MACHINE TOOLS

LECTURE NOTES 2
Constructive Structures of Machine Tools
and Elements

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Definition: It is a power driven machine

having capable of producing various shapes in
metal by cutting away the surplus material
(called as chip).

The basic principle in all machine tools is the

generating surface by providing suitable
relative motions between the cutting tool and
the workpiece.
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The general design of the machine tool takes

care of the maximum cutting forces like
tangential, axial and radial forces, weight of
the structures, rotation of workpiece or
cutting tool, and bending moment and torque
produced by them.

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Main parts of machine tools

1. Main frame (bed, column)
2. Power unit
3. Driving mechanisms (transmission linkage)
4. Spindle and bearing
5. Cutting tool and workpiece holding devices
6. Guideways and guides (slideways and slides)
7. Couplings

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1. MAIN FRAME
Main frame (bed, column) forms the vital part of the
machine tool on which table and other relevant parts of the
machine tool move. It is therefore evident that the main
frame should be sufficiently strong and rigid. It should also
be easier to remove the chips produced during machining.

The machine tool frame supports all the active and passive
components of the cutting tool, spindle, table, and controls.

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1. MAIN FRAME

The configuration of machine tool structure is

governed by the arrangement of the necessary cutting
and feed movements and their stroke lengths, as well
as the size and capacity of the machine.

Chip disposal, transport, and maintenance are also

considered.
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1. MAIN FRAME
Keeping in view of the strength, rigidity and chip
disposal, box type construction of the main frame
(bed) is normally used.

Main frames of the machine tools are generally made

from cast iron or steel. Grey cast iron with some
percentage of nickel and chromium is preferred. Main
frames are generally produced by casting or sometime
fabricated from steel plates.
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1. MAIN FRAME
The most important parameters for determining the
shape of the body:

 Position and length of motion axes

 Volumetric arrangement of groups such as spindles, slides,
speed boxes
 Important passageways in installation, operation and
maintenance
 Magnitudes of cutting forces and moments

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1. MAIN FRAME

Machine tool structures are classified by

layouts into open (C-frames) and closed
frames.

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1. MAIN FRAME

Open Frames (C-frames)

Open frames provide excellent accessibility to the

cutting tool and the workpiece. Typical examples of
open frames are found in turning, drilling, milling,
shaping, grinding, slotting, and boring machine
tools.

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1. MAIN FRAME
Open Frames (C-frames)
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1. MAIN FRAME
Closed Frames

Closed frames find

application in planers,
jig boring, and
double-spindle milling
machine tools.
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1. MAIN FRAME
Factors governing the choice of frame materials
are:
 resistance to deformation (hardness),
 resistance to impact and fracture (toughness),
 limited expansion under heat (coefficient of
thermal expansion),
 high absorption of vibrations (damping),

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 resistance to shop-floor environment (corrosion
resistance),
 specific weight,
 modulus of elasticity and modulus of shear,
 coefficient of friction,
 low cost.

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1. MAIN FRAME
Machine tool frames can be produced as cast or welded
construction. Welded structures ensure great saving of the
material and the pattern costs. Figure shows typical cast and
welded machine tool structures.

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1. MAIN FRAME

A cast iron 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
 Easily cast and machined.

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1. MAIN FRAME
Composite Materials (Concrete) consists of mineral fillers and
reaction resins. Quartz is used in spherical form as filling
material.

Reaction resins are generally;

Methacrylate resin, Epoxy resin, Polyester resin (unsaturated)

Wall thickness can vary between 60-80 mm. It can be integrated

without any problems due to its strong adhesion to cast iron and
steel.

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A crisscross rib structure for long bodies

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1. MAIN FRAME

This figure shows a typical

machine tool main frame
(bed) of the lathe and a
main frame (bed) of the
drilling machine tools.

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1. MAIN FRAME
The main functions of the machine structure include the
following:

1. Ability of the structure or the main frame (bed) to resist

distortion caused by static and dynamic loads
2. Stability and accuracy of the moving parts
3. Wear resistance of the guideway
4. Freedom from residual stresses
5. Damping of vibration
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1. MAIN FRAME
The following points should be considered in the design of
a main frame which is subjected to stresses such as
tensile, bending and torsion due to mass forces and
moments:

1. Having high static rigidity to maintain geometric accuracy,

2. Vibration damping ability should be good.
3. Dynamic stiffness should be good.
4. It should be designed according to lightweight construction
principle.
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1. MAIN FRAME
The following points should be considered in the design of
a main frame which is subjected to stresses such as
tensile, bending and torsion due to mass forces and
moments:

5. Thermal stability should be good.

6. It should be cleaned easily and should not interfere the chip
disposal.
7. Having long life and being ergonomic.

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Stresses on Machine Tools:
Stresses produced during machining tend to
deform the machine tool or workpiece and are
usually caused by one of the following factors:

1. Static loads
2. Dynamic loads
3. Cutting forces
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Stresses on Machine Tools:

1. Static loads: The weight of the machine and its
various parts
2. Dynamic loads: The rotating or reciprocating parts
(loads during working of the machine tool)
3. Cutting forces: Generated by the material removal
process
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1. MAIN FRAME

Effects of Stresses in Machining:

Both the static and the dynamic loads affect the

machining performance in the finishing stage, while the
final degree of accuracy is also affected by the
deflection caused by the cutting forces.
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2. POWER UNIT

Power unit of machine tool is based on electric

motor. There may be only one motor from which
other movements are transmitted or there may be a
main motor with separate drive motor for individual
element such as a coolant pump motor or a feed
movement motor.

It provides rotation to main driving mechanism and

transmission linkage transfers this motion to desired
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2. POWER UNIT

The majority of the machine tool drives are made

suitable for operation on standard 3 phase 50 cycle
400/440 volts, AC supply.

It provides motion to main driving mechanism and

transmission linkage transfers this motion to desired
sections of machine tool.

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3. DRIVING MECHANISMS
(TRANSMISSION LINKAGE)
Machine tool requires variety of speeds and feeds.
This is provided by a suitable designed driving
mechanisms such as stepped or stepless types.

The maximum cutting speed, feed and circulation of

the lubricating oil are to be taken into account for the
selection of drive motor in a machine tool.

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3. DRIVING MECHANISMS
(TRANSMISSION LINKAGE)
These sections are used to transmit and control the
essential movement from the motor, including the drives to
the spindle and feed drives. They are divided following
types:
Stepped (Belts, gears, screws-nuts pulleys)
Stepless (mechanical, hydraulic, pneumatic, electrical)

Guide/slide movements are usually controlled by a lead

screw and nut arrangement which may be hand driven or
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4. SPINDLE AND BEARING

The shaft and spindles should be so designed that

they can take axial, bending and twisting loads.
The bearings should be so selected that they can
resist static and dynamic loads.

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4. SPINDLE AND BEARING

The spindle delivers torque to the cutting tool, so its precision is
essential to machine tool operation.

The key factors influencing precision are bearing type and

placement, lubrication, and cooling.

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4. SPINDLE AND BEARING

Machine tool spindles are supported inside housings

by means of ball, roller, or antifriction bearings.
Precision bearings are used for a precision machine
tool. The geometrical accuracy and surface
finish of the machined components depend on the
quality of the spindle bearings.

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4. SPINDLE AND BEARING

Bearings are divided into two groups as sliding bearings and ball
bearings.

Sliding Bearings
In such bearings, the shafts can be strictly fitted in terms of precision.
Adjustable bearing bushings should be used as there may be some
wears in time.
In addition, suitable constructions and lubrication systems should be
used in order not to create heat due to friction.

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4. SPINDLE AND BEARING

Bearings are divided into two groups as sliding bearings and ball
bearings.

Ball Bearings
Ball bearings are preferred at high revolutions.
Maintenance and lubrication of ball bearings are easier.
They can also carry axial load as well as radial load.
They work noisy.
Their cost is high because of manufacturing accurately.
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4. SPINDLE AND BEARING

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4. SPINDLE AND BEARING

Sleeve bearing of center lathes

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4. SPINDLE AND BEARING

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5. CUTTING TOOL AND WORKPIECE HOLDING DEVICES

These types of equipment are used to hold cutting

tool or workpiece during machining operation.
Various equipment are available according to
machine tool type.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Guideways or slideways on which workpiece or cutting

tool with their relevant units move should be strong
and should have long life. The surfaces of the
guideways should be perfectly machined so that it
maintains good amount of accuracy and precision.
The guideways are made of cast iron or steel. The
guideways should have a hardness of 50-55 HRC.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Guideways/slideways carry the workpiece table or spindles. Each

type of way consists of a slide moving along a track in the frame.
This slide carries the workpiece table or a spindle. The oldest and
simplest way is the box way. As a result of its large contact
area, it has high stiffness, good damping characteristics, and
high resistance to cutting forces and shock loads. Box slides can
experience stick-slip motion as a result of the difference between
dynamic and static friction coefficients in the ways. This
condition introduces positioning and feed motion errors.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

A linear way also consists of a rail and a slide,

but it uses a rolling element bearing, eliminating
stick-slip. Linear ways are lighter in weight and
operate with less friction, so they can be
positioned faster with less energy. However, they
are less robust because of the limited surface
contact area.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Guideways are required to perform the necessary

machine tool motion at a high level of accuracy
under severe machining conditions. Generally
guideways, therefore, control the movement of the
different parts of the machine tool in all positions
during machining and non-machining times.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Slides are moved by hydraulics, rack-and-pinion systems, or

screws.
Hydraulic pistons are the least costly, most powerful, most
difficult to maintain, and the least accurate option. Heat build-up
often significantly reduces accuracy in these systems.
Motor-driven rack-and-pinion actuators are easy to maintain
and are used for large motion ranges, but they are not very
accurate and require a lot of power to operate.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Motor-driven screws are the most common actuation method.

The screws can either be lead screws or ball screws, with the
former being less expensive and the latter more accurate. The
recirculating ball screw has very tight backlash; thus, it is ideal
for CNC machine tools since their tool trajectories are essentially
continuous. A disadvantage of the ball screw systems is the
effective stiffness due to limited contact area between the balls
and the thread.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Requirements of guideways:

 It should be strong.
 It should be possess sufficient stiffness.
 There should be less wear.
 The pressure distribution should be uniform.
 It should provide good guidance.
 There should be less friction.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Mostly, main frames take on the tasks of guideways. Nowadays,

the demountable guideways are also used especially in CNC
machine tools.

Holding strips are used in order to prevent the displace of guide

due to moments and forces. In addition, the adjusting strips are
used in order to compensate the gap caused by the wear of the
guideways.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

In general, cast iron is used due to the requirement of abrasion

resistance of guides.

The guideways are subjected to hardening at a given layer

thickness to increase the resistance to abrasion.

After machining the guides, they are scraped razed, 2-3 contact
points per cm² are good machining.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

Rollers, needles, or
balls are inserted
between the
moving parts to
minimize the
frictional
resistance, which is
kept constant
irrespective of the
traveling speed.

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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

(a) Flat type; (b) Symmetrical type; (c) Asymmetrical type;

(d) Dovetail type; (e) Cylindrical type
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6. GUIDEWAYS AND GUIDES (SLIDEWAYS AND SLIDES)

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7. COUPLINGS

Shaft couplings are used to fasten together the ends of two

coaxial shafts. Permanent couplings cannot be disengaged while
clutches engage and disengage shafts in operation. Safety
clutches avoid the breakdown of the engaging mechanisms due
to sharp increase in load, while overrunning clutches transmit
the motion in only one direction.

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7. COUPLINGS
On machine tools; there are three types of couplings as solid couplings,
flexible couplings, and safety couplings for motion transmission.
Solid Couplings
It is between the engine and the shaft driven firstly. Although it is easy to
assembly and disassembly, it should not be sensitive to dust, dirt and
water.
Flexible Couplings
These couplings can be of two types: couplings which allow the drive
transmission by contacting the profiles or the surfaces with each other.
Safety Couplings
These couplings are dissolved by itself when a given moment is exceeded.
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7. COUPLINGS

Cardan Coupling
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7. COUPLINGS

Coupling with pin

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7. COUPLINGS

Multiple-disc friction coupling

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7. COUPLINGS

Conical friction coupling

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7. COUPLINGS

Rigid coupling
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7. COUPLINGS

Flexible coupling
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7. COUPLINGS

Elastic coupling
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7. COUPLINGS

Demountable Coupling
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7. COUPLINGS

Friction Coupling
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References in English
M.P. Groover PRINCIPLES OF MODERN John Wiley.

MANUFACTURING

Helmi A. Youssef, MACHINING TECHNOLOGY: CRC Press, 2008

CRC Press,
Hassan 2008
El-Hofy MACHINE TOOLS AND OPERATIONS

P.H. JOSHI MACHINE TOOLS HANDBOOK: TATA McGRAW-HILL

PUBLICATION, 2007
DESIGN AND OPERATION

N.K. MEHTA MACHINE TOOL DESIGN AND TATA McGRAW-HILL

PUBLICATION, 1999
NUMERICAL CONTROL

G.C. SEN PRINCIPLES OF MACHINE TOOLS New Central Book

Agency, 2011
[Link]
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References in Turkish
Erhan ALTAN LECTURE NOTES / DERS NOTLARI

Faruk AKÜN MACHINE TOOLS (VOL 1-2)/ İTÜ Yayınları,

TAKIM TEZGAHLARI (CİLT 1-2) 1973-1978
MUSTAFA AKKURT MACHINING SCIENCE AND TECHNOLOGY, Birsen Yayınevi,
CNC MACHINE TOOLS AND PRODUCTION 2009
AUTOMATION /
TALAŞ KALDIRMA BİLİMİ VE TEKNOLOJİSİ
CNC TAKIM TEZGAHLARI VE ÜRETİM
OTOMASYONU
H. Oktay BODUR MACHINE TOOLS / Birsen Yayınevi,
TAKIM TEZGAHLARI 1984

Faruk MENDİ DESIGN OF MACHINE TOOLS / Gazi Kitapevi, 1999

TAKIM TEZGAHLARI TASARIMI