MACHINE TOOLS

DESCRIPTION OF MACHINE TOOLS.

A machine tool is a power driven device in which energy is utilized in shaping and machining
the material. On the processes of machining, the material shape is changed and shaped into the
required shape and size.
Machine tools are mainly used for:
I. For shaping the work piece into a certain desired form.
II. To produce a desired finished product/ finished surfaces.
In order to achieve the above, the work piece is surfaces are subjected to the machine cutting tool
for the specific work/purpose required to shape and surface finish. These depends on the tool
speed and the motion path of the tool.
This one can be achieved either by the motion of the tool around the surface of the work piece or
the movement of the work piece along the tool or by a combination of the two.
The motion is classified into two categories. One is referred to as the primary motion where this
is the drive motion and then secondary motion which is the feed motion.
This exercises are achieved through other exercises like clamping of the tool and the work piece
on various machine tools.
MACHINE TOOLS SAFETY:
As it was discussed earlier on safety chapter, any machine tool must be handled with a lot of care
with safety in mind first.
Here are some of safety precautions that should be observed:
a. Machine operators must be well trained on each machine before any operation.
b. Machines with guarded parts should never be operated when unguarded. In case any
guard is broken or worn out, it must be replaced immediately.
c. All machine tools must be well maintained.
d. All machine tool ergonomics must not give in any fatigue factor.
e. Never operate any machine while someone is not in the right attire. All PPEs must be
worn before any operation.
f. In case of any doubt, always consult your supervisor before operating any machine tool.
g. Manufacturer’s manuals and guidelines must be adhered to always.

Machine Tools Classification.

When it comes to machine tool classification, there are various classification methods that may
be used. They can either be classified according to the motion while working, type of job they
perform. Here are some of classification methods used.
Machine Tools for Flat Surface Work:
For generating a straight-cut plane surface, the work-piece is moved past the cutting tool in a
straight path and the tool is traversed in perpendicular direction or vise-versa.
These machine are the ones that perform such operations. Planning, slotting and shaper machine
tools and/or miller and surface grinding machines via the rotary motion of the cutting edge and
the translated motion to the work piece.

Cylindrical Work Machine Tools.

The work piece is rotated about an axis, or the work being at rest and then the tool rotating on its
surface. Lathe machine works on this principle.
Production of Holes on work piece.
Holes are produced mainly by the drilling machine. Lathe machine and even miller machines can
produce holes on work pieces. This is achieved via the drill bit being rotated by these machine
tools. For a drilling machine, the drilling bit is attached to the chuck. For the lathe, the bit is
attached to the tail stock and the work piece held to the chuck.

EXAMPLES OF VARIOUS MOTIONS.

Lathes Machine tool:
Definition: It is a machine tool that rotates a work piece about an axis of rotation to perform
various machining operations e.g. facing, turning, knurling drilling sanding and catting.
Its Drive motion rotary motion of work piece while the feed motion is translatory motion of
cutting tool in the axial or radial direction
Drilling Machine tool:
Definition: it is a machine or device that is used for producing holes on hard materials via drill
bits embedded in its chuck.
Drive motion—rotary motion of drill
Feed motion—translatory motion of drill
Milling Machine tool:
Definition: it is a machine tool in which a horizontal arbor or vertical spindle rotates a cutting
tool above a horizontal table which is used to move a work piece.
Its Drive motion is rotary motion of the cutter while Feed motion is translatory motion of the
work piece.
Shaper Machine tool:
Definition: A shaper is a type of machine tool that uses linear relative motion between the work
piece and a single –point cutting tool to machine a linear tool path. Its cut is analogous to that of
a lathe except that it is linear instead of helical. (Archetypally).
Its Drive motion is reciprocating motion of cutting tool and the Feed motion is intermittent
translatory motion of work piece.
Grinding Machine tool:
Definition: Usually shortened into grinder. It is used for grinding by use of abrasive wheel as its
cutting tool. Each abrasive grain of the wheel surface cuts a small chip from the work piece
through shear deformation.
Its Drive motion is rotary motion of the grinding wheel while the Feed motion is rotary as well as
translatory motion of the work piece.

Machine tools are also classified through the work they perform.

1. General Purpose or ‘Basic’ Machine Tools:

These are used for performing all metal cutting operations within their range. These include
lathes, shapers, drilling machines, milling machines, grinding machines, planning machines etc.
2. Production Machine Tools:
These are used to reduce the manufacturing cost and to increase the rate of production. These are
generally multi-station tooling machines and designed to do one type of job at a time. These
include Capstan and turret lathes, semi- automatic lathes, production milling machines, multiple
head drilling machines etc.
3. Special Purpose or Single Purpose Machine Tools:
These are used for mass production and generally one machine is capable of producing only one
type of job. These include gear generators, camshaft grinders, piston turning lathes, thread
rolling machines etc.
The surface finish depends upon the lay and the feed of the tool or work. Various machines are
capable of producing different types of finish.
Some of surface finish activities/ exercises may include the following but not limited to.
a. Hand grinding
b. Boring
c. Lapping
d. Surface grinding
e. Sawing
f. Filing
g. Turning
h. Shaping
i. Milling
j. Drilling
k. Polishing super finishing, etc.

CHARACTERISTICS OF MACHINE TOOLS:

I. Safety
Safety is of prime importance. Any machine tool designed must take safety measures as of
paramount considerations. Safety of operators and anyone around must be of paramount.
Ends should not be loose with all possibilities of accidents taken into considerations and
prevention measures put in place. Where moving parts are, must be fully guarded.
II. Reliability:
Any production machine must be reliable. The mean time between failures should be high. All
non-wearing out parts should be designed to be fail proof. All parts subject to wear and tear
should be designed for easy replacement.

III. Ease of Operation:

The controls for operation of machine tool should be located so as to cause least strain on
operation. The relative location should follow standard conventional procedures to avoid
possibility of any cases of mal-operation during operation processes. Loading and unloading of
parts should be as simple and fast as possible. The operator should not be fatigued in any way
while operating the machine tool.

IV. Cost

Both Initial Cost and Operation Cost should be taken into considerations. It should be
competitive in both the cost.
V. Accuracy:
The machine tool should be able to produce accuracy in regard to dimensions and geometrical.
The surface finish should be accurate without much expertise. The machine should not be
subjected to any wobbling during the operation process.

VI. Easy Maintenance:

The parts requiring any maintenance attention should be easily accessible. Lubrication and oiling
nipples should be easily accessed.

VII. Production Capacity:

The machine tool should be designed for maximum metal removal rate and maximum production
time, and least setting up time.

VIII. Repeatability:
Machine tool should be designed to produce same dimensions with one setting, repeatedly.

IX. Compactness:
The overall size of machine tool should be least possible depending on the sophistication of
design and production capacity.

X. Standardisation:
The machine tool should be standard such that in case of any parts replacement, they can be
replaced easily and assembled. The design should be simple.

XI. Aesthetic Appeal:

Machine tool should possess aesthetic value. It should not have protruding parts and parts that
can be an accident sources. Colour too finishing should be appealing.
 XII. Features of Advanced Machines:
The design should allow for future features such that the machine tool can shift and fit to the
modern design easily. E.g. automatic applications and tool changes.

Machine Tools Cutting Motion.

Chip removal process is effected by the relative motion between tool and work piece. The
motions of machine tool may be transmitted either to the cutting tool, or to the work or
simultaneously to both.
The already discussed machine tool motions are primary and secondary motions.
I. Primary Cutting Motion:
It provides for cutting the chip from the blank.
The most commonly used types of primary cutting motions are either Rotary primary cutting
motion or Reciprocating primary cutting motion.
a. Rotary Primary Cutting Motion
Rotary motion may be transmitted either to the work as in lathe machine tools or to the tool as in
grinding machine, drilling machine or milling machine.

b. Reciprocating Primary Cutting Motion

This motion can be transmitted to the tool for example in a shaper machine or to the work piece
as in the planar case. Machine tools using reciprocating primary cutting motion, the cutting cycle
consists of a working stroke during which the tool cuts the chips and the idle or return stroke
during which the tool or work returns to its initial position.
Sometimes, a combination of rotary and reciprocating motions are used in some machine tools.

II. Secondary motion/Feed Motion:

This motion, which is referred to as a feed motion, enables the cutting process to be extended to
the whole surface to be machined on the work. The rate of feed is substantially less than the
cutting speed. It is good to note that the rate of the feed determines the cross sectional area of the
chip. Bearing in mind that a machine tool is always subjected to other loads/forces in form of
both static and dynamic forces due to the rotation and the cutting forces.
Feed motion can be expressed as feed per revolution or feed per stroke, or feed per revolution, or
feed per tooth etc.
WHAT ARE MACHINE TOOL REQUIREMENTS?
These are some of machine tool requirements.
a. Low cost of manufacturing and operation.
b. Ability to produce the desired shape and size.
c. Simple in design.
d. High productivity.
e. Design for required accuracy and surface finish.
f. Good ergonomics, i.e., convenience of controls and safe design.
g. Aesthetics, i.e., good appearance and finish.

Machine tools maintenance.

There are three main types of maintenance routines performed on machine tools.
These are namely, preventive maintenance, predictive maintenance and corrective maintenance.
a. Preventive Maintenance:
Preventive maintenance is the planned maintenance of machine tools and equipment. The main
aim of the preventive maintenance is to reduce wear and tear and take timely action before
failure occurs. The main actions of preventive maintenance are regular lubrication, cleaning and
greasing and daily checks.
b. Predictive maintenance.
This type of maintenance focuses mainly on some foreseeable failures and measures taken into
considerations to prevent full failure. It is carried out on main parts and it includes replacement
of worn parts and to carry out repairs. The maintenance team should carry out regular inspections
of the specific parts/elements of the machine in order to determine whether wear has reached the
stage when corrective maintenance should be carried out before failure occurs.
It is essential to maintain a record of the nature and cost of all repairs carried out. This is purely
prediction.
c. Corrective Maintenance:
This type of maintenance is carried out when there is a total failure of the machine tool.
RECONDITIONING
It is the rebuilding of the machine tool to give it the required production. The need to recondition
the machine can be determined by the frequency of the corrective maintenance.

EXAMPLES OF VARIOUS MACHINE TOOLS AS INDICTED.

h.