Faculty of engineering

Mechanical Engineering Dept.

Machine Tools Design

Part (2)
Prof. Dr. Abdelrhman Moussa
Dr. Ahmed Mahrous
Dr. Mohamed Abdallah Bhlol
Introduction

➢ A machine tool is a machine for making useful product

of a given shape, size, accuracy and surface finish by
removing metal from the workpiece in a form of chip.

➢ Machine tools constitute about 70% of the total

operating production machines in industry.
Machine tools should possess the
following general requirements:
➢ High static stiffness of the different machine tool elements such as
structure, joints, and spindles.
➢ Avoidance of unacceptable natural frequencies that cause
resonance of the machine tool.
➢ Acceptable level of vibration.
➢ Adequate damping capacity.
➢ High speeds and feeds.
➢ Low rates of wear in the sliding parts.
➢ Low thermal distortion of the different machine tool elements.
➢ Low design, development, maintenance, repair, and manufacturing
cost.
Machine tools classification
1- Machine tools are divided according to their
specialization into the following categories:

➢ General purpose (universal) machines, which are used to machine

a wide range of products.
➢ Special purpose machines, which are used for machining articles
similar in shape but different in size.
➢ Limited-purpose machines, which perform a narrow range of
operations on a wide variety of products.
Machine tools classification
2- Machine tools are divided according to their
level of accuracy into the following categories:

➢ Normal-accuracy machine tools, which includes the majority of

general purpose machines
➢ Higher accuracy machine tools, which are capable of producing
finer tolerances and have more accurate assembly and adjustments.
➢ Machine tools of super-high accuracy, which are capable of
producing very accurate Parts.
Machine tool include the following
elements:

➢A structure that is composed of bed, column, or frame.

➢Slides and tool attachments.
➢Spindles and spindle bearings.
➢ A drive system (power unit).
➢Control systems.
➢ A transmission linkage.
 Machine tool Structures
Machine tool structure

➢Machine tool structure includes a

body which carries and
accommodates all other machine
parts.
Lathe bed

➢It is the skeleton of the machine

tool.

➢ Without a good structure, the rest

of the machine will be ineffective.

Frame of radial drill

The main functions of the machine
structure include the following:

➢ Ability of the structure or the bed to resist distortion

caused by static and dynamic loads.
➢ Stability and accuracy of the moving parts.
➢ Wear resistance of the guideway.
➢ Freedom from residual stresses.
➢ Damping of vibration.
 Machine tool Structures
Structural elements
Structural elements can be classified as:
➢ Machine beds (i.e. flat-bed and slanted bed)
➢ Columns
➢ Bridges
 Machine tool Structures
Classification of machine tool structures

Machine tool structures are classified by layouts into :

➢Open Frame
➢Closed Frame

Open Frame structures

 Most traditional machine tools employ this configuration. Also
known as C- or G frames.

 Provide excellent accessibility to the tool and the WP.

 Not as stiff as the closed frames.

 typical examples are found in turning, drilling, milling, shaping,

grinding, slotting and boring machines.
Machine tool Structures

Slotting machine Boring machine

Examples of open frames (C-frames)

 Machine tool Structures
Closed Frame structures
 Most precision machine tools utilize this structure.
 Commonly referred to as O frames.
Closed frames find application in planers, jig boring, and double
spindle milling machines.

Jig boring machine Double-spindle milling machine

 Machine tool Structures
Deformation and deflections of the structure, which
should be kept within specified limits.
 Machine tool Structures
Deformation and deflections of the structure, which
should be kept within specified limits.
 Machine tool Structures
Vibration and Chatter in Machining Operations

 Low stiffness of the machine tool structure can cause

vibration and chatter of the cutting tools and the
machine components, causing adverse effects on
product quality.

 Chatter results in:

1. Poor surface finish
2. Loss of dimensional accuracy
3. Premature wear and failure of the cutting tool
4. Damage to the machine-tool components
5. Objectionable noise
 Increasing stiffness of machine tool Structure
➢The ribbing system is an
effective method for
increasing the stiffness of the
machine tool structures.

➢Simple vertical stiffeners,

seen in Fig. a, increase the Fig. (a)
stiffness of the vertical
bending but do not improve
horizontal bending.

➢The diagonal stiffness

arrangement, shown in Fig. b,
gives higher stiffness in both
bending and torsion.
Fig. (b)
 Machine tool structure materials
The commonly used material for machine tool structures are cast
iron and steel. Earlier cast iron structures were widely used but due
to advances in welding technology, welded steels are widely used
now days.

1- A cast iron (CI) structure ensures the following advantages:

➢Better lubricating property (due to the presence of free graphite);

most suitable for beds in which rubbing is the main criterion.

➢ High compressive strength.

➢ Better damping capacity than steel.

➢Easily cast and machined.

 Machine tool structure materials

2- Welded steel structures:

➢ Welded structures of steel have much thinner wall thickness as

compared to cast structure. Walls of different thickness can be
welded more easily than casting it.

➢ Lower manufacturing cost for small lot size.

➢Steel has higher strength under static and dynamic loading.

➢ The unit rigidity of steel under tensile, torsional and bending loads
is higher than cast iron.

➢Steel should be used for simple and heavy loaded structures which
are to be produced in small number.
Machine tool structure materials

Cast and Welded structures

 Machine tool structure materials
New materials for machine tool structures:

3. Polymer Concrete (PC) Casting

➢ Polymer concrete is a relatively new

material used in precision machine design.

➢PC structures can have the stiffness

of cast iron structures.

➢Polymer concrete does not diffuse heat as

well as cast Iron

➢Exterior surface can be smooth and is ready

to paint
 Machine tool structure materials
New materials for machine tool structures:

4. Granite-Structures

➢ Used exclusively in
precision instruments
and CMMs.
➢Quite costly

➢very hard and brittle

material

➢Dimensionally very
stable

➢Provides excellent
damping
 Design criteria for machine tool structure
➢ The simple machine tool bed with two-side wall is represented as a
simply supported beam. Figure below depicts a simply supported
beam. Point load F acts at its center.

➢The maximum bending stress acting on the beam is given by:

M max . ymax
 max  I
----------------------------------- (1)
 Design criteria for machine tool structure
Where:
Mmax. = maximum bending moment =
Fl
4
h
ymax. = distance of outermost fiber from the neautral axis = 2
bh3
I = moment of inertia of the beam section about the neutral axis =
12

By substituting theses values in eq. (1), σmax changes to

Fl h

4 2 3 Fl
 max  bh3

2 bh2
----------------------------------- (2)

12
 Design criteria for machine tool structure
The permissible bending stress for the beam material is given by:

3 Fl
 per

2 bh 2
----------------------------------- (3)

Or minimum volume of material ( Vσ) required to make sure that beam

has sufficient strength is given by:

3 F l2 
V   b  h  l  2  per   ----------------------------------- (4)
h 
➢The maximum deflection of simply supported beam is given by:

Fl 3
 max .  48EI ----------------------------------- (5)
 Design criteria for machine tool structure
Where:
E : is Young’s modulus (modulus of elasticity) of beam material.

If the deflection of the beam δper. Is not to exceed a permissible value, then

Fl 3 Fl 3
 per .  48EI  bh3
----------------------------------- (6)

48E
12
Or
2
F l 2

V   b  h  l  4E per   ----------------------------------- (7)
h 
Where:
Vδ: is the minimum volume of material required to make sure that
deflection of the beam under load dose not exceed the permissible value
 Design criteria for machine tool structure
The condition for optimum design is given by:
Vσ = Vδ

l 
2
l 
2 2
3 F F
     
2  per h  4 E per h

l 2
 6 E per .
    ----------------------------------- (8)
h   per .
Hence Eq. (8) indicates that for every structure, there exists an optimum
ratio (L/h) and the ratio (L/h) depends upon :
(a) Operation constraint (i.e. δper.)
(b) The material of the structure (i.e. E and σper.)
 Solved problem (1)
➢ A rectangular cross sectional machine tool’s structure or bed with
concentrated load F and volume V, as shown in Fig

(A) Prove that at optimum conditions (where Vσ = Vδ)


l 2
 6 E per .
  
h   per .

Your analysis should be based on maximum bending stress and

maximum deflection for the critical section of the bed.

(B) Compare the dimensions of both the cross-sections of gray cast

iron bed (E = 120 Gpa, σ =230 MPa), and that of steel bed (E = 208
Gpa, σ =450 MPa), where F = 24 KN, L = 500 mm, and δ = 25 µm
 Solution
(A)The maximum bending stress acting on the beam is given by:

M max . ymax
 max  I
----------------------------------- (1)

h bh3
Mmax. = Fl ymax. = 2 I=
4 12
By substituting theses values in eq. (1), σmax changes to

Fl h

4 2 3 Fl
 max

bh3

2 bh2
----------------------------------- (2)

12
 Solution
The permissible bending stress for the beam material is given by:

3 Fl
 per

2 bh 2
----------------------------------- (3)

Or minimum volume of material ( Vσ) required to make sure that

beam has sufficient strength is given by:

3 F l  2

V   b  h  l  2  per  h -----------------------------------

(4)

➢The maximum deflection of simply supported beam is given by:

Fl 3
 max .  48EI ----------------------------------- (5)
 Solution
If the deflection of the beam δper. Is not to exceed a permissible value, then

Fl 3 Fl 3
 per .  48EI  bh3
----------------------------------- (6)
48E
Or
12
2
F l 2

V   b  h  l  4E per   ----------------------------------- (7)
h 
The condition for optimum design is given by:
Vσ = Vδ
l 
2
3 F 2
F l2  
     
l 2
 6 E per .
2  per 4 E per h
h     
h   per .
 Solution
(B) For cast iron:


l 2
 6 E per .
   
h   per .
6  120  103  25  10 3
  78.26mm  0.07826m
230
At L = 500 mm h = 3194.4 mm

2
F l 2

V   b  h  l  4E per  
h 
Solution
2
F l 2

V   
 4 E per h 
24  103 5
 ( 0 . 07826) 2
 1 . 2249  10 m 3

4  120  109  25  10 6

V   bhl

1.2249 10 5
b   7.669  10 6 m
3.1944 0.5
 Solution
For steel:


l 2
 6 E per .
   
h   per .
6  208  103  25  10 3
  77.03mm  0.07703m
405
At L = 500 mm h = 3245.488 mm

2
F l2

V   b  h  l  4E per  
h 
Solution
2
F l 2

V   
 4 E per h 
24  103 6
 ( 0 .07703) 2
 6 .846  10 m 3

4  208  109  25  10 6

V   bhl

6.846  10 6
b   4.219  106 m
3.245  0.5
Exercise 1
➢ A circular cross sectional machine tool’s structure with
concentrated load F and volume V, as shown in Fig.

➢ Find the optimum value of  
 2
l where Vσ = Vδ .
h
 
Quiz 2 (15 min)
a machine tool fram (such as the
overarm of a radial drill) of a
rectangular cross sectional with
concentrated load F and volume
V, as shown in figure.

(a) Derive the condition of (L2/h)

at optimum design ( where Vσ
= Vδ).
(b) How you can increase the
stiffness of this structure?