Faculty of engineering

Mechanical Engineering Dept.

Machine Tools Design

Instructors:
Prof. Dr. Abdelrhman Moussa
Prof. Dr. Mohamed Fekry
Dr. Ahmed Mhroos
Dr. Mohamed Abdallah Bhlol
 Faculty of engineering
Mechanical Engineering Dept.

Machine Tools Design

Chapter 3
Mechanisms of machine
tools

Dr. Mohamed Abdallah Bhlol

Drive systems of machine tools

Gear-box drive

Step cone pulley drive

Stepped pulley drive with back gearing

Feed gearbox with gear cone and sliding key (diving key)

Feed gearbox with tumbler gear (Norton’s gear)

Gearboxes with sliding gears

Gearboxes with jaw clutch

Meander drive with a tumbler gear

Pick of gears

Feed gearbox with change gear quadrant

Disk-type friction stepless drive

Infinitely Variable Drive (Variator)

 Drive systems of machine tools
A drive is a system of mechanisms used to actuate the
operative members of the machine tool.

Machine tool drives can be either stepped or stepless.

 Stepped drives include:

Step pulley drives

Gear-box drives
Multispeed induction motor drives, or
Combinations of the above mechanisms.

 Steppless drives include:

Mechanical infinitely variable speed drives
Variable speed direct current drive motors
Hydraulic drives
 Gear-box drive

The gear-box drive is now prevalent in machine tools as

the drive for the principal movement.

It is compact
Easy to handle, and
Reliable

Howevere,
It does not provide infinite speed variation, and
Has a comparatively low mechanical efficiency at high
speeds.
 Gear-box drive

The gearboxes may utilize:

 sliding gears,
 claw clutches,
 friction clutches,
magnetic clutches,
composite gear change, and
 pick-off gears.
 Step cone pulley drive
It is simple in construction.

The belt is arranged on the four

different steps of the cone pulley
to obtain four different speeds.

The cone pulley has four steps

(A, B, C & D). Another cone pulley
having four steps (E, F, G and H)
is placed parallel to the spindle
cone pulley. Both the cone pulleys
are connected by a flat belt. The
belt can be arranged between the
steps A & H, B & G, C & F and D
& E.
 Step cone pulley drive
The cone pulley at the bottom is
connected to the electric motor by
a ‘V’belt. So the cone pulley at the
bottom rotates at a particular
speed.

The spindle speed is increased

if the belt is placed on the smaller
step of the driven pulley. The
spindle speed will be maximum
when the belt is arranged
between A & H and the speed will
be minimum when the belt is
arranged between D & E.
Step cone pulley drive
The output speeds:

DH
n1  n i .
DA
DG
n 2  ni .
DB
DF
n3  ni .
DC
DE
n 4  ni .
DD
 Step cone pulley drive
The advantages of stepped pulleys drive

Simple and economical design

Possibility of employing group drive scheme
Smooth running especially with v-belt
High mechanical efficiency

The disadvantages of stepped pulleys drive

Very large number of speed steps is not feasible

Speed change is time consuming
Dangerous shifting of the drive belt
 Stepped pulley drive with back gearing
Back gear mechanism is
housed within the headstock of
the lathe.
 A step cone pulley having
steps ABCD and a small pinion
‘P’ are mounted on the spindle
and rotates freely on it.
 The gear ‘S’ is keyed to the
headstock spindle. So, the
spindle will rotate only when the
gear ‘S’ rotates.
The step cone pulley ABCD
and the gear ‘S’ can be kept
separately or made as one unit
with the help of a pin ‘T’. Back gear mechanism
 Stepped pulley drive with back gearing
When the pin is disengaged,
the cone pulley along with the
gear P will rotate freely on the
spindle and the spindle will not
rotate.

There is another shaft parallel

to the spindle axis having back
gears Q and R mounted on it.
These back gears can be made
to mesh with gears P and S or
kept disengaged from them. The
spindle can get drive either from
the cone pulley or through back
gears. Back gear mechanism
 Stepped pulley drive with back gearing
Drive from step cone pulley

When the spindle gets drive

from the cone pulley, the back
gears Q and R are disengaged
from the gears P and S. The pin
‘T’ is engaged with cone pulley.
The belt can be arranged on the
steps A,B,C or D to get four
different direct speeds for the
spindle.

Back gear mechanism

 Stepped pulley drive with back gearing
Drive through back gears
Back gears Q and R are
engaged with gears P and S. The
pin ‘T’ is disengaged from the
cone pulley to make the cone
pulley and the spindle separate
units. When the cone pulley gets
drive through the belt, the power
is transmitted through the gears
P,Q and R to the gear S.
Because of number of teeth on
these gears, the spindle rotates
at slower speeds. By arranging
the belt on the different steps of
the cone pulley, four different
spindle speeds are obtained. Back gear mechanism
 Stepped pulley drive with back gearing
The output speeds: (Drive from step cone pulley)
d1 d 5
n1  n i . .
d2 d6
d1 d 7
n 2  ni . .
d2 d8
d1 d9
n3  ni . .
d 2 d 10
d3 d5
n 4  ni . .
d4 d6
d3 d7
n5 ni . .
d4 d8
d3 d9
n 6  ni . .
d 4 d 10
 Stepped pulley drive with back gearing
The output speeds: (Drive through back gears)
d1 d 5 Z1 Z 4
n1  n i . . . .
d2 d6 Z2 Z3
d1 d 7 Z1 Z 4
n 2  ni . . . .
d2 d8 Z 2 Z3
d1 d 9 Z1 Z 4
n3 ni . . . .
d 2 d 10 Z 2 Z 3
d 3 d 5 Z1 Z 4
n 4  ni . . . .
d4 d6 Z2 Z3
d 3 d 7 Z1 Z 4
n5 ni . . . .
d4 d8 Z 2 Z3
d 3 d 9 Z1 Z 4
n6  ni . . . .
d 4 d 10 Z 2 Z 3
 Stepped pulley drive with back gearing
The advantages of stepped pulleys drive with back
gears

Simple and economical design

Smooth running (less noise)
Duplicating of output speeds of the main spindle

The disadvantages of stepped pulleys drive with back

gears

Very large number of speed steps is not feasible

Speed change is time consuming
Dangerous shifting of the drive belt
 Feed gearbox with gear cone and sliding
key (diving key)
It consists of a cone of
gears mounted on a hollow
shaft.
 Gears rotate independently
freely on the shaft.
Steel washers are placed
between the gears to prevent
simultaneous engagement of
adjacent gears.
With the help of sliding key
(that slides within the hollow
shaft), any one of the gears
may be engaged to the cone
gears on the driven shaft.
 Feed gearbox with gear cone and sliding
key (diving key)
The output speeds:

Z1
n1  n i . Key at Z2
Z2
Z3
n 2  ni . Key at Z4
Z4
Z5
n3  ni . Key at Z6
Z6
Z7 Key at Z8
n 4  ni .
Z8
 Feed gearbox with gear cone and sliding
key (diving key)
The advantages of diving key mechanism

Simple control as all transmissions are engaged by a

single lever
Compact design which enables 8-10 transmission in a
single group
Helical gears may be used

The disadvantages of diving key mechanism

The key may get stuck
Low rigidity of the driven shaft due to long keyway
Power loss and wear occurring due to the rotation of idle
gears.
Inability to transmit large torques
Feed gearbox with tumbler gear (Norton’s gear)
It comprises a cone of gears
1 to 8 mounted on the driver
shaft. The number of gears
equal to the number of
transmissions

The tumbler gear can slide

on the driven shaft.

It can mesh with any gear on

the drive shaft through an
intermediate gear which is
located on a swinging and
sliding lever so that it can
engage gears 1 to 8 of different
diameters, on the drive shaft .
Feed gearbox with tumbler gear (Norton’s gear)
The output speeds:
Z1
n1  n i .
Z B
Z
n 2  ni . 2
Z B

Z3
n3  ni .
Z B
Z
n 4  ni . 4
Z B

Z5
n5  ni .
Z B
Z
n 6  ni . 6
Z B

Z
n 7  ni . 7
Z B

Z8
n8  n i .
Z B
Feed gearbox with tumbler gear (Norton’s gear)
The advantages of Norton mechanism

Compact design 10-12 transmissions may be obtained in

one group
Short length of shaft
Simple control as all transmissions are engaged by a
single lever

The disadvantages of Norton mechanism

Low rigidity
Requires a long, odd shaped opening in the gear-box
wall
It is difficult to protect the mechanism against dust
 Gearboxes with sliding gears

Gear wheels on the main

shaft engage with gear
wheels on the counter shaft
by sliding themselves.
The output speeds:
(3 speeds gear box)
Z1
n1  n i .
Z2
Z3
n 2  ni .
Z4
Tow speeds Three speeds
Z5
n3  ni . sliding gear-box sliding gear-box
Z6
 Gearboxes with sliding gears
The advantages of sliding gear box

They are capable of transmitting high torque

Being comparatively small in radial dimension
Only gear wheels in mesh are those, which rotate the
spindle, thereby preventing the other gear box wheels from
wearing out.

The disadvantages of sliding gear box

Impossibility of changing speeds on the run.
Relatively large axial dimensions
A large force is required to shift the gear blocks
 Gearboxes with jaw clutch
A clutch consists of two
mating surfaces with
interconnecting elements, such
as teeth, that lock together
during engagement to prevent
slipping.

These clutches are used to

positively connect and
disconnect rotating shafts.
 Gearboxes with jaw clutch
The output speeds:

Z1 C2
n1  n i .
Z2
C2 C1
Z3
n 2  ni .
Z4
Z5 C1
n3  ni .
Z6
Z1 Z 4 Z 5
n 4  ni . . .
Z2 Z3 Z6
 Gearboxes with jaw clutch
The advantages of jaw clutch gear box

Small axial displacement needed for speed change

Less engagement force compared with sliding
mechanisms
Helical and herring ball gears can be used

The disadvantages of jaw clutch gear box

inherent power losses and wear due to the rotation of idle
gears.
The clutch teeth may be broken
Meander drive with a tumbler gear
The Meander mechanism consists of
identical double cluster gears mounted
on driving shaft I and intermediate shaft
II.

Only the first gear block on the driving

shaft is rigidly mounted, the rest of the
gear blocks on shafts I and II are
mounted freely.

Transmission to the driven shaft III

takes place through a tumbler gear Z0
which is mounted on pin in the arm.
The arm can rotate about shaft III and
can also slide axially along its splines.
 Meander drive with a tumbler gear
The output speeds:
Z1 Z1 Z 0 Z
n1  ni . . .  ni.( 1 ) 2
Z2 Z0 Z2 Z2
Z1 Z 2 Z 0 Z
n 2 ni . . .  ni.( 1 )1
Z2 Z0 Z2 Z2
Z 2 Z1 Z 0 Z
n3  ni . . .  ni.( 1 )0
Z1 Z 0 Z 2 Z2
Z2 Z2 Z0 Z 1 1
n 4 ni . . .  ni.( )
Z1 Z 0 Z 2 Z2
Z 2 Z 2 Z 2 Z1 Z 0 Z
n5  ni . . . . .  ni.( 1 ) 2
Z1 Z1 Z1 Z 0 Z 2 Z2

Z2 Z2 Z2 Z2 Z2 Z2 Z0 Z
n8  n i . . . . . . .  ni.( 1 ) 5
Z1 Z1 Z1 Z1 Z1 Z 0 Z 2 Z2
 Meander drive with a tumbler gear

The advantages of Meander drive

Small axial overall size

Wide range of transmission ratios
Simple control as all transmissions are engaged by a
single lever

The disadvantages of Meander drive

Insufficient accuracy and rigidity of meshing.
All the cluster gears rotate continuously in mesh,
including cluster gears which do not participate in a
particular engagement.
 Pick of gears
Pick-off gears are used for
machine tools of mass and batch
production (automatic and
semiautomatic machines,
special-purpose machines, and
so on) when the changeover
from job to job is comparatively
rare.

Pick-off gears may be used in

speed or feed gearboxes.
 Pick of gears
As shown in figure, the change
of speed is achieved by setting
gears A and B on the adjacent
shafts.

As the center distance is

constant, correct gear meshing
occurs if the sum of teeth of
gears A and B is constant.
 Pick of gears
The advantages of pick-off gears

Simple design
Small axial dimensions

The disadvantages of pick-off gears

Relatively large time is required for changing speed
 Feed gearbox with change gear quadrant
This mechanism is used in
thread cutting on a lathe.

The mechanism consists of

a gear train which adjust the
rotation of the lead screw and
the main spindle (i.e.
workpiece rotational speed) in
order to maintain the required
thread pitch.
The main drawback of this
method is that A lot of time is p wp Za Zc
wasted in calculating and  .
setting the required change
p Ls Zb Zd
gears.
 Disk-type friction stepless drive
Also this type called
faceplate variator.
The drive shaft rotates at a
constant speed n1 as well as
the friction roller of diameter d.
The output speed of the
driven shaft rotates at a
variable speed n2 that depends
on the instantaneous diameter
D.
By axially moving the roller,
the ratio d/D can be changed. n2 d
The instantaneous i  
n1 D
transmission ratio of this
variator is determine as:
Infinitely Variable Drive (Variator)
A pair of conical pulleys is
mounted both on driving shaft
I as well as driven shaft II.

The conical pulleys can

slide axially on splines or key.

A belt, chain or ring

transmits rotation from shaft I
to shaft II.

When one pair of pulleys is

moved closer, the other pair
automatically moves a part.
Infinitely Variable Drive (Variator)