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INTRODUCTION TO
MACHINE TOOLS

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 AREA OF STUDY
• Background Information
• A machine tool
• Application of Machine Tools
• Major types of Metal shaping processes
• Functions of machine Tools
• Classification of machine tools
• Requirement for a machine tool
• Elements of Machine Tools
• Machine tools working motions
• Variable in Production System
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 Introduction:
• The gaining of new dimensions accuracy in
the present industrial age, allows for
precision increasing of machining operations
in the manufacturing industry.
• The growing achievement calls for all the
efforts to be directed towards the
economical (cost -effective manufacture) of
machines and machine parts.

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The basic objectives of economical and efficient
machining practice are:
• Quick Metal Removal Rate (MRR)
• High class surface finish (aesthetics) and
accuracy
• Economy in material and tool cost
• Economy in power consumption
• Economy in the cost of replacement and
sharpening of tool/ tools
• Minimum deal time to accomplish the task
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A. A machine tool:
• Is a metal cutting machine or a hard material
processing machine, that produces different
parts from point of view of correct shape,
dimension accuracy, surface finish,
productivity and other conditions(i.e
properties), using specific technological
process.
• This is done by removing the excess material
in the form of chips (unwanted material from
a particular workpiece).
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B. A machine tool is a power driven device in
which energy is utilized in the deformation of
material for shaping, sizing or processing a
product to a desired accuracy by removing the
excess material in the form of chips.

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C. A machine tool is a machine for shaping or
machining metal or other rigid materials,
usually by cutting, boring, grinding,
shearing, or other forms of deformation.
• Machine tools employ some sort of tool
that does the cutting or shaping. All
machine tools have some means of
constraining the workpiece and provide a
guided movement of the parts of the
machine.
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• Thus the relative movement between the
workpiece and the cutting tool (which is called
the toolpath) is controlled or constrained by
the machine to at least some extent, rather
than being entirely "offhand" or "freehand".
• It is a power driven metal cutting machine
which assists in managing the needed relative
motion between cutting tool and the job that
changes the size and shape of the job material

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 Machine tools mostly find application in
machine shops. Where many machines
are installed for various works.
 Machine tools when taken as a group
can be able produce themselves. ####

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Application of Machine Tools
Machine tools are generally applied mostly
for two purposes:
To produce a certain form of a
product(semi finished product) by
machining processes (Why?)
To produce a finished product by
machining processes (Why ?)

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 Major types of Metal shaping processes
Metals are shaped into usable forms through
various processes:
i. Non chip formation: The metal is shaped under
the action of heat, pressure or both (i.e.forging ,
drawing, spinning, rolling extruding e.t.c
ii.Cutting action: The parts are brought to the
required size by removal of chips (unwanted
material) from the parent metal through
machining operation(turning, milling, shaping,
planning, broaching, sawing)
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Although machining is the broad term removal of
material from the workpiece, it covers several
processes, which are usually divided into the
following categories:
• Cutting generally involves single point or multi
point cutting tools, each with a clearly defined
geometry.
• Abrasive processes, such as grinding.****
• Nontraditional machining processes, utilizing
electrical, chemical, thermal and hydrodynamic
(forces exerted) by methods (TEST I)
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 Functions of machine Tools:
The main functions any machine tool are:
i. To hold, support and guide the work to be cut
ii. To hold, support and guide the cutting tool/tools
iii. To produce a relative movement so as to
enable the cutting tool to generate a
required surface and dimensions
iv. To regulate the cutting motion, feeding
movement, approach movement between
the tool and the work

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 Classification of machine tools:
Machine tools are classified as follows:
A: Classification based on the desired purpose:
a. General purpose or basic machine tools: Sometimes
are called Multi-purpose machine tools. These are
used for performing all metal cutting operations
within their range (i.e lathe, milling, shaper, drilling,
etc)
b. Production machine tools: These are generally multi
stations tooling machines and designed to do one
type of job at a time (Capstan and Turret lathes,
semi-automatic lathes, production milling machines,
multiple head drilling machine etc.)
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 c. Special purpose or single purpose machine tools:
They are used for mass production and generally one
machine is capable of producing only one type of job.
(ie gear generators, camshaft grinders, piston turning
lathes etc)

d. Transfer machine or Flexible manufacturing system:

Is one in which several individual machine tools have
been sequentially arranged, coupled together and
operated automatically as a single unit. They are the
latest machines, can be used to machine any jobs.
They perform less time per part, reduced loading,
greater compatibility, improved safety etc
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 e. The tape controlled machine (NC)
In this type the relative movements of the tools
and the job, the cutting speed and feeds, the
changing of tools when necessary and the
sequence of operations are controlled by punched
hole tape or magnetic tape.(Study)
Such machines are employed when the jobs
require considerable accuracy, are of complex
form and have to be produced in small butches at
regular intervals

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 B: Classification based upon the Size of chips
removed
a. Machine tools using cutting tools and producing
comparatively larger sized chip (i.e. milling m/c,
drilling m/c, shaping m/c)
b.Machine tools using abrasives and producing chips of
very small size (grinding m/c, honing m/c , lapping
m/c, die polishing m/c)

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C: According to the type of surface produced:
a. Machine tools producing mainly plane or
ruled surfaces (slotting , shaping, planning,
milling, broaching etc)
b. Machine tools producing surfaces of
revolution (Lathe, drilling m/c, boring)
c. Gear cutting m/c ( spur gear, bevel gear,
worm gear m/c)
d. Miscellaneous machines (die sinking
machines, thread milling, worm gear
cutting) e.t.c
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• Machine tools can be classified into several
other ways ,viz. as per weight, as light duty(up
to 1 ton), medium duty(up to 10 t),heavy duty
(more than 10 t) , as per degree of automation
as manual, or semi- automatic or automatic
machine tools.

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 Requirement for a machine tool
• Ability to produce the required shape size,
accuracy and surface finish
• High productivity
• Simple design -ease in operation and
maintenance
• Good ergonomics i.e Convenience of controls
and safety
• Aesthetics- good appearance and finish
• Low cost of manufacturing and maintenance
• Environment friendly
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 Elements of Machine Tools:
Various of elements of any machine tool are
1)Structure which is formed by bed, column and
frame
2)Slides, slide ways and tool structure
3)Spindle and bearing
4)Kinematics of machine tools drives-transfers
motions and power (power source) from the input
shaft to the output spindle, transforms motion
from rotation to translation or reciprocating or
vice versa
5)Work holding and tool holding elements
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 Machine tools working motions:
The working motions of the machine tools are
primary cutting motion, feed motion and
other auxiliary motions
1. The Primary cutting motion of machine tool
may either be transmitted to the cutting tool,
or to the work or both simultaneously. These
are:
• Rotary primary cutting motion: Transmitted to the work
(lathe mc), to the tool (grinding, drilling or milling
machines)

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 • Reciprocating primary cutting motion( shaper and
planner)
2.Feed motion: This enable the cutting process to
be extended to the whole surface to be machined
to the work. The rate of feed is substantially less
than the cutting speed. The rate of feed
determines the cross section area of the chip
3.Auxiliary motions: are motions to allow the tool
to advance to the work (tool or work approach)
etc.

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 Variable in Production System
All production systems can be viewed as
consisting of independent (input) variables,
and dependent (output) variables
relationships.
The machine tool operator has a direct control
over the input variables and can specify or
select them when setting up the machining
process

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The following are independent input variables:
i. Workpiece material-Is selected to meet
functional design.
ii. Part geometry- the size and shape of a
worpiece form the source.
iii.Type of machining process-(chip formation,
abrasive machining, or Non- traditional
machining process)
iv.Tool material

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v. Cutting parameters(speed, feed and depth of
cut.
vi. Tool geometry
vii. Work holding devices
viii.Use of cutting fluids.

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Dependent Variables
• These are determined by the process based
on the prior selection of the input or
independent variables
• The following are dependent variables:
i. Cutting force and power
ii. Size and geometry of part(product accuracy)
iii.Type of chip produced
iv.Surface fish
v. Tool wear and tool failure
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Vi. Temperature rise in the workpiece

When unacceptable conditions result from

machining operations ,the manufacturing
engineer must question to determine the
problem course.

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 HOME TASK I
Discuss the following:
1)Machine tool structure(bed column and frame)
2)Essential requirements of machine tool
structure, types and materials
3)Design requirement of machine tool bed
4)Machine tool slides and slideways design
requirement and material.

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 !Thanks!

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