UNIT TWO:

2.1. Working & auxiliary motion in machine tools:

To obtaining required shape,
Cutting edge move with respect to work piece,
Relative motion b/n the tool & the work piece,
Obtain motion from either the tool or work piece, or
Motion by combination motion of tool & work piece,
The motion is essential to impart the required shape to the
work piece are known as working motions.
The working motions categories are:
Primary cutting motion or Drive motion
Rotary & Translatory motion
Feed motion
1 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]
2 October 2019
 Cont…
Working & auxiliary motion in machine tools:

2 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]

2 October 2019
 Cont…
Working & auxiliary motion in machine tools:

3 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]

2 October 2019
 Cont…
Working & auxiliary motion in machine tools:
Machine tool also has provision for auxiliary motion,

Auxiliary do not participate in the formation of product,

Nevertheless necessary to make the working motion,

Clamping & unclamping of the work piece,
Changing the speed of drive & feed motion,
Engaging & disengaging of working motion,
Working motions are powered by electric or hydraulic motor,

General purpose Machines auxiliary M. are executed manually,

Automatic machine all auxiliary motions are automated.

4 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]
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 Cont…
Parameters Defining Working Motion of Machine Tools:
The working motions are numerically defined by their speeds,
The velocity of primary or drive motion is cutting speed,
The velocity of feed motion is feed,

Machine tool with rotary primary cutting motion, the cutting

speed is determined by the relationship:

5 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]

2 October 2019
 Cont …
Cutting Speed: is given in surface feet per minute (sfpm)
& the speed at which the metal is removed by the tool from
the work piece, expressed in meters per minute.
V = πDN ;V = πDN / 1000 for the metric units.
Feed: the distance, the tool advances for each revolution of
the work piece, measured in the direction of the feed
motion, It is expressed in mm/rev.
Depth of cut: It is the penetration of the cutting tool into
the work-piece in a single cut, & expressed in mm
Speeds, Cuts, & Feeds for Turning Operations:
The surface speed (sfpm), depth of cut (in), & feed (ipr) for
various materials using high speed steel (HSS), cast-alloy, &
carbide cutting tools.

6 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]

2 October 2019
 Cont …
Procedures for Selection of Speed, Feed, & Depth of Cut:
Use the preceding speed, feed, & depth of cut figures as a
basis for these choices. Useful tool life is influenced most by
cutting speed. The feed rate is the next most influential
factor in tool life, followed by the depth of cut.
When the depth of cut exceeds approximately 10 times the
feed rate, a further increase in depth of cut has little effect
on tool life. In selecting the cutting conditions for a turning
or boring operation, the first step is to select the depth of
cut, followed by selection of the feed rate & then the cutting
speed.
The machinist or machine operator will know if the selected
speed, depth of cut, & feed are more than the given machine
can tolerate & can make corrections accordingly.
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 Cont …
Parameters Working Motion of Machine Tools:
Principal Cutting Operations:
The 3 most widely used cutting operations are: The cutting speed at the tool corner is given by:
1. Turning V = π dm nw
2. Milling
3. Drilling V = π dw nw
Vav = π nw(dw +dm)/2
Lathe Operations: Cylindrical turning, Where: nw, is the rotational frequency of the work-piece, &
facing, boring, external threading, & cutoff. dm , is the diameter of the machined surface.
dw , is the diameter of the work surface.
All work-piece has three important surfaces. Vav, is the average or mean cutting speed.
The work surface,
The machined surface, The Metal removal rate:
The transient surface.
Zw = AcVav
Machined
Zw = πafapnw (dw +dm)/2
Transient surface Zw = πafapnw (dm +ap)
Where: Zw, is the rotational frequency of the work-piece,
Ac , is the diameter of the machined surface.
af , is the uncut chip width.
ap, is the Uncut chip thickness (depth of cut).
The power Pm & the power efficiency Ps required
to perform any machining operation:
Pm = ps Zw; Pe = pm /m
Where: Pm, is the power required,
Ps , is the specific power.
, is the efficiency of the motor
8 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]
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 Cont …
Parameters Working Motion of Machine Tools:
V = π dm nw /1000 ;
Turning: Where dm, is the diameter of the machined surface &
nw , is rotational frequency of the work piece
Ex1: Determine the cutting speed of a turning operation if the
rotational frequency is 75 rpm & the diameter of the machined surface is
90 mm. Solution:V = π dm nw /1000
V= π 75rpm*90mm/1000
V = 21.2 m/min
Ex2: Calculate the rotational frequency RPM setting for a Lathe
machine to turn Ø 50mm. Grey C.I work-piece with throwaway
carbide insert tool. The feed is 0.38mm/rev. The depth of cut is 3.8mm
& the recommended cutting speed is 60 m/min.
Solution: RPM setting (Rotational Frequency):
V = π dm nw /1000
60m/mim = π*50mm*nw /1000
nw = (1000*60)/(π *50)
= 381.8 rpm
9 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont …

Ex3: Determine the time required to machine the part. In a turning

operation of 100mm length cylindrical part, the feed is 0.38 mm/rev, the
rpm of the spindle is 380. Assume 1.5mm approach & 1.5 mm over travel
allowances. Solution: tm = lw/fnw lw =100+1.5 +1.5 =103mm
tm = 103mm/(0.38mm/rev*380rpm)
tm = 0.713 min = 42.79 sec
Ex4: Determine the power required to cut a cylindrical shaft Ø 50 mm
on lathe when the cutting conditions are as follows; cutting speed =18
m/min, feed =0.26 mm/rev, depth of cut =0.058 cm, specific power ps=
3.7 kw for removing one cubic cm per min, efficiency of motor η = 80%)
Solution: Rotational frequency V = π dm nw /1000
nw = (1000*18)/(π *50) =114.65 rpm
Metal removal rate: Zw = πfapnw (dm +ap)
=π*0.026*0.058*114.65*(5+0.058)
= 2.7cm3/min
Power required at the tool:
Pm=Ps *Zw =3.7kw*2.7cm3/min =10 KW
Motor power required:
Pe = pm /m = 10/0.8 = 12.5HP
10 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 TYPICAL LATHE OPERATION:
Quiz:
1. Determine the rotational frequency as well as the metal removal rate of
machining for turning operation with the following conditions; Cutting speed =
50 m/min; Diameter to be turned = 75 mm; Depth of cut = 2.5 mm; Feed =
0.25 mm/rev.

2. Estimate the time required for a single cut to turn Ø25mm, 100 mm long work-
piece with a cutting speed of 30 m/min, & a feed of 0.25 mm/rev.

3. Determine the total production time for a batch of 400 components to be

turned one at a time in an engine lathe given that; Diameter of the work-piece:
Ø 50 mm, Length of the work-piece: 100 mm, Rotational frequency: 380 rpm,
Approach: 1.5 mm, Over run: 1.5 mm, Feed: 0.25 mm/rev.

4. A mild steel rod of Ø 60 mm is machined on a lathe with a single point cutting

tool. Find the motor power using the following data. Cutting Speed = 90
m/min, Feed = 0.5 mm/rev, Depth of Cut = 2.54 mm, specific power ps= 3.7
kw for removing one cubic cm per min, Efficiency of motor η = 50%.

11 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont …
Parameters Working Motion of Machine Tools:
Principal Cutting Operations:
Milling Operations: Horizontal or Horizontal, Slab on knee type milling machine:
slab milling: The feed f, which is equal to the distance moved by the
work-piece during one revolution of the tool, is given by:
f =Vf/Nt
Where: Nt, is the rotational frequency of the cutter, &
Vf , is the feed speed of the work-piece.
d n
The cutting seed V, v  c t
1000
Length for slab milling:
lw=length of work-piece+approach ae d t  ae  +overrun
lw  a e d t  a e   overrun
Machining time: t m  vf
Metal removal rate: Z w  a e a p v f

dt/2 The power Pm & the power efficiency Pe required

to perform any machining operation:
Pm = ps Zw; Pe = pm /m
Where: Pm, is the power required,
Ps , is the specific power.
Over travel/overrun , is the efficiency of the motor
12 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]
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 Cont …
Vertical, Face or End milling machine:
Principal Cutting Operations: The feed f, which is equal to the distance moved by
Milling Operations: Vertical the work-piece during one revolution of the tool, is
milling: given by: f =Vf/Nt ;Vf=f *Nt
Where: Nt, is the rotational frequency of the cutter, &
Vf , is the feed speed of the work-piece.
Length for slab milling: FACE MILLING: Cutter Ø
larger than width of work-piece
lw=length of work-piece + Ø
Machining time: t  l w  d t 
m
vf
Z  ae a p v f
FACE MILLING: Cutter Ø larger than width of work-piece Metal removal rate: w

Length for slab milling: FACE MILLING: Cutter Ø

less than width of work-piece
lw=length of work-piece + 2 ae d t  ae 

l w  2 a e d t  a e 
Machining time: t m 
vf
FACE MILLING: Cutter Ø less than width of work-piece Metal removal rate: Z w  a e a p v f
13 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected]
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 Cont …
Parameters Defining Working Motion of Machine Tools:
Milling: V = π dc nt /1000 ; Where dc, is the diameter of the cutter &
nwt , is rotational frequency of the tool
Ex1: For a slab milling operation determine the rotational frequency
setting for a 100 mm dia HSS cutter machining grey cast iron at a cutting
speed of 15m/min & feed is 58 mm/min, depth of cut is 15mm, width of
work-piece is 50mm, the cutter has 8 teeth. Determine feed per tooth &
metal removal rate.
Solution:
Rotational frequency: V = π dc nt /1000
15m/min= π * nt *100mm/1000
nt = 47.7 rpm
Feed per minute: Feed =58mm/min
Feed per revolution: 58/47.7 = 1.2mm/rev
Feed per tooth: 1.2/8= 0.15mm/tooth
Metal removal rate: Zw = ae ap Vf
Vf = f * nt =1.5cm*5cm*276.6cm/min
=58*47.7 = 2075cm3/min
=2766.6mm/min
14 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont …
Milling: Ex2: A carbide face milling cutter of 75 mm diameter is used to take
three cut across the face of a block of aluminium which 200mm wide. The length of
the block is 450 mm. If a feed of 0.75 mm/rev is used.The depth of cut is 1.2 mm.
a. Calculate the time taken if the cutter dia. is 75 mm, depth of engagement is (ae) is 70 mm.
b. Calculate power required at the cutter & at the electric motor if the specific horse power is
0.03 HP/cm3/min & η = 70 %
Solution: Rotational frequency: V = π dc nt /1000
320m/min= π * nt *75mm/1000
nt = 1358.2 rpm
Feed per revolution: = Feed speed
Vf= f*Nt= 0.75mm/rev*1358.2rpm = 1018.5
Machining time for first cut: 450  2 7075  70 
ae = 70 mm tm   0.47 min  28.7 sec
0.75 *1358.2
Machining time for second cut: same =28.7sec
Machining time for third cut: 450  75
cutter diameter is greater t m   0.45 min  26.5 sec
0.75 *1358.2
Total Machining time: = 28.7*2+26.5 = 83.9 sec
Metal removal rate: =7*0.12*.075*1358.2)*2 +(6*0.12*0.075*1358.2)
=244.5cm3/min
Power required= ps Zw;= 0.03*244.4= 7.33HP
Electrical power Pe = pm /m = 7.33*0.7= 10.5HP
15 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 TYPICAL MILLING OPERATION:
Quiz 2:
1. A carbide milling cutter 250 mm in diameter is used to cut a block of mild steel.
The block is 500 mm long. If the feed is 0.5 mm/rev & depth of cut is 1.2 mm,
determine the time taken to take one cut. The over travel is 16 mm & the cutting
speed is 80 m/min.
2. The feed of an 8-teeth face mill cutter is 0.325 mm per tooth at 200 rpm. If the
depth of cut is 3 mm & width of cut is 100mm, calculate the power required at the
cutter & at the motor. (Specific power ps= 0.03 HP/cm3/min & η = 60 %).
3. Determine the power required for a milling cutter to take a cut 100 mm wide 3
mm deep at 75 mm/min feed for an alloy steel. Cutter diameter is 100 mm &
cutting speed is 15 m/min. (Specific power ps= 0.03 HP/cm3/min & η = 60 %).
4. For a horizontal milling operation determine the following a) RPM setting, b)
Metal Removal Rate, c) Feed per tooth. Data Given: Cutter Diameter= 90mm;
Depth of cut = 6.5 mm;Width of cut = 38 mm; No. of teeth in the cutter = 12.
5. Calculate the milling cutter offset distance for a 100 mm dia cutter that is to cut a
slot of 25 mm deep. Also determine the time required to mill the slot in a work
piece of 250 mm long with a feed of 12mm/min. Assume 1.5 mm approach and
over travel allowance.
6. Determine the total production time for a batch of 800 components to be milled
two at a time in a fixture on a horizontal milling machine: Length of the workpiece
= 180 mm, Approach = 25 mm, over run = 10mm, Feed/tooth = 0.25 mm, No.
of teeth = 10, RPM = 80, Time allowances = for unloading loading and cleaning 1
16 ½ mins/cycle and for other allowances = ½ min/cycle.
Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 2. 2. REGULATION OF SPEED & FEED RATE:
Aim of speed & feed rate:
Machining operation parameters: Speed, Feed & Depth of cut.
Ensure minimum cost of machined surface.
C = Cmt + Cnpt + Ctc + Ct ; Where:

17 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
General tool life equation:T = C/Va Sb t
Optimum Tool life can be obtained only by working at
optimum value of cutting speed, feed & depth of cut.
In order to machine arbitrary dia. The RPM must be
n=1000V/π D, i.e. there must be a step-less regulation of V
so any desired value of RPM may be set corresponding to the
optimum cutting speed.
Economically step-less speed & feed rate regulation
have however, not yet been designed for majority of machine
tool.
Most of the NC machine tools are still designed for
stepped regulation of speed & feed rate. In such
machine tools only certain discrete values of the spindle RPM
& feed rate are available.
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 Cont…

The provision of regulating the spindle RPM & feed

rate is an essential requirement of machine tool to
ensure economic machining of work-pieces of different
materials &

Size by cutting tools of different shapes & composition.

Design of Speed Box

Principle of designing speed boxes, Gear boxes are

employed for stepped regulation of the RPM.

19 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 VARIOUS LAWS OF STEPPED REGULATION:

In stepped regulation of speed only certain value of the

spindle RPM are available on the machine tools.
Criterion for choosing the discrete steps, Two extreme
available n1 & nZ spindle RPM.
The same number of Z intermediate steps may be placed in
number of ways.
The various series of RPM value have diff. operational
characteristics.
Let us analyze 4 cases & select the most suitable
law of speed range distribution:
Arithmetic, Geometric, Harmonic & Logarithmic progression
20 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
1.The RPMValues Constitute an Arithmetic Progression:
The diff b/n adjacent RPM value is constant:
Where a=common diff of the arithmetic progression
N12 = n1 + 11a
a = 375-30/11
= 31.4

For particular V the maximum selected cutting condition the dia

range of work-piece that can be machined by a particular spindle
RPM value nx can be determined as:

Hence the dia. Range served

by this particular RPM is:

21 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Stepping of Speeds According to Arithmetic Progression:
Let n1, n2, … , nz be arranged according to arithmetic progression.
Then n2 – n1= n3 – n2 = constant
For an economical cutting speed v0, the lowest speed vl is not constant;
it decreases with increasing diameter.

22 Speed stepping according to arithmetic progression.

Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
Let us calculate the RPM value & dia. Range served by each RPM for
the ffing conditions n1=30RPM, nz=375RPM, number of speed steps
Z=12,V=20m/min. these value are tabulated below in table.
Table1: Dia. Range for diff. rpm values in arithmetic progression.

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 Cont…
Suppose we start machining a wp of dia. 212mm. For cutting speed of
V=20m/min, the value n1=30rpm will correspond to optimum
cutting.
Before we change over to the next higher rpm value of n2=61.4, we
must remove 108.3mm of metal from the dia. Assume depth of cut of
5mm, this will involve 11passes.
During all passes except the first one, we would be machining
uneconomically as the actual cutting speed would be less than the
permissible value.
On the other hand in changing over from an rpm value of n11=344 to
n12=375, we have to reduce the wp. dia. only by 1.6mm. We could
actually remove more than this allowance in one pass.
It follows from the above analysis that in the high rpm range some
value of speed steps are redundant, whereas in the low rpm range
there is clearly a need to add more steps b/n the calculated value.
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 Cont…
EX.1 Let us calculate the RPM value & dia. Range served by each
RPM for the ffing conditions n1=20RPM, nz=250RPM, number of
speed steps Z=8,V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in arithmetic
progression
RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=
N9 =
N10 =
N11 =
N12 =
25 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 2.The RPM Values Constitute a Geometric Progression:

Stepping of Speeds According to Geometric Progression

The percentage drop from one step to the other is constant & the
absolute loss of economically expedient cutting speed δv is
constant all over the whole diameter range. The relative loss of
cutting speed δvmax/v0 is also constant.
 = (nZ /n1)1/(z-1)
= (n12 /n1)1/(12-1)
= (375 /30)1/(11)
= 1.26
26 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Stepping of Speeds According to Geometric Progression:
The percentage drop from step to step δn decreases as the speed increases.
Thus the speeds are not evenly distributed & more concentrated & closely
stepped, in the small diameter range than in the large one.

27 Speed stepping according to geometric progression.

Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
Let us calculate the RPM value & dia. Range served by each RPM for
the conditions n1=30RPM, nz=375RPM, number of speed steps
Z=12,V=20m/min. these value are tabulated below in table2.
Table2: Dia. Range for diff. rpm values in geometric progression

28 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
Before we change over from a speed n1=30rpm to
n2=37.5rpm an allowance of 42mm must be machined
from the wp dia.
Again, providing for a maximum depth of cut of t=5mm,
this allowance may be removed in 5 passes.
In changing over from n11=300rpm to n12=375rpm, we
have to take 4.2mm or a depth of cut of 2.1mm which can
be easily accomplished in one pass.
We thus see that in order to make the machine tool
performance equally feasible in the whole rpm range, the
low rpm value should be brought still closer while the high
rpm value can be widened a little.
29 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
EX.2 Let us calculate the RPM value & dia. Range served by each
RPM for the ffing conditions n1=20RPM, nz=250RPM, number of
speed steps Z=8,V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in geometric
progression
RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=
N9 =
N10 =
N11 =
N12 =
30 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
3.The RPMValues Constitute a Harmonic Progression:
The HP is developed from the basic idea that the dia. range served
each rpm of the progression is equal. i.e.

= 2.75x10-3

The harmonic progression can be

written as follows:

C = 1/nx – 1/nx+1
=1/n1 – 1/n1+1
= 1/30 – 1/32.7
= 0.00275229
31 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
The value of rpm & dia. range for the same data used in the previous
examples are tabulated in table3.
Table3: Dia. Range for diff. rpm values in harmonic progression

32 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…

It may be seen that in order to change from

n11=183rpm to n12=375rpm, the wp dia. must be
reduced from 35mm to 17mm.
On a slender wp of 35mm, a large depth of cut can’t
be taken as this would lead to the deformation of the
wp.
Assuming a permissible depth of cut of t=2mm on
the slender wp, the total allowance will be machine
in 4 to 5 passes.
It may be concluded that in harmonic progression the
rpm value in the high range are too wide apart,
making this range uneconomical for exploitation.

33 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
EX.3 Let us calculate the RPM value & dia. Range served by each
RPM for the ffing conditions n1=20RPM, nz=250RPM, number of
speed steps Z=8,V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in Harmonic
progression
RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=
N9 =
N10 =
N11 =
N12 =
34 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
4.The RPMValues Constitute a Logarithmic Progression:
In this progression the dia. range is a function of the dia.
Where: M is known as the location coefficient;
generally p=0.5.

35 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…

The logarithmic progression can be written as follows

36 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…

For a given value of n1, nz & Z it is difficult to develop the

logarithmic progression as this has to be done by successive
trials with different values of M.
For instance
Knowing d2 the next dia. Is found as
In this manner d12 can be found for two values of M. say M=1.0
& 0.5. As it is known that d12=17mm, the correct value of M is
found by linear interpolation.
The logarithmic progression for the data of previous ex. Is
given in table4. It would be developed for a value of M=0.88.

37 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
The value of rpm & dia. range for the same data used in the previous ex.
are tabulated in table4. It has been developed for a value of M=0.88.
Table4: Dia. Range for diff. rpm values in logarithmic progression

38 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
EX.4 Let us calculate the RPM value & dia. Range served by each
RPM for the ffing conditions n1=20RPM, nz=250RPM, number of
speed steps Z=8,V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in logarithmic
progression
RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=
N9 =
N10 =
N11 =
N12 =
39 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…

A comparison of the rpm value of table2-4 reveals that in the low as

well as high rpm range the value of table4 lie b/n the values of
table2&3.
It may be thus concluded that from the point of view of the
operational efficiency of the machine tool, logarithmic progression
is most suitable. The efficiency of geometric progression if poorer in
the low rpm range, whereas that of the harmonic progression is
poorer in the high rpm range.
Despite the major shortcoming discussed above, geometric
progression is commonly used in machine tool drives owing to the
following advantages:
1. Constant loss of economic cutting speed in the whole rpm range
2. Constant loss of productivity in the whole rpm range
3. Better design feature
40 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
Geometric progression is commonly used in machine tool
drives owing to the following advantages:
1. Constant loss of economic cutting speed in the whole rpm range:
Suppose the spindle rpm value constitute: n1, n2, n3, …, nj, nj+1
Consider optimum cutting speed lie b/n nj & nj+1

Obviously, of the two rpm nj & nj+1, we select the one which gives a cutting
speed closer to Vopt. The diff. b/n the actual & optimum cutting speed is known
as the loss of economic cutting speed & hence the loss of economic cutting
speed is maximum when the optimum cutting speed lie at the middle of two
speeds provided by nj & nj+1

It may concluded that in order that (Vj)max may be constant & j must be
41
constant. this means that the rpm value must lie in a geometric progression.
Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…

2. Constant loss of productivity in the whole rpm range:

The productivity of a machining operation can be expressed as

the surface area of metal removed in unit time. i.e. by the
quantity:

Where: V= the cutting speed, m/min

S = the feed, mm/rev

____ =V

For a constant value of feed s & depth of cut t, the productivity of

machining operation is constant in the whole rpm range.

42 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
3. Better design features:
When all the rpm value of a spindle are obtained from a single
transmission, i.e. by changing gears only b/n two shafts, then any of
the series discussed above can be utilized for designing the speed box.
If the rpm value are changed by mounting a new pair of gears on the
shaft every time, then changing of speeds becoming time-
consuming, inconvenient & economically infeasible. If the
rpm values are obtained by mounting gear pairs of the transmission
ratio the dimension of the speed box becoming too large.
These consideration underline the fact that speed steps in a speed box
should be obtained not through a singe transmission b/n two shaft but
through a group of transmission b/n a number of shaft.
This feature can be realized in an actual speed box design only if the
rpm value lie in a geometric progression.
43 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Cont…
The Initial Information Required for Designing a Speed box:
Selection of Range of Ratio:
Essential information before start designing stepped drive:
1. The highest out put rpm, nmax
2. The lowest out put rpm, nmin
3. The number of steps Z into which the range b/n nmax &
nmin is divided
4. The number of stages in which the required number of
speed steps are to be achieved.
An important parameter in designing
speed boxes is the range ratio:

The very wide speed range is generally neither practicable

nor economically feasible. The value Rv should therefore, be
kept within reasonable limits.

44 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
The range of dia. Should be selected & reveals that a ratio of:
covers more than 85% of the wp., while
6 covers 92% of the wp.
After selecting the proper values of Rv & Rd, then the range ratio Rn is
determined. Typical values of Rn for some groups of machine tools are
given in table5:
Table5: typical range ratio value for some machine tools.

45 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
A variety of cutting tools of diff. shapes & compositions are
used on general-purpose machine tools, & therefore, Rn values
are relatively large.

On the other hand, in grinding machines the grinding wheel

diameter generally varies in the range Rd<2 & the wheel
material being the same, Rn values are small.

Low Rn value in the range of Rn=5-10 are also characteristic of

special purpose machine tools.

The Rn value calculated on the basis of conditions discussed

above should be increased about 25% to provide for future
progress in machining techniques, cutting tool materials &
design.
46 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019
 Stepped Regulation of Feed:
Design of Feed Box:

In machine tools the feed motion in generally obtained through

following kinematics train:
1. The driving member, it may be driven by the spindle through
gear, belt or chain transmission in lathe & drilling, or may be
powered by an independent motor as in milling machine;
2. The device for engagement & reversing the feed mechanism;
3. The feed box;
4. The single transmission which provide heavy speed regulation;
5. The traction device which is generally a screw & nut or rack &
pinion transmission;
6. A rapid travers mechanism which is generally powered by a
separate motor & is kinematically linked to the feed mechanism
immediately after the single gear transmission.

47 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019

 Cont…
The accuracy of the kinematic train of the feed box is determined
by its function.
• Productivity & accuracy in turning, drilling, boring are not high
• Generating obtain profile thread, gear, worm cutting
In a majority of machine tools stepped feed regulation is employed
b/c economically viable step-less methods of feed regulation are
not available.
The machining time of the an
operation is in general
calculated from the expression

The productivity of the machine tool, which may be

described as the length of machined surface per unit time.
Let Qopt of the machine tool corresponding to the nopt & sopt,
which lie b/n spindle speeds nj & nj+1 & feed rate sj & sj+1

48 Compiled by: Abrha Meressa (M.Sc. MEng.) [email protected] 2 October 2019