LESSON ONE

INTRODUCTION
TO MACHINE TOOL DESIGN
AND NUMERICAL CONTROL

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

 Machine tools are devices for cutting materials (mostly metals), to impart them
the required shape.
 Machine Tools: Machining equipment that cuts, shears, punches, presses,
drills, grinds.
 Machine tools are generally the power driven metal cutting or metal forming
machines used to change the workpiece to the required shape and size by:
1. Cutting away the unwanted sections
2. Pressing, drawing, punching or shearing
3. Controlled electrical machinery process
 The cut-off material obtained is usually in the form of chips.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

 Machine tools can be classified according to size:

 light duty (weighing less than 1 tonne),
Medium duty (1 to 10 tonnes), and
Heavy duty (above 10 tonnes).

 Some people prefer classification according to the method

of actuation:
 Manually operated,
 Semi-automatic,and
 Fully automated
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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

 Another method classifies machine tools according to the

types of motions used for removing material.
 Rotary cutting machines rotate workpiece (turning
lathes), 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 (planing,
surface grinding), in a straight line.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

Generation of Machine Tools

1. Machine tools are operated manually or with automatic control. The earlier
machines used flywheels to stabilize their motion and had complex system of gears
and levers to control the machine and the piece being worked on.
2. Machines continued to be improved and soon after World War II, the numerical
controlled (NC) machine was developed. The NC machines used a series of numbers
punched on paper tape or punch cards to control their motion.
3. Lately computers have been added and the Computerized Numerical Control
(CNC) machines have allowed industry to produce parts quickly and accurately. The
same part can be reproduced to the exact accuracy, any number of times if the part
programme has been properly prepared. The operating commands that control the
machine tool are executed with amazing speed, accuracy, efficiency and reliability.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

 For becoming the finished product, various operations such as

turning, drilling, milling, threading, reaming, grinding etc., have to
be performed.
 A variety of machine tools to perform these operations and the
choice of a particular machine essentially depends on:
1. Material of the workpiece
2. Nature of metal cutting operations
3. Number of parts to be machined
4. Degree of accuracy desired
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

Any machine tool chosen will have the capability to:

1. Hold and support the workpiece and cutting tool
2. Impart suitable reciprocating or rotary movement to the cutting
tool or workpiece
3. Regulate the cutting speed and feeding movement between the
tool and workpiece so that the desired cutting actions, accuracy
and repeatability can be achieved.

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

MACHINE TOOL REQUISITES

 A good machine tool should have high productivity, and
precision commensurate with workpiece specifications, and
controlling levers, hand-wheels, push buttons, etc. at a
position, convenient for the operator.
 It should ensure operator and machine safety, its
manufacturing and running costs should be reasonable and
breakdown frequency and duration, minimal.

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

PRODUCTIVITY CAN BE MAXIMIZED BY

Optimum speeds and feeds usage
 General purpose machines call for a wider range of speeds
and feeds, to accommodate a variety of workpiece sizes and
materials.
 Special purpose machines, meant for either a single or few
specific workpieces and operations, do not warrant
flexibility in speeds and feeds, nor wide variety of
tool/workpiece motions provided in general purpose
machines. 9

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN
PRODUCTIVITY CAN BE MAXIMIZED BY
Multi-tool cutting that can help overlapping of cutting time
Reduction of non productive (non-cutting ) time by
Jigs and fixtures: to reduce workpiece positioning (locating)
and clamping time.
 Minimizing maintenance: by reckoning fatigue stress on
parts, while designing running parts, providing easy access
for quick replacement of broken/worn parts, and adopting a
practice of preventive maintenance (replacing vulnerable
parts just before they are likely to break), on weekly
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

Precision depends up on
Geometrical manufacturing accuracy: straightness, squareness,
concentricity, etc. of guideways, carriages, and spindles.
When a machine is subjected to high variation in temperature (as in
grinders), thermal stress and ensuing deformation should be
minimized by diffusing (conducting away) the heat to a solid
structure, and/or by providing for an arrangement for cooling the
structure.

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

Safety of operator and machine

 Operator safety can be ensured by
 Guards, which can prevent entanglement of operator’s
clothes in rotating/moving machine parts; and shield him
from hot, sharp, flying chips of the cut-off material
 Adequate clamping of workpiece, to withstand cutting
forces, to prevent the workpiece from flying off and injuring
the operator
 Handling equipment for heavy workpieces, to avoid
accidental fall and injury.

 Electrical safety through earthing, to avoid shock to the

operator
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

Safety of operator and machine

 MACHINE SAFETY CAN BE ACCOMPLISHED BY
Stops (mechanical obstacles), and limit, and proximity
switches, to confine carriage travel within safe limits

 Interlocks through mechanical, hydraulic, and electrical

elements, to prevent engagement of conflicting and risky
motions simultaneously, or in a wrong order, e.g. ensuring that
workpiece is clamped, before cutting commences

 Overload prevention through cheap, easy-to-replace shear

pins, electrical fuses, etc. to eliminate the possibility of
breakage of costly gears, burning of electrical motor, etc.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

Economic Considerations for the type machine tool chosen

It is necessary to meticulously consider the economic aspects of
various machine tools available for production, to check for their
suitability. Recovery of capital investment usually takes 5 to,10 years.
Production costs(p)comprises
a) Material cost(M)
Depends upon the size and shape of the workpiece and condition
of the raw material (casting or rolled stock). This will be same
for existing and new machine tools, unless there is a change in
the production process.
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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN
Production costs (p) comprises
b) Machining cost (C)
Depends on the time the machine takes for producing the workpiece.
The time/piece (T) decreases with the passage of time, as the machine
operator learns and masters the production cycle. But it stabilizes at
the minimum possible, for the operator, after some time. The stabilized
time/piece for an average operator, can be estimated fairly accurately
from the optimum speeds and feeds for the workpiece, and the
operator motions involved.

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

Production costs (p) comprises

c) Labour cost (W)
Or operator wages, is higher for general purpose machines, which
call for more skillful operators. Special purpose machines, with a
higher degree of automation, can do with an unskilled operator, who
only has to load and unload workpiece, and press start/stop buttons.
d) Overheads
Comprise all indirect costs such as money spent on the maintenance
department, tool room (for resharpening tools), managers, even sales
personnel and advertising. Overheads are usually expressed in overall
percentage which ranges from 50% for small workshops, to 500% for
large establishments with modern amenities and a better qualified
workforce.
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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

Economic Considerations for the type machine tool chosen

2.INVESTMENT
Comprises cost of machine and tooling (jigs and fixtures), expenses
incurred on the space for setting up the machine, its accessories, and for
temporary storage of incoming and finished workpiece banks, near the
machine.

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Machine tool design and

 INTRODUCTION
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Economic Considerations for the type machine tool chosen

2.1 Machine and tooling costs (Im)

Should include transportation and installation costs such as foundation,

additional power cable, etc. (which account for about 5% of machine
cost). Tooling (jigs and fixtures) cost usually ranges from 10% of the
machine cost for general purpose machine tools, to 20% for fully
automated transfer machines, and is about 15% for semi-automatic
special purpose machines.
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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

Economic Considerations for the type machine tool chosen

2.2 Space comprises

Machine area
 Accessories and tooling storage area (about 25% of machine area)
 Workpieces storage area: Generally there should be enough space
near the machine tool to temporarily store input required, and
output obtained during a period of 2 to 7 hours. Depending upon
the size and shape of the workpiece and the production time/
piece, the storage area can range from 50% to 200% of the
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machine area.
Machine tool design and
INTRODUCTION TO MACHINE TOOL DESIGN

CRITERIA FOR BUYING NEW MACHINE TOOL

INCREASE IN PRODUCTION

Usually, purchase of a new and improved better machine tool is

thought to help in meeting the rise in demand for workpieces. It
will however, be fool hardy to buy a new machine tool,
producing lesser number of workpieces per annum.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

CRITERIA FOR BUYING NEW MACHINE TOOL

REDUCTION IN TOTAL PRODUCTION COST PER WORKPIECE

 Is a sound reason for buying a new machine tool or

replacing an existing one with a new one.
 It is an important criterion for buying a new and better
machine tool.

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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

BASIC MACHINE TOOLS

Basic machining operations comprise turning, drilling,

reaming, boring, facing, milling, broaching, grinding,
shaper machine,, Planer machine, Slotting machine etc.

TURNING MACHINE
 Turning machine or Lathe is the mother of all machine
tools.

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

Lathe machine (Center lathe or Universal machine)

It is the machine tool used for moving undesirable
material, in the form of chips from the cylindrical
surfaces
Cutting tool used is made of the harder material than
work piece
Generally carbide, tungsten carbide tools are used

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

CENTER LATHE
The center lathe has been in use for over 200 years now. A
general purpose machine, it comprises a bed with a
guideway. On one end of the bed is mounted the headstock,
which provides drive to the spindle mounted with a work-
holder. The other end is mounted with a tailstock which
supports longer workpieces on the center

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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

LATHE MACHINE
Working Principle: The lathe is a machine tool which holds the workpiece between
two rigid and strong supports called centers or in a chuck or face plate which
revolves.
The cutting tool is rigidly held and supported in a tool post which is fed
against the revolving work.
The normal cutting operations are performed with the cutting tool fed either
parallel or at right angles to the axis of the work.
The cutting tool may also be fed at an angle relative to the axis of work for
machining tapers and angles

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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

LATHE MACHINE

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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN
Construction: The main parts of the lathe are the bed, headstock, quick changing
gear box, carriage and tailstock.

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Machine tool design and

 INTRODUCTION
TO MACHINE TOOL DESIGN

LATHE MACHINE
1. BED: The bed is a heavy, rugged casting in which are mounted the working parts
of the lathe. It carries the headstock and tail stock for supporting the workpiece and
provides a base for the movement of carriage assembly which carries the tool.
2. LEGS: The legs carry the entire load of machine and are firmly secured to floor by
foundation bolts.
3. HEADSTOCK: The headstock is clamped on the left hand side of the bed and it
serves as housing for the driving pulleys, back gears, headstock spindle, live centre
and the feed reverse gear. The headstock spindle is a hollow cylindrical shaft that
provides a drive from the motor to work holding devices.

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

LATHE MACHINE
4. GEAR BOX: The quick-change gear-box is placed below the
headstock and contains a number of different sized gears.
5. CARRIAGE: The carriage is located between the headstock and
tailstock and serves the purpose of supporting, guiding and feeding
the tool against the job during operation. The main parts of carriage
are:
A). THE SADDLE is an H-shaped casting mounted on the top of

lathe ways. It provides support to cross-slide, compound rest and

tool post. 29

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

B). THE CROSS SLIDE is mounted on the top of saddle, and it provides a
mounted or automatic cross movement for the cutting tool.
C). THE COMPOUND REST is fitted on the top of cross slide and is used
to support the tool post and the cutting tool.
D). THE TOOL POST is mounted on the compound rest, and it rigidly
clamps the cutting tool or tool holder at the proper height relative to the work
centre line.
E). THE APRON is fastened to the saddle and it houses the gears, clutches and
levers required to move the carriage or cross slide. The engagement of split nut lever
and the automatic feed lever at the same time is prevented she carriage along the
lathe bed. 30

Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

6. TAILSTOCK: The tailstock is a movable casting located opposite the

headstock on the ways of the bed.

The tailstock can slide along the bed to accommodate different lengths
of workpiece between the centers.
A tailstock clamp is provided to lock the tailstock at any desired
position.
The tailstock spindle has an internal taper to hold the dead centre and
the tapered shank tools such as reamers and drills.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS
The engine lathe is an accurate and versatile machine on which many operations can
be performed. These operations are:
1. Plain Turning and Step Turning
2. Facing
3. Parting
4. Drilling
5. Reaming
6. Boring
7. Knurling
8. Grooving
9. Threading
10. Forming
11. Chamfering
12. Filing and Polishing 32

13. Taper Turning Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

1. Plain Turning: Plain turning is the operation of removing excess

amount of material from the surface of a cylindrical job.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

2. Step Turning: Step turning produces various steps of different

diameters.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

3. Facing: The facing is a machining operation by which the end

surface of the workpiece is made flat by removing metal from it.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

4. Parting: The parting or cutting off is the operation of cutting away a

desired length of the workpiece, i.e., dividing the workpiece in two or
more parts.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

5. Drilling: Drilling is the operation of producing a cylindrical hole in

the workpiece.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS
6. Reaming: The holes that are produced by drilling are rarely straight and
cylindrical in form. The reaming operation finishes and sizes the hole already
drilled into the workpiece.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

7. Boring: The boring operation is the process of enlarging a hole

already produced by drilling.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

8. Knurling: The knurling is a process of embossing (impressing) a

diamond-shaped or straight-line pattern into the surface of workpiece.
Knurling is essentially a roughening of the surface and is done to
provide a better gripping surface.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

9. Grooving: Grooving is the act of making grooves of reduced

diameter in the workpiece.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

10. Threading: Threading is the act of cutting of the required form of

threads on the internal or external cylindrical surfaces.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

11. Forming: The forming is an operation that produces a convex,

concave or any irregular profile on the workpiece.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

12. Chamfering: Chamfering removes the burrs and sharp edges, and
thus makes the handling safe. Chamfering can be done by a form tool
having angle equal to chamfer which is generally kept at 45°.

13. Filing and Polishing: The filing is the finishing operation that
removes burrs, sharp corners and feed marks from the workpiece.
After filing, the surface quality is the workpiece is improved by the
polishing operation with the help of emery cloth of fine grades.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

LATHE OPERATIONS

14. Taper Turning: The taper turning is an operation of producing a

conical surface by gradual reduction in the diameter of a cylindrical
workpiece.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

SHAPER MACHINE
Introduction: The shaper is a machine tool used primarily for:
1. Producing a flat or plane surface which may be in a horizontal, a
vertical or an angular plane.
2. Making slots, grooves and keyways
3. Producing contour of concave/convex or a combination of these

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

SHAPER MACHINE
Working Principle: The job is rigidly fixed on the machine table. The
single point cutting tool held properly in the tool post is mounted on
a reciprocating ram. The reciprocating motion of the ram is obtained
by a quick return motion mechanism. As the ram reciprocates, the tool
cuts the material during its forward stroke. During return, there is no
cutting action and this stroke is called the idle stroke. The forward
and return strokes constitute one operating cycle of the shaper.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

SHAPER MACHINE
Construction: The main parts of the Shaper machine is Base, Body (Pillar,
Frame, Column), Cross rail, Ram and tool head (Tool Post, Tool Slide,
Clamper Box Block).

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

PLANER MACHINE
Introduction: The planer is a machine tool designed to produce
plane and flat surface on a workpiece which is too large or too
heavy. The workpiece is securely fixed on a table called platen, and
it reciprocates horizontally against a single edged cutting tool. The
surface machined may be horizontal, vertical or at an angle.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

PLANER MACHINE

Operations of planer machine: The planer is used for:

1. Planing flat horizontal, vertical and curved surfaces.
2. Planing at an angle and machining dovetails.
3. Planing slots and grooves.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

PLANER MACHINE
Operations of planer machine: The planer is used for:
1. Planing flat horizontal, vertical and curved surfaces.
2. Planing at an angle and machining dovetails.
3. Planing slots and grooves.
Construction: The main parts of the double Housing Planer machine is Bed and
table, Housings, Cross rail, , Tool heads, Driving and feed mechanism.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

MI LL ING MACHINE
Introduction: Milling is the cutting operation that removes metal
by feeding the work against a rotating, cutter having single or
multiple cutting edges. Flat or curved surfaces of many shapes can
be machined by milling with good finish and accuracy.
A milling machine may also be used for drilling, slotting,
making a circular profile and gear cutting by having suitable
attachments.

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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

MI LL ING MACHINE

Working Principle: The workpiece is holding on the worktable of

the machine.
The table movement controls the feed of workpiece against the
rotating cutter.
The cutter is mounted on a spindle or arbor and revolves at high
speed. Except for rotation the cutter has no other motion. As the
workpiece advances, the cutter teeth remove the metal from the
surface of workpiece and the desired shape is produced.
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Machine tool design and

 INTRODUCTION TO MACHINE TOOL DESIGN

MI LL ING MACHINE
Horizontal Milling Machine Construction: The main part of machine is
base, Column, Knee, Saddle, Table, Overarm, Arbor Support and
Elevating Screw.

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

DRI LL ING MACHINE

Introduction: The drilling machine or drill press is one of the most common and
useful machine employed in industry for producing forming and finishing holes in
a workpiece. The unit essentially consists of:
1. A spindle which turns the tool (called drill) which can be advanced in the
workpiece either automatically or by hand.
2. A work table which holds the workpiece rigidly in position.

Working principle: The rotating edge of the drill exerts a large force on the
workpiece and the hole is generated. The removal of metal in a drilling operation is
by shearing and extrusion.
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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

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Machine tool design and

INTRODUCTION TO MACHINE TOOL DESIGN

SLOTTING MACHINE
Introduction: The slotting machine is a reciprocating machine tool in
which, the ram holding the tool reciprocates in a vertical axis and the
cutting action of the tool is only during the downward stroke.
Construction: The slotter can be considered as a vertical shaper and its
main parts are:
1. Base, column and table
2. Ram and tool head assembly
3. Saddle and cross slide
4. Ram drive mechanism and feed mechanism.

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Machine tool design and