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