices: Holds the blank and cutting tools properly and firmly
• Motion and Power Drivers: Provide motion and power to workpiece and cutting
tools
• Kinematic Systems: Transform and transmit the motions and power from the power
source(s) to the tool(s) and workpiece.
• Automation and Control Systems: Control the movement of workpiece and cutting
tools accurately and precisely
• Heavy Structural Body: support and accommodate above components and systems
quite strongly, rigidly and safely
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Basic Functions of Machine Tools
• The functions of the machine tools like lathes, drilling machines, shaping machines,
milling machines etc. are basically to produce or impart one or more desirably
accurate and well finished geometrical surfaces like flat surfaces, cylindrical surfaces
or contoured surfaces on the solid blank, which are generally mathematically
expressible.
• Production of such surfaces in machine tools need appropriate relative positioning
and motions of the cutting tool and the workpiece.
• The motions of workpiece and cutting tools to generate surfaces can be expressed by
Generatrix and Directrix.
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Directrix and Generatrix
• A Generatrix is a point, curve or surface that, when moved along a given path,
generates a new shape. The path directing the motion of the generatrix motion is
called a Directrix.
• In other words, the line generated by cutting motion is called Generatrix and the
line generated by feed motion is called Directrix
Directrix
Generatrix
Generatrix
Generatrix
Directrix
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Generation of Flat Surfaces
• Following typically shows the principle, where on a flat plain a straight line called
Generatrix (G) is traversed in a perpendicular direction called Directrix (D) resulting
in a flat surface.
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Generation of Cylindrical Surfaces
• The principles of generation of various cylindrical surfaces are
typically shown in the following Figures where,
• a long straight cylindrical surface is obtained by a circle (G) being
traversed in the direction (D) parallel to the axis as indicated in (a)
• a cylindrical surface of short length is obtained by traversing a
straight line (G) along a circular path (D) as indicated in (b)
• form cylindrical surfaces are obtained by traversing a curved line
(G) along a circular path (D) as typically shown in (c) and (d)
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Tool-workpiece Motions in Machine
Tools
• The lines representing the Generatrix and Directrix are usually produced by the locus
of a point moving in specified directions and are actually obtained by the motions of
the tool-tip (point) relative to the work surface.
• Hence, for machining flat or curved surfaces the machine tools need relative tool-work
motions, which are categorized in following two groups:
Formative Motions – (i) Cutting Motion (CM) and (ii) Feed Motion (FM)
Auxiliary Motions – (i) Indexing motion of work or tool
(ii) Additional feed motion if required (example: gear
shaper)
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Motions in Turning Operation
• The Directrix, Generatrix and cutting motion, feed motion are generally associated
with cutting tool and workpiece.
• The connections are expressed in the following manner
Directrix/Generatrix – cutting motion/feed motion – cutting tool/workpiece
• For straight longitudinal turning, the connections are as follows
Generatrix (G) Cutting Motion (CM) Work (W) [G-CM-W]
Directrix (D) Feed Motion (FM) Tool (T) [D-FM-T]
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Motions in Shaping and Planing
Machine
• While producing flat surfaces in shaping machine the Generatrix is provided by the
cutting motion imparted to the cutting tool and the Directrix is provided by the feed
motion of the work. The connections are:
Generatrix (G) Cutting Motion (CM) Tool (T) [G-CM-T]
Directrix (D) Feed Motion (FM) Work (W) [D-FM-W]
• Flat surfaces are also produced by planing machines, mainly for large jobs, where the
cutting motion is imparted to the work and feed motion to the tool and the
connections will be:
Generatrix (G) Cutting Motion (CM) Work (W) [G-CM-W]
Directrix (D) Feed Motion (FM) Tool (T) [D-FM-T]
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Sources of Directrix and Generatrix
The Generatrix and Directrix can be obtained in four ways:
1. Tracing (Tr) - Where the continuous line is attained as a trace or path of a moving
point shown in following figures
2. Forming (F) - Where the Generatrix is simply the profile or form of the cutting edge.
Remember, CM/FM is not assigned to a connection if that has forming as source
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Sources of Directrix and Generatrix
3. Tangent Tracing (T.Tr) - Where the Directrix is taken as the tangent to the series of
paths traced by the cutting edges as in milling operation. The following figure
typically shows the tool-work motions and the corresponding Generatrix (G) and
Directrix (D) while producing flat surface by a plain or slab milling cutter in a
conventional horizontal arbor milling machine. The connections are -
G– x – T – F
D – FM – W – T.Tr
CM – T
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Sources of Directrix and Generatrix
4. Generation (G) - Here the Generatrix or Directrix is obtained as an envelope being
tangent to the instantaneous positions of a line or surface which is rolling on another
surface. Gear teeth generation by hobbing or gear shaping is the example of this
kind of source.
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Motions in Drilling Machine
• For making holes in drilling machines both the cutting motion and the feed motion are
imparted to the cutting tool i.e., the drill bit whereas the workpiece remains stationary
G – CM – T – Tr
D – FM – T – Tr
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Tool-workpiece Motions and G and D in Different
Machining
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Tool-workpiece Motions and G and D in Different
Machining
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Tool-workpiece Motions and G and D in Different
Machining
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Tool-workpiece Motions and G and D in Different
Machining
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Tool-workpiece Motions and G and D in Different
Machining
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Tool-workpiece Motions and G and D in Different
Machining
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Kinematic Structure of Machine
Tools
• The desired formative and the auxiliary motions (along with power) of the tool-work
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 connected in series. Again, the gear box itself is made of number of
mechanisms.
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Need of Kinematic Chains
The kinematic chains usually accomplish:
• Transfer of motion (and power) from the source(s) to the tool and work
• Transformation of motion
rotation to rotation (different speed)
rotation to translation (and often vice-versa) or oscillation
direction of motion
splits one speed into number of speeds (rpm)
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Expressing Kinematic Structures
• The overall system of all the kinematic chains taken together in a machine tool is
called kinematic structure of that machine tool.
• In the figure, denotes power source (), denotes kinematic chains (), denotes
mechanisms and denotes motions ().
• Mathematically the relations can be expressed as follows where is Kinematic
Structure
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Different Forms of Kinematic
Structures
• Kinematic structure of any machine tool may be broadly classified into three types
depending upon the nature of interconnections of the kinematic chains. They are -
Elementary (Kinematic) Structure
Complex (Kinematic) Structure
Compound (Kinematic) Structure
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Elementary (Kinematic) Structure
• This is the simplest type of kinematic structure where all the kinematic chains are
independent.
• 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 where, stands for elementary,
the first stands for number of power sources and second stands for number of
kinematic chains (s). The value of may be 1,2,3……
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Elementary (Kinematic) Structure
• One typical application of elementary structure is center lathe where the kinematic
structure is represented by . 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.
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Elementary (Kinematic) Structure
• Another application of elementary structure is broaching machine where the
kinematic structure is represented by . This machine usually has only one motion
(tool) driven by only one kinematic chain and one power source.
• A third example can be 3-axis CNC milling machine where the kinematic structure is
represented by . In this machine, the spindle rotation and the three feed motions are
provided by four independent sets of power source and kinematic chain.
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Complex (Kinematic) Structure
• This is very common kinematic structure where all the kinematic chains (s) 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 , where, indicating number of
kinematic chains.
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Complex (Kinematic) Structure
• The following figure visualizes a typical type complex Kinematic structure of a center
lathe where the two Kinematic chains are interdependent and derives the cutting
motion and the feed motion from only one motor.
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Complex (Kinematic) Structure
• 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 type as
indicated in the figure, where three kinematic chains, producing rotation of the job
and two feed motions of the tool are interconnected having only one power source.
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Complex (Kinematic) Structure
• Following figure visualizes another application of 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.
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Complex (Kinematic) Structure
• All these three motions are derived from a single motor by three interconnected
kinematic chains;
I. Motor rotation of tool (hob), CM
II. Tool rotation indexing motion IM of blank
III. Blank rotation tool feed motion FM
Where,
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Compound (Kinematic) Structure
• It is actually combination of and type structures. Here, some of the kinematic chains
(s) are independent and some are interdependent.
• Compound structures are symbolically expressed by , where, is the number of power
sources and indicates the number of kinematic chains. For example,
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Compound (Kinematic) Structure
• An application of a simple type compound Kinematic structure is a grinding machine
which can be expressed by .
• Here the Kinematic chains, providing work feed (rotation) motion and the tool feed
motion are interdependent and connected to a motor, and thus constitute structure.
Grinding motion provided by another motor, can be taken as . Thus combination of
and results in the compound structure .
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