‫” َو ُقل َّر ِّب ِّز ْد ِِّن ِّعلْ ًما “‬

‫سورة طه (‪)114‬‬

‫صدق هللا العظيم‬

FACULTY OF INDUSTRY AND ENERGY TECHNOLOGY
AUTOTRONICS PROGRAM
COURSE NAME: Workshop Technology
COURSE CODE:
2022-2023

ASS. PROF./ Samy M. Lawaty

 Lecture: (2)
MACHINE TOOL
DRIVES
Learning Objectives:
 Working and auxiliary motions in machine tool
 Parameters defining working motions of machine tool
 Mechanical transmission and its elements
 Broadly Classification of transmission of rotary motion
 Stepped Speed Drives in Machine Tools
 Belting
 Pick-Off Gears
 Gear boxes
 AP &GP for steeping speeds of gears
 Structural formula & structural diagrams
 Feed gear boxes
 Steeples Speed Drives in Machine Tools.
 Hydraulic transmission and its elements

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

The material removal processes are a family of shaping operations in which excess
material is removed from a starting workpart, using cutting tools that are harder and stronger
than the work metal so that what remains is the desired final geometry. The most important
branch of the family is:
 Conventional machining, in which a sharp cutting tool is used to mechanically cut the
material to achieve the desired geometry. The three principal machining processes are
turning, drilling, and milling. The ‘‘other machining operations’’ in include shaping,
planing, broaching, and sawing.
 Abrasive processes, which mechanically remove material by the action of hard, abrasive
particles. This process group, which includes grinding,. The ‘‘other abrasive processes’’
include honing, lapping, and superfinishing.
 Nontraditional processes, which use various energy forms other than a sharp cutting
tool or abrasive particles to remove material. The energy forms include mechanical,
electrochemical, thermal, and chemical (lasers, electron beams, chemical erosion, electric
discharges, and electrochemical energy )
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
CLASSIFICATION OF
MATERIAL
REMOVAL PROCESSES.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

Definition of machining
Machining is an essential process of finishing by which work pieces are produced
to the desired dimensions and surface finish by gradually removing the excess
material from the preformed blank in the form of chips with the help of cutting
tool(s) moved past the work surface(s).
Purpose of machining
Most of the engineering components such as gears, bearings, clutches, tools, screws and nuts
etc. need dimensional and form accuracy and good surface finish for serving their
purposes.
Preforming like casting, forging etc. generally cannot provide the desired accuracy and finish.
For that such preformed parts, called blanks, need semi-finishing and finishing and it is done
by machining and grinding. Machining to high accuracy and finish essentially enables a
product:
 Fulfill its functional requirements.
 Improve its performance.
 Prolong its service.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
 Machining is a manufacturing
process in which a sharp cutting tool
tool(s) moved past the work
surface(s) is used to gradually
remove the excess material from the
preformed blank in the form of chips
with the help of cutting.
 Machining is generally performed
after other manufacturing processes
such as casting or bulk deformation
(e.g., forging, bar drawing). The other
processes create the general shape
of the starting workpart, and
machining provides the final
geometry, dimensions, and finish.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

Principle of machining
A metal rod of irregular shape, size and surface is converted into a finished product of desired
dimension and surface finish by machining by proper relative motions of the tool-work pair.

Principle of machining (Turning)

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Requirements of machining
The blank and the cutting tool are
properly mounted (in fixtures)
and moved in a powerful device
called machine tool enabling
gradual removal of layer of
material from the work surface
resulting in its desired dimensions
and surface finish. Additionally
some environment called cutting
fluid is generally used to ease
machining by cooling and
lubrication.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

Commercially and Technologically importance Machining
 Variety of work materials. Machining can be applied to a wide variety of work materials.
Virtually all solid metals can be machined. Plastics and plastic composites can also be cut
by machining. Ceramics pose difficulties because of their high hardness and brittleness;
however, most ceramics can be successfully cut by the abrasive machining processes.
 Variety of part shapes and geometric features. Machining can be used to create any
regular geometries, such as flat planes, round holes, and cylinders. By introducing
variations in tool shapes and tool paths, irregular geometries can be created, such as screw
threads and T-slots. By combining several machining operations in sequence, shapes of
almost unlimited complexity and variety can be produced.
 Dimensional accuracy. Machining can produce dimensions to very close tolerances.
Some machining processes can achieve tolerances of 0.025 mm (0.001 in), much more
accurate than most other processes.
 Good surface finishes. Machining is capable of creating very smooth surface finishes.
Roughness values less than 0.4 microns (16 m-in.) can be achieved in conventional
machining operations. Some abrasive processes can achieve even better finishes.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Disadvantages are associated with machining and other material removal
processes:
 Wasteful of material. Machining is inherently wasteful of material. The chips generated
in a machining operation are wasted material. Although these chips can usually be
recycled, they represent waste in terms of the unit operation.
 Time consuming. A machining operation generally takes more time to shape a given part
than alternative shaping processes such as casting or forging.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

TYPES OF MACHINE TOOLS
Definition of machine tool
A machine tool is a non-portable power operated and reasonably valued device or system of
devices in which energy is expended to produce jobs of desired size, shape and surface
finish by removing excess material from the preformed blanks in the form of chips with the
help of cutting tools moved past the work surface(s).
Basic functions of machine tools
Machine tools basically produce geometrical surfaces like flat, cylindrical or any contour on
the preformed blanks by machining work with the help of cutting tools.
The physical functions of a machine tool in machining are:
1. Firmly holding the blank and the tool.
2. Transmit motions to the tool and the blank.
3. Provide power to the tool-work pair for the machining action.
4. Control of the machining parameters, i.e., speed, feed and depth of cut.

Dr. Samy M. Lawaty Lect. (1) Lathe Macine

Classification of machine tools
Number of types of machine tools gradually increased till mid 20th century and after that
started decreasing based on group technology. However, machine tools are broadly classified
as follows:
 According to direction of major axis:
 Horizontal - center lathe, horizontal boring machine etc.
 Vertical - vertical lathe, vertical axis milling machine etc.
 Inclined - special (e.g. for transfer machines).
 According to purpose of use:
 General purpose - various operations on workpiece of different shapes and sizes.
(Piece and small Production), e.g. center lathes, milling machines, drilling machines
etc.
 Single purpose - perform single operation on work pieces of a particular shape and
different size, e.g. facing lathe, roll turning lathe etc.
 Special purpose - a single operation on workpiece of particular shape and size. for
mass production.
 Limited purpose for mass production (keymilling and spline)
Dr. Samy M. Lawaty Lect. (1) Lathe Macine
Classification of machine tools: (Continue)
 According to degree of automation:
 Non-automatic (Manual control) - e.g. center lathes, drilling machines etc.
 Semi-automatic - capstan lathe, turret lathe, hobbing machine etc.
 Automatic - e.g., single spindle automatic lathe, Swiss type automatic lathe, CNC
milling machine etc.
 According to size:
 Heavy duty - e.g., heavy duty lathes (e.g. ≥ 55 kW), boring mills, planning machine,
horizontal boring machine etc.
 Medium duty - e.g., lathes - 3.7 ~ 11 kW, column drilling machines, milling machines
etc.
 Small duty - e.g., table top lathes, drilling machines, milling machines.
 Micro duty - e.g., micro-drilling machine etc.
 According to blank type:
 Bar type (lathes). Slender rod like jobs being held in collets.
 Chucking type (lathes). Disc type jobs held in chucks.
 Housing type. Odd shapes jobs, being held in face plate
Dr. Samy M. Lawaty Lect. (1) Lathe Macine
Classification of machine tools: (Continue)
 According to precision:
 Ordinary - e.g., automatic lathes.
 High precision - e.g., Swiss type automatic lathes.
 According to accuracy:
 Standard accuracy ( standard of manufacturing from assembly of parts and adjusting
them)
 Above standard accuracy (for critical parts)
 High accuracy
 According to number of spindles:
 Single spindle - center lathes, capstan lathes, milling machines etc.
 Multi spindle - multi spindle (2 to 8) lathes, gang drilling machines etc.
 According to type of automation:
 Fixed automation (Conventional) - e.g., single spindle and multi spindle lathes.
 Flexible automation (Modern) - e.g., CNC milling machine, CNC lathe.

Dr. Samy M. Lawaty Lect. (1) Lathe Macine

Classification of machine tools: (Continue)
 According to weight into:
 Light duty machine tools weighing up to 1 tone.
 Medium duty machine tools weighing up to 10 tone and
 Heavy duty machine tools weighing greater than 10 tone. (large heavy 10-30 ton,
heavy – heavy 30-100 ton, extra heavy, above 100 ton)
 According to configuration:
 Stand alone type - most of the conventional machine tools.
 Machining system (more versatile) - e.g., transfer machine, machining center, FMS
etc.

Machine model 1235

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

What are the Machine Tools?
Machine tools refer to power devices used to process work pieces and are important
equipment in the manufacturing process of mechanical parts. Machine tools are generally used
for forming, cutting, and joining other tools.
Basic elements of Machine tools:
The various components that are used in machine tools are discussed
under:
1. Work holding device:
Work holding devices are used to hold the work-piece in the correct
orientation to achieve the required accuracy in manufacturing.
Example: chuck

2. Tool holding device

Tool holding devices are used to hold the cutting tool in the correct
position with respect to the workpiece and to provide enough holding
force to contract the cutting forces acting on the tool.
Example: Tool post Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Basic elements of Machine tools: (Continue)
3. Work motion mechanism
Work motion mechanism is generally used to provide the
necessary speed to the workpiece for generating the
required surface.
Example: headstock
4. Tool motion mechanism
Tool motion mechanism is generally used to support all
the mechanisms and to maintain the relative position with
respect to each other and to allow for relative movement
between the various parts.
5. Support structures
Support structures are used to support all the mechanisms
and to maintain the relative position with respect to each
other and to allow for relative movement between the
various parts.
Example: Bed.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Some common parts in machine tools and their features:
1. BED:
Important considerations in the design of bed are high strength, rigidity,
alignment, accuracy and damping qualities and wear resistance.
Functions:
1.It is acting as a rigid support.
2.It is used to absorb vibrations induced during machining.
3.It will act as a house.
Material used: Generally, grey cast iron material is used.
Manufacturing process used: Generally casting will be used to
manufacture the beds.
Shape of the bed: The shape of the bed is selected such that the reduction
in the rigidity will be minimum and should provide the maximum amount
of free space.
Example: X,I,H cross-section shapes etc.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Some common parts in machine tools and their features
(Cont.) :
2. Lead screw:
Function: Lead screw is used for feeding the cutting tool in a
direction parallel to the axis of rotation and this will convert rotational
movement into translation motion.
Material used: The material used for making lead screw must have
wear resistance.
Brass: for length less than 2 meters.
Stainless steel: Length 2 to 10 meters. For above 10 meters length
rack and pinion is used.
Manufacturing process: Thread rolling or thread machining process
will be employed to manufacture lead screws.
Shape: Square threads are preferable because of high efficiency in
power transmission. And buttress and acme threads can also be used
as the second choice. Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Some common parts in machine tools and their
features (Cont.) :
3. Guide ways:
Function: Guideways are used to guiding and allow the other parts
moves in their directions relative to other parts.
Material used: Generally, high carbon steel will be used.
As guide ways subjected to many forces during machining low ductile
like brass and high hard like stainless steel will not be preferable
because of having the localized hardening.
Manufacturing process: The final manufacturing process used in
manufacturing the guide ways is flame hardening to give hardened
localized surface require for guide ways to avoid wearing.
Shape: Rectangle shaped guideways have the highest bearing area but
it is difficult to align.
‘V’ shaped guide ways even aligned automatically but bearing area is
less so the combination of ‘V’ and rectangular will be used i.e.
Dovetail shaped guideways will be employed.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Some common parts in machine
tools and their features (Cont.):
4. Prime Mover:
Whatever energy required for machining
operation is obtained from Prime mover.
Types of Prime Mover:
1. IC Engine: Due to some disadvantages
of IC engines they are obsoleted.
2. Electrical motor: Induction motor is
the most commonly used motor. The cost
of the induction motor is less compared
to other motors. No reciprocating parts
and no noise. So to get variable speeds
of the job even though the motor is
rotating is only speed we will use
mechanical transmission system.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Specification of machine tools
A machine tool may have a large number of various features and characteristics. But only some
specific salient features are used for specifying a machine tool. All the manufacturers, traders
and users must know how machine tools are specified. The methods of specification of some
basic machine tools are as follows:
Centre lathe:
 Maximum diameter and length of the jobs that can be accommodated.
 Power of the main drive (motor).
 Range of spindle speeds and range of feeds.
 Space occupied by the machine.
Shaper:
 Length, breadth and depth of the bed.
 Maximum axial travel of the bed and vertical travel of the bed / tool.
 Maximum length of the stroke (of the ram / tool).
 Range of number of strokes per minute.
 Range of table feed.
 Power of the main drive.
 Space occupied by the machine.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Specification of machine tools (Cont.)
Drilling machine (column type):
 Maximum drill size (diameter) that can be used.
 Size and taper of the hole in the spindle.
 Range of spindle speeds.
 Range of feeds.
 Power of the main drive.
 Range of the axial travel of the spindle / bed.
 Floor space occupied by the machine.
Milling machine (knee type and with arbor):
 Type; ordinary or swiveling bed type.
 Size of the work table.
 Range of travels of the table in X - Y - Z directions.
 Arbor size (diameter).
 Power of the main drive.
 Range of spindle speed.
 Range of table feeds in X - Y - Z directions.
 Floor space occupied. Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
 Drilling Machine
Drilling machine
process:
• Used to create a round hole,
usually by means of a
rotating tool (drill bit) with
two cutting edges.
• Main motion is rotating
motion done by tool.
• Feed motion is linear motion
done by work piece.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

 Drilling Machine
The configuration of drilling machine, column drill in
particular. The salient parts are :
 Column with base: it is the basic structure to hold the
other parts
 Drilling head: this box type structure accommodates the
power drive and the speed and feed gear boxes.
 Spindle: holds the drill and transmits rotation and axial
translation to the tool for providing cutting motion and
feed motion – both to the drill.
Drilling machines are available in varying size and
configuration such as pillar drill, column drill, radial drill,
micro-drill etc. but in working principle all are more or less
the same.
Drilling machines are used:
 Mainly for drilling (originating or enlarging cylindrical
holes)
 Occasionally for boring, counter boring, counter sinking etc.
 Also for cutting internal threads in parts like nuts using
suitable attachment. Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
 Planing Machine
Planing machine The general configuration is schematically shown in Fig. 2.12. This
machine tool also does the same operations like shaping machine but the major differences
are:
 In planing the job reciprocates for cutting motion and the tool moves slowly for the feed
motions unlike in shaping machine.
 Planing machines are usually very large in size and used for large jobs and heavy duty
work.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

 Milling Machine
Milling machine process:
• Rotating multiple-cutting-edge tool is moved across work to cut a
plane or straight surface.
• Main motion is rotating motion done by tool.
• Feed motion is linear motion done by work piece.
• The cutting tool is multi-toothed tool used to less heat generated.
• It is fast and fine machining used for all kinds of surfaces.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

33 12/23/2022
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Milling machine The general configuration of knee
type conventional milling machine with horizontal
arbour is shown in Figure. Its major parts are
 Milling arbour: to hold and rotate the cutter
 Ram: to support the arbour
 Machine table: on which job and job holding
devices are mounted to provide the feed motions
to the job.
 Power drive with Speed and gear boxes: to
provide power and motions to the tool-work
 Bed: which moves vertically upward and
downward and accommodates the various drive
mechanisms
 Column with base: main structural body to
support other parts.
Milling machines are also quite versatile and can do
several operations like
 making flat surfaces
 grooving, slitting and parting
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
 helical grooving
 Shaping Machine
Shaping machine process:
• The main cutting motion is a
reciprocating motion done by the tool or
the machine.
• The feed motion is linear motion.
• The machine tool is similar to the turning
tool but bigger.
Shaping operations:
• Slots, keyways, and gears.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

 Turning Machine
Turning machine process:
• Turning is the most important
machining process and can
produce a wide variety of
parts. Primarily, turning is
used to produce parts
Cylindrical in shape by a
Single point cutting tool on
Lathes.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

 Shaping Machine
Shaping machine
Figure shows the general configuration of
shaping machine. Its major parts are:
 Ram: it holds and imparts cutting motion to
the tool through reciprocation
 Bed: it holds and imparts feed motions to the
job (blank)
 Housing with base: the basic structure and
also accommodate the drive mechanisms
 Power drive with speed and feed change
mechanisms.
 Shaping machines are generally used for
producing flat surfaces, grooving, splitting
etc. Because of poor productivity and process
capability these machine tools are not widely
used now-a-days for production.Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
 Turning Machine (Cont.)
Turning machine Operation:
• Turning is the oldest machining
method.
• It represents 30-40% of machining
process.
Relative motion of turning
machine:
• Main motion is rotary motion done
by work piece.
• Feed motion is linear motion done
by tool.
A lathe is a machine that rotates the workpiece about an axis of rotation to perform various operations such
as turning, undercutting, knurling, drilling, facing, boring, and cutting, with lathe cutting tools that are applied
to the workpiece to create an object with symmetry about that axis.
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Lathe Cutting Tools:
Following are the types of lathe
cutting tools used in lathe machine:
1.Turning tool.
2.Chamfering tool.
3.Thread cutting tool.
4.Internal thread cutting tool.
5.Facing tool.
6.Grooving tool.
7.Forming tool.
8.Boring tool.
9.Parting-off tool.
10.Counterboring tool
11.Undercutting tool
12.According to the method of
applying feed
1. Right-hand tool
2. Left-hand tool
3. Round Nose
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Centre lathes
- configuration: the general configuration of
center lathe. Its major parts are:
 Head stock: it holds the blank and
through that power and rotation are
transmitted to the job at different speeds
 tailstock: supports longer blanks and
often accommodates tools like drills,
reamers etc for hole making.
 carriage: accommodates the tool holder
which in turn holds the moving tools
 bed:
 headstock is fixed and tailstock is
clamped on it. Tailstock has a
provision to slide and facilitate
operations at different locations
 carriage travels on the bed
 columns: on which the bed is fixed
 work-tool holding devices
Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives
Uses of center lathes Centre lathes are quite versatile being used for various operations:
 Turning [external + internal]
 straight
 taper
 stepped
 facing, centering, drilling, recessing and parting
 ⎯ thread cutting; external and internal
 ⎯ knurling.
Some of those common operations are shown in Fig. 2.10. Several other operations can also be done in
center lathes using suitable attachments.

Some
common
machining
operations
done in center
lathes.

Dr. Samy M. Lawaty Lect. (2) Machine Tool Drives

 Process Planning:
 Process Planning:
• Now, you know the operation on
the Turning machine.
• To make a true planning, you
must put your work piece in
sequential process to avoid any
mistakes or failure in the machine
processes.
• That will charge the factory with
a lot of money, and your manger
will throw you out from the
factory.
 Example 1
Develop the process plan for the shown work piece (part material
25 Diameter and 42 mm long)?

45𝑜

43
Example 1 (Cont.)
Example 1 (Cont.)
 Example 2
Use the below table to develop the process plan sheet for the
following work pieces?

46
 Example 2 (Cont.)

Dr. Abdelaziz Hussien

Example 2 (Cont.)
 Report 2
Develop the process plan for the shown work piece (part material
25 mm Diameter and 43 mm long)?

49