Lecture 5 Machine Tool Structure

Machine tool structure consists of beds, columns, bases and housing and makes up around three fourths of the total weight. It transmits both static and operational loads. Structures can be classified by purpose, manufacturing process, or pattern of load transmission. Common types include beds, frames, bases, housings, columns, and casings. Rigidity, shape, layout, assembly, maintenance and cost are important considerations in the design. Materials like cast iron and steel are commonly used due to their properties and availability. Manufacturing process must consider accurate dimensions, internal stresses, and production capabilities. Chip handling also influences design to prevent heat issues.

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Lecture 5 Machine Tool Structure

Uploaded by

MD Al-Amin

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Download as PPTX, PDF, TXT or read online on Scribd

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Machine Tool Structure

Introduction
Backbone of the Machine tool
Consists of beds, columns, bases and housing
Weight is around three fourth
Transmits the static load and operational load
Modern machine tools are lighter
Classification of Machine tool structure
According to Purpose
Bed, Frame works etc.
Bases, bed plates
Housing, boxes, columns etc.
Casing and covers
According to manufacturing process
Cast
Welded
Partly cast, partly welded
According to Pattern of operational load transmission
Closed
Open
Classification of Machine tool structure

Lathe Machine
Milling Machine

Drill Machine Milling Machine Planer Milling Machine

Figure: Open and Closed structural design of machine Tools

Milling Machine
Grinding Planer

Radial Drilling Machine

Milling Machine

Automatic Lathe Machine

Figure: Open and Closed structural design of machine Tools

Requirements of a Machine Tool Structure
High Static and dynamic rigidity
Shape and Layout of the m/c tool and various components
Easy chip removal
Easy machining operation
Easy and safe observation
Easy assembly and dismantling of parts
Easy accessibility and maintenance
Cost consideration
Easiness in installation and transportation
Aesthetic appeal
Requirements of a Machine Tool Structure
To achieve the requirements following points should
be considered
Stress and deformation
Materials of the structural components
Shape, volume and other properties of chips
Transportation and installation of machine tool
Manufacturing capability
Aesthetic aspects
Cost reduction
Strength, static and dynamic rigidity
Forces and torques caused by
Cutting forces
Drive elements
Reaction in the bearing
Dynamic load in high speed machining process cause
force, self excited or/ and parametric vibrations
Stress is very high for resonance vibration
Accuracy and surface finish depends on the relative
motion
Strength, static and dynamic rigidity
Actual stress is kept low with the help of various
reinforcing stiffeners, the improvement in Layout and
section design

Figure: The effect of various cover plate designs on the static

rigidity of a box type beam
Strength, static and dynamic rigidity

Figure: Influence of stiffeners on rigidity

Materials of the structural components
Cast iron is most widely used
Also made of steel
Ceramics, concrete, granite can be used
Comparative advantages depends on
Material properties and its availability
Manufacturing process
Cost economy
Material properties
High static stiffness
Good dynamic rigidity
Good machinability
Low coefficient of thermal expansion
Dimensional stability
Reduced weight
Easy availability
Sliding properties
Low cost of lot production
Materials Used
Cast Iron
Grey CI is most widely used for beds
Nodular CI is used for high strength
CI with perlitic structure has high strength as well as high wear
resistance
Advantages:
 It has high resistance to wear
 If slideways are integral part grey CI is the natural choice of the designees
 Not expensive and has good damping capacity

 Easy to cast in any shape

Disadvantages
 Needs long lead time
 Possibility of rejection of cast bed

 Demands of high allowance in casting requires further machining process.

Manufacturing Process
Maintenance of accurate wall thickness
Change over of thickness or cross section
 In case of casting sharp change over of cross-section should be avoided
Machining allowance
 Ordinary sand casting requires more machining allowance then plates
and sheets
Internal stress are to be removed as far as possible. (e.g. heat
treatment of welded joints
Production facilities and manpower
 Casting needs furnaces
 Clamps and fixtures required for welding
 Nodular and lamellar CI casting is more difficult then grey CI

 Many shops do not have casting facility

 Thin wall casting and heavy casting are difficult
Economy
Material cost
Fixture cost
Pattern and other aids, such as cores
Machining cost
Cost related to production lead time
Effect of chips on the design of structure
Reduction of production lead time attained by high
MRR
High volume of chip formation
Chip acts as a source of heat
Rise in the temperature of m/c tool causes
Thermal expansion
Development of internal stress
Dimensional inaccuracy
Function of bearing is hampered
Effect of chips on the design of structure
To avoid these problems
Modification like mechanize chip handing system is
used
Space between the stiffeners can be large to facilitate
free falling of chips
Inclined lathe bed can be used
Quick removal can be attained by using screw or belt
conveyors
That’s all for today