M/C TOOL STRUCTURES DESIGN

ME6202 3 credits [3-0-0]

Dr C K Biswas
Prof., Dept of ME

MTT
 CONTENT

• Forces on m/c tools

• Design requirements
• Forces on lathe
• Design for strength
• Design for stiffness
 CLASSIFICATION STRUCTURES
1. Beds and bases where various sub assemblies are mounted
2. Speed box housing, spindle head, etc where individual units are
housed
3. Table, carriage, knee, tail stock, etc, are the parts support and move
w/p & cutting tools
 FORCES ON M/C TOOLS
Sources and the types of the forces that develop in machine tools
1. Cutting forces originating at the cutting point(s)
In continuous type machining;
• Main cutting force, PZ along the velocity vector, VC
• Feed or thrust force, PX along the feed direction
• Transverse force, PY normal to PZ – PX plane in turning, boring and similar
single point cutting process
• Torque and thrust force in drilling, counterboring, counter sinking etc.
In impact initiated type;
• Shaping, planing, slotting, gear shaping etc.

In intermittent type;
• Fluctuating forces due to intermittent cutting in milling, hobbing etc.
 FORCES ON M/C TOOLS
2. Gravitational forces
• Dead weight of the major and heavy components of the Machine – Fixture –
Tool – Work (M – F – T – W) system, e.g., workpiece, headstock, tailstock,
saddle, bed and moving tables etc.

3. Frictional forces
• Due to rubbing at the sliding surfaces.

4. Inertia forces
• Due to acceleration and deceleration at the end points of sliding and
reciprocating motions of heavy parts like carriage or saddle, turret slide, tool
slides, moving beds, reciprocating tables, rams, jobs etc.

5. Centrifugal forces
• Due to high speed rotation of eccentric masses
• Due to wide run out or eccentric rotation of jobs, machine tool parts, spindle,
shafts, tools etc.
EFFECTS OF THE VARIOUS FORCES ON MACHINE TOOLS

• Energy or power consumption

• Increased cutting zone temperature and its detrimental effects
• Dynamic forces resulting vibration and chatter cause poor surface quality
and reduction of life of cutting tools as well as damage of the machine tools
• Elastic deflection and thermo-elastic deformation of several bodies leading
to dimensional inaccuracy
• Rapid wear and tear at the sliding surfaces
• Noise and inconvenience
• Chances of premature mechanical failure of cutting tools and other
components due to excessive stresses, thermal fracture, wear, fatigue,
resonance etc.
 DESIGN REQUIREMENTS
1. All important mating surfaces of the structures should be machined with
high degree of accuracy to provide desired geometrical accuracy
2. The initial geometrical accuracy of the structures should be maintained
during the whole lifetime of the machine tool
3. The shape and size of the structures should provide scope for safe
operation and maintenance of the machine tools. The stresses and
deformations due to mechanical forces as well as thermal stresses should
be with safe limits.

Design considerations
1. Selection of proper materials
2. High static and dynamic stiffness
 FORCES ON LATHE

1. The
4. G = Weight of the work piece
2. force
Reaction forces
acting on in the
the work piecevertical direction
at the given location
RAZ thetool.
of the5.cutting head force
= Reactive stock each
centeracting
A at A and B
RBZ at tail
PZ– Tangential stock center
component, B
main force,
6. K = Pressing force acting on w/p at the tailstock B
3.
PX – Reaction forces
Axial component, feedin the horizontal direction
force,
7. RAY
Tightening
= Reactionforce Pxthe
force at +Khead
acting oncenter
stock w/p atAthe headstock A
PY – Transverse component, thrust
RBY = Reaction force at the tail stock center B
 FORCES ON LATHE
Consider vertical plane, the forces are under equilibrium at A:

Reaction forces in the vertical direction tail stock center B,

Similarly, the forces in vertical plane is under equilibrium at B:

Reaction forces in the vertical direction head stock center A,

 FORCES ON LATHE

Consider horizontal plane, the forces are under equilibrium at A:

Reaction forces in the horizontal direction tail stock center B,

 FORCES ON LATHE

Similarly, the forces in horizontal plane is under equilibrium at B:

Reaction forces in the horizontal direction head stock center A,

 DESIGN FOR STRENGTH

The maxm bending moments will occur when saddle is at the center, i.e.

Reaction forces
 TORSION

𝑀𝑇 𝐻 𝑆 𝑀𝑇 𝑆
𝑀𝑇 𝑇 𝑆
The torquemaxm
Hence, transmitted to bed under the head stock (looking from tailstock side)
shear stress
Now, +
Cutting
Torquevalue of will occur when d =2h
The maxm
The torque transmitted to bed at the tail stock
torsional moment of inertia
The maxm value of
= the distance of the outer edge of the bed section along neutral axis and y axis
The torque transmitted to bed under the saddle
= the distance of the outer edge of the bed section along neutral axis and z axis
 BENDING IN VERTICAL DIRECTION

The maxm bending moment will occur at the middle of the bed, so the maxm normal stress in
vertical
The
The bendingdirection
bending momentproduced
moment producedby
bythe
theforces
forces
underthe
under thehead
headstock
stock
underthe
under thetail
tailstock
stock
Where =the
under
under moment
thesaddle
saddleof inertia of the bed section about y axis.
 BENDING IN HORIZONTAL DIRECTION

The maxm bending moment will occur at the middle of the bed, so the maxm normal stress in
horizontal direction

The bending moment produced by the forces

under the head stock since d << L
Where = moment of inertia of the bed section about Z axis.
under the tail stock
under the saddle
 PRINCIPAL STRESS
The maxm principal stress,

So,

Where = permissible stress of the material

For steel = 150 – 200 kgf/cm2
For cast iron = 80 – 120 kgf/cm2
 DESIGN FOR STIFFNESS
The design criteria for bending stiffness is

Where

The design criteria for torsional stiffness is

Where
Usually, 0.5 degrees per meter length
 DESIGN FOR STIFFNESS

The moment of inertia of the bed section about YY axis

 DESIGN FOR STIFFNESS

The moment of inertia of the bed section about ZZ axis

The torsional moment of inertia of the bed section

DESIGN FOR STIFFNESS
The machine tool beds consist of partially or fully closed
box sections with ribs, partitions, etc.
Beds are usually used in machine tools with wall
arrangements and are evaluated as bars subjected to
bending and torsion.
The deflection of a bar depends on and twist depends on ,
where E = modulus of elasticity and G = shearing
modulus. (constant material properties)
These terms are analogues to rigidity, thus the reduced
bending rigidity of a bed will be represented as
The beds have perpendicular or diagonal stiffeners.
 DESIGN FOR STIFFNESS
The bending rigidity have perpendicular stiffeners is given by the equation:

Where E = Young’s modulus of the bed material, kgf/cm2,

= moment of inertia of the wall cross section in the plane of minimum rigidity
against bending, cm4,
= coefficients that depend upon the arrangement of stiffeners. The value of are
given in Table
 DESIGN FOR STIFFNESS
The reduced bending rigidity of a bed with diagonal stiffeners is given by the
equation:

Where E = Young’s modulus of the bed material, kgf/cm2,

L = length of the bed that undergoes deformation,
Ac = area of cross section of the wall, cm2,
= coefficients that depend upon the arrangement of stiffeners. The value of are
given in Table
 DESIGN FOR STIFFNESS

The diagonal stiffeners, the angle between diagonal stiffeners between 60 – 90

degrees
The perpendicular stiffeners, the distance between adjacent stiffeners should
approx. equal to width of the bed.
 DESIGN FOR STIFFNESS
where

= half angle between diagonal stiffeners

 DESIGN FOR STIFFNESS
The reduced bending rigidity of a bed in vertical plane is given by the equation:

Where E = Young’s modulus of the bed material, kgf/cm2,

L = length of the bed that undergoes deformation,
= area of vertical cross section of the wall, cm2,
Coefficients