Machine Tools:-

A machine tool is a power driven device in which energy is utilised in deformation of material for
shaping, sizing or processing a product to a desired accuracy by removing the excess material in
the form of chips.
The machine tools are generally used for two purposes:
• To produce certain form.
• To produce finished surfaces.

The form of surfaces produced depends upon the shape of the cutting tool and the relative path of
motion between the cutter and work-piece. The relative motion, also known as working motion,
between cutter and workpiece can be obtained either by the motion of workpiece or cutting tool,
or by a combination of both.
The working motions are of two types:
• primary cutting motion (drive motion)
• feed motion.
Working motions are powered by external source of energy. In addition to working motion,
auxiliary motions such as for clamping/unclamping of workpiece, tool holder, idle travel, changing
speed, engaging/disengaging of working motions, etc. are also provided on machine tools.

Classification of Machine Tools:-

According to the type of the surface generated, the machine tools can be classified as follows:
(a) Machine Tools for Cylindrical Work:
In this case, the workpiece is rotated about an axis, or alternatively the work may be at rest and the
tool is rotated as well as traversed. Various machines used for this type of work are lathe, turret
and capstan lathes, boring machine, cylindrical grinder and surface grinder.
(b) Machine Tools for Flat Surface Work:
For generating a straight-cut plane surface, the work-piece is moved past the cutting tool in a
straight path and the tool is traversed in perpendicular direction or alternatively the tool is moved
in straight path and work is traversed in perpendicular direction. In both these cases, the tool or
the work is traversed in perpendicular direction only after one cut has been completed. The
machines doing this type of operation are planning, shaping, slotting and broaching.
The flat surface could also be produced by having rotary motion of multi-cutting edged tool and
translatory motion of job. The examples of machines employing such motions are milling, surface
grinding machines.
Holes are produced in workpieces by drilling operation.
(i) For Lathes and Boring Machines:
Drive motion—rotary motion of workpiece
Feed motion—translatory motion of cutting tool in the axial or radial direction

(ii) For Drilling Machines:

Drive motion—rotary motion of drill
Feed motion—translatory motion of drill

(iii) For Milling Machine:

Drive motion—rotary motion of the cutter
Feed motion—translatory motion of the workpiece

(iv) For Shaping, Planing and Slotting Machines:

Drive motion—reciprocating motion of cutting tool
Feed motion—intermittent translatory motion of workpiece

(v) For Grinding Machines:

Drive motion—rotary motion of the grinding wheel
Feed motion—rotary as well as translatory motion of the workpiece.

Another way of classifying the machine tools is as follows:

(a) General Purpose or ‘Basic’ Machine Tools:
These are used for performing all metal cutting operations within their range. These include lathes,
shapers, drilling machines, milling machines, grinding machines, planning machines etc.
(b) Production Machine Tools:
These are used to reduce the manufacturing cost and to increase the rate of production. These are
generally multi-station tooling machines and designed to do one type of job at a time. These
include Capstan and turret lathes, semi- automatic lathes, production milling machines, multiple
head drilling machines etc.
(c) Special Purpose or Single Purpose Machine Tools:
These are used for mass production and generally one machine is capable of producing only one
type of job. These include gear generators, camshaft grinders, piston turning lathes, thread rolling
machines etc.
The surface finish depends upon the lay and the feed of the tool or work. Various machines are
capable of producing different types of finish.
In the increasing order of good surface finish, various operations used for machining are arranged as:
i. Cutting,
ii. Sawing,
iii. Hand grinding,
iv. Filing,
v. Turning,
vi. Shaping,
vii. Milling,
viii. Boring,
ix. Drilling,
x. Surface grinding,
xi. Cylindrical grinding,
xii. Boring,
xiii. Lapping,
xiv. Polishing super finishing,
xv. Buffing etc.
The most important requirement to be fulfilled by any machine tool is that it should be able to produce
jobs within high degree of accuracy consistently over a long period of time. For this, it is essential that
they possess static as well as dynamic rigidity. Rigidity of a machine tool is its capability to resist
deformation produced due to the introduction of cutting forces generated while machining.

Cutting Motion in Machine Tools:

The process of chip removal is effected by the relative motion between tool and work piece. The
motions of machine tool may be transmitted either to the cutting tool, or to the work or to both
simultaneously.
Working motions of a machine tool are:
(a) Primary cutting motion,
(b) Feed motion, and these are specified by speed or feed rate.
(a) Primary Cutting Motion:

The most commonly used types of primary cutting motions are:

(i) Rotary primary cutting motion,
(ii) Reciprocating primary cutting motion.

(i) Rotary Primary Cutting Motion:

Rotary motion may be transmitted either to the work as in lathe group of machine tools or to the
tool as in grinding machine, drilling machine or milling machine.
(ii) Reciprocating Primary Cutting Motion:
This motion can be transmitted to the tool as in shaper and slotter or to the work as in planer. In
machine tools using reciprocating primary cutting motion the cutting cycle consists of a working
stroke during which the tool cuts the chips and the idle or return stroke during which the tool or
work returns to its initial position.

In some machine tools, the primary cutting motion may be a combination of rotary and
reciprocating motions.

(b) Feed Motion:

The feed motion enables the cutting process to be extended to the whole surface to be machined
on the work. The rate of feed is substantially less than the cutting speed. Other conditions being
equal, the rate of feed determines the cross sectional area of the chip. A machine tool is subjected
in addition to its static load, to the dynamic loads due to rotation/reciprocation, cutting forces and
friction forces.

Feed motion can be expressed as feed per revolution or feed per stroke, or feed per revolution, or
feed per tooth etc.
Requirements of Machine Tools:
Any machine tool should meet the following requirements:
(i) Ability of produce desired shape and size.
(ii) Design for required accuracy and surface finish.
(iii) High productivity.
(iv) Simple design—ease in operation and maintenance.
(v) Good ergonomics, i.e., convenience of controls and safe design.
(vi) Aesthetics, i.e., good appearance and finish.
(vii) Low cost of manufacturing and operation.
For any machining process, the layout of machine tool must be such that necessary combination
of forming and setting motions are provided. Adequate rotary and translatory motions, either
powered or manual, are provided to realise the required relative motion between the cutting tool
and workpiece.

Process Capability of a Machine Tool:

Process capability of a machine tool is defined as its ability to produce jobs within specified degree
of accuracy consistently over a long period of time. The process capability of a machine tool
depends upon its rigidity which is defined as its capability to resist deformation produced due to
the introduction of cutting forces generated during machining. A machine tool must possess both
static as well as dynamic rigidity.
Process capability can be improved by reducing number of links and changing their rigidity and
reducing range of cutting forces.