IPE 4821

MACHINE TOOLS
Lecture 1:

Introduction to Machine Tools

Reference Books
• Elements of Machine Tools by Dr. M.
Anwarul Azim

• Machining Technology by Helmi A. Youssef

• Fundamentals of Machining and Machine

Tools by Geoffrey Boothroyd and Winston
A. Knight
What is Machine Tools?
• M a c h i n e t o o l s a r e s p e c i a l i z e d d e v i c e s o r a p p a ra t us
d e s i g n e d t o p e r f o r m s p e c i f i c m a c h i n i n g o p e ra t i o n s t o
s h a p e , c u t , o r f i n i s h m a t e r i a l s , p r i ma r i l y m e t a l s . T h e s e
o p e ra t i o n s r e l y h e a v i l y o n p r e c i s e m o v e m e n t s a n d a c t i o ns .

• T h e s i g n i f i c a nc e o f m a c h i ne t o o l s l i e s i n t h e i r a b i l i ty
t o p r o d u c e u n i f o r m a n d s t a n d a rd i z e d p a r t s , i n t e g ra l f o r
l a r g e - s c a l e m a n u f a c t ur i ng . T h e p r o w e s s o f m a c h i n e t o o l s ,
f r o m a n c i e n t l a t h e s t o s t a t e - o f - t he - a r t C N C m a c h i n e s , h a s
u n d e r p i nn e d t h e w o r l d ’s i n d u s t r i a l a d v a nc e m e n t s .
What is Machine Tools?

Machine tools are power-driven machines that have the capability of

producing various shapes in metal by cutting away surplus materials.

These are the machines that give special forms to the materials in desired
shapes and tolerances.

These can be metal forming, machining, welding, casting machines plastic

processing machines, non-traditional manufacturing machines, etc.
 Evolution of Machine Tools

Middle Age: 18th Century:

3000 BC: Development of Steam
Development of Mechanical
Introduction of hand-driven
Power using windmill and Engine paved the way of
Lathe in Ancient Egypt.
waterwheel. mechanized process.

Modern Age:
Development of Modern 1960s: Late 19th to early 20th
Techniques like 3D printing,
Digitalization through the Century:
reverse engineering, and
implementation of software and
integration of CNC and Development of Electrically
CAD in Manufacturing. Powered Tools.
machine learning in
manufacturing.
General Aspect of Machining Technology
 What Powers the Machine Tools?
❖ Machine tools have undergone various power transformations over the years. In the early days, manual
efforts were the primary force behind these tools. However, as technology progressed, water and steam
became dominant power sources. With the advent of electricity, electric motors became the predominant
drivers. Today, we find a combination of electric, hydraulic, and even pneumatic systems powering
machine tools. Some advanced machine tools are even powered by computer numerical control (CNC)
systems, which not only drive the machine but also ensure precision and repeatability.

❖ Can Machine Tools Function Automatically?

• Early automation was introduced with the use of templates and cams.

• The 20th century saw the integration of electrical and hydraulic systems.
• CNC machining arrived in the late 20th century, revolutionizing automatic control.
• Advanced software today allows for intricate designs to be automatically machined with precision.
 Characteristics of Machine Tools

Machine tools have certain unique characteristics:

• Precision: They are designed to manufacture parts

with high precision.

• Rigidity: They can withstand the forces exerted

during the cutting process.

• Power: They can drive cutting tools through tough

materials.

• Repeatability: Able to produce the same part, again

and again, maintaining the same quality.
 Basic Elements of Machine Tools
1) Work holding device: Workholding is a catchall term referring to any device or apparatus used to keep a workpiece stable and
immobile. Some common examples are chucks, toggle clamps, power clamps, end stops, soft or hard jaws, locators, vises,
fixtures, and jigs. Ideal work-holding devices have easily repeatable setups.
2) Tool holding device: A tool holder is a machining component that holds the cutting/shaping/forming tool in place. Its purpose is
to hold the tool in place as precisely and firmly as possible, as a barely perceptible increase in runout can ruin your project or
break your cutting tool. Different types of holders have varying levels of runout and balance.
3) Work motion mechanism: The work motion mechanism of machine tools involves the controlled movement of the workpiece
relative to the cutting tool during machining. Common mechanisms include linear motion along precision slides and ways, rotary
motion facilitated by rotary tables or additional axes in CNC machines, reciprocating motion in shapers and planers, and feed
mechanisms utilizing lead screws or ball screws. Hydraulic, pneumatic systems, and computer numerical control (CNC)
employing servo motors are also integral. The selection of a specific mechanism depends on the machining process requirements,
emphasizing precision, speed, and flexibility for optimal manufacturing performance.
4) Tool motion mechanism: Tool motion mechanisms in machine tools control how the cutting tool moves relative to the workpiece
during machining. This involves linear, rotary, or reciprocating motion, facilitated by precision surfaces, rotary tables, or CNC
axes.
 Basic Elements of Machine Tools
5) Support structure:

In the realm of machine tools, the support structure plays a pivotal role in ensuring precision, stability, and

optimal functionality. It serves as the foundation upon which the entire machine tool system rests, absorbing

vibrations, minimizing deflections, and providing structural integrity during machining operations. The

support structure's design and materials must be meticulously considered to withstand dynamic forces and

environmental conditions, thus contributing significantly to the overall accuracy and efficiency of the

machining process. A robust support structure is paramount for achieving consistent and high-quality results

in various manufacturing applications, underscoring its fundamental importance in the domain of machine

tools.
 Classification of Machine Tools
Based on Structure:
• Bed-Type Machines: Have a stationary bed providing support for various components.
• Column and Knee Type Machines: Feature a vertical column supporting a horizontal knee for vertical movement of the
worktable.
• Planer-Type Machines: Have a single-point cutting tool mounted on a cross rail, suitable for machining large workpieces.
• Multi-Spindle Machines: Equipped with multiple spindles for simultaneous machining.
Based on Automation:
• Manual Machines: Operated by human intervention without automation.
• Semi-Automatic Machines: Involve a combination of manual and automated operations.
• CNC (Computer Numerical Control) Machines: Controlled by computer programs for precise and automated machining.
Based on Tool Type:
• Single-Point Cutting Tool Machines: Use a single-point cutting tool, common in lathes.
• Multi-Point Cutting Tool Machines: Use tools with multiple cutting edges, typical in milling and drilling machines.
Based on Motion Control:
• Linear Motion Machines: Operate along linear axes for straight-line movements.
• Rotary Motion Machines: Involve rotary movements, such as in lathes and rotary tables on milling machines.
 Classification of Machine Tools
Based on Function:
• Turning Machines: Primarily for turning or cylindrical machining operations. Includes lathes and turning centers.
• Milling Machines: Used for milling operations to create flat or contoured surfaces.
• Drilling Machines: Designed for creating holes in workpieces using rotating cutting tools.
• Grinding Machines: Specialized for precision grinding operations using abrasive wheels.
• Electrical Discharge Machines (EDM): Utilize electrical discharges for material removal. Includes wire EDM and
sinker EDM.

Based on Application:
• Turning Centers: Combine turning and milling capabilities for enhanced versatility.
• Machining Centers: Integrate multiple machining processes, such as milling and drilling, in a single machine.
• Gear Cutting Machines: Specifically designed to produce gears.
• Boring Machines: Used for enlarging existing holes or creating precise bores.
 Classification of Machine Tools

Based on the capability of production of

machine tools:
• General-purpose machine tools
They can be used for almost any type of
application but, the speed of production is very
low.
• Production machine tools
Slightly more productive than general-purpose
M/C tools and are used for production purposes.
• Special purpose machine tools
They are specially made for mass production
and are designed for particular applications.
• Single-purpose machine tools
They are used for highly automated production
processes, where the production rate is very
high. They are the least flexible.
Classification of Machine Tools
Classification of Machine Tools
 Important Considerations before Designing Machine Tools

The successful design of a machine tool requires the following fundamental knowledge:
1. Mechanics of the machining processes to evaluate the magnitude and direction and to
control the cutting forces.
2. The machinability of the different materials to be processed.
3. The properties of the materials used to manufacture the different parts of the machine
tool.
4. The manufacturing techniques that are used to produce each machine tool part
Economically.
5. The durability and capability of the different tool materials.
6. The principles of engineering economy.
 Enhancement of Productivity
The productivity of a machine tool is measured either by the number of parts produced in a unit of
time, by the volumetric removal rate or the specific removal rate per unit of power consumed.

Productivity levels can be enhanced using the following methods:

1. Increasing the machine speeds and feed rates.
2. Increasing the machine tool available power.
3. Using several tools or several WPs machined simultaneously.
4. Increasing the traverse speed of the operative units during the non-machining parts of the
production time.
5. Increasing the level of automation for the machine tool operative units and their switching
elements.
6. Adopting modern control techniques such as NC and CNC.
7. Selecting the machining processes properly based on the machined part material, shape
complexity, accuracy, and surface integrity.
8. Introducing jigs and fixtures that locate and clamp the work parts in the minimum possible
time.
 Stability Requirements
Machine tools are designed to achieve the maximum possible productivity and to maintain the prescribed
accuracy and the degree of surface finish over their entire service life. To satisfy these requirements, each
machine tool element must be separately designed to be as rigid as possible and then checked for resonance
and strength.
Furthermore, the machine tool must have adequate stability and should possess the following general
requirements:
1. High static stiffness of the different machine tool elements such as structure, joints, and spindles.
2. Avoidance of unacceptable natural frequencies that cause resonance of the machine tool.
3. Acceptable level of vibration.
4. Adequate damping capacity.
5. High speeds and feeds.
6. Low rates of wear in the sliding parts.
7. Low thermal distortion of the different machine tool elements.
8. Low design, development, maintenance, repair, and manufacturing cost.
 Maintenance of Machine Tools

Machine tool maintenance refers to the systematic and planned activities performed to ensure the proper

functioning, reliability, and longevity of machine tools used in manufacturing and machining processes.

Machine tools cannot produce accurate parts throughout their working life if there is excessive wear in their

moving parts. Machine tool maintenance delays the possible deterioration of machine tools and avoids the

machine stoppage time which leads to lower productivity and higher production costs. Maintenance is

classified under the following schemes:

• Preventive Maintenance

• Corrective Maintenance

• Reconditioning
Maintenance of Machine Tools
Maintenance of Machine Tools
Maintenance of Machine Tools
 Maintenance of Machine Tools
Comparison Between Preventive and Corrective Maintenance:

Timing: Preventive maintenance is planned and scheduled in advance, while corrective maintenance is reactive and
occurs in response to issues.

Cost: Preventive maintenance incurs upfront costs for routine activities, whereas corrective maintenance may have
higher immediate costs for repairs or replacements.

Downtime: Preventive maintenance aims to reduce downtime by addressing issues proactively, while corrective
maintenance can lead to unplanned downtime when breakdowns occur.

Risk Management: Preventive maintenance is a risk management strategy to prevent failures, while corrective
maintenance is a strategy to deal with failures after they happen.

Long-Term Impact: Preventive maintenance contributes to the long-term reliability and lifespan of equipment, while
corrective maintenance addresses immediate issues without necessarily addressing underlying causes.

Both preventive and corrective maintenance are important elements of a comprehensive maintenance strategy, and
organizations often use a combination of both approaches to optimize the performance and reliability of their
equipment.
 Elements
The main functions of a machine tool are holding the WPs to be machined, holding the tool, and achieving the required
relative motion to generate the part geometry required.
Machine tools include the following elements:
1. A structure that is composed of a bed, column, or frame
2. Slides and tool attachments/ Guideways
3. Spindles and spindle bearings
4. A drive system (power unit)
5. Work-holding and tool-holding elements
6. Control systems
7. A transmission linkage
Stresses produced during machining, which tend to deform the machine tool or a WP, are usually
caused by one of the following factors:
1. Static loads that include the weight of the machine and its various parts.
2. Dynamic loads that are induced by the rotating or reciprocating parts.
3. Cutting forces generated by the material removal process.
Both the static and the dynamic loads affect the machining performance in the finishing stage, while the
final degree of accuracy is also affected by the deflection caused by the cutting forces.
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