MAK4462 - MACHINE TOOLS

WEEK 1
Machine Tools,
Basic Concepts and Classifications
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Weekly Subjects and Related Preparation Studies

Week Subjects Related Preparation
1 Machine tools, basic concepts and classifications Lecture Notes Part 1
2 Constructive structures of machine tools and elements Lecture Notes Part 2
3 Drive systems and Mechanisms in machine tools Lecture Notes Part 2
4 Drive systems and Mechanisms in machine tools Lecture Notes Part 2
5 Working principles of lathe and its mechanism Lecture Notes Part 3
6 Working principles of lathe and its mechanism Lecture Notes Part 3
7 Working principles of drilling machine tool and its mechanism Lecture Notes Part 3
8 Midterm 1
9 Working principles of milling machine tool and its mechanism Lecture Notes Part 4
10 Working principles grinding and superfinish machine tool, their mechanism Lecture Notes Part 5
11 Working principles of broaching and planing machine tools and their mechanism Lecture Notes Part 6
The functions, working principles and mechanisms of gear benches, Saw cutting
12 Lecture Notes Part 7
machine tools and their mechanism
13 Numerical controlled machine tools- General principles Lecture Notes Part 8
14 Accuracy in machine tools and test methods Lecture Notes Part 9
15 Final
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Evaluation
Activities Number Percentage of Grade

Attendance/Participation
Laboratory
Application
Field Work
Special Course Internship (Work Placement)
Quizzes/Studio Critics 1 10
Homework Assignments 1 20
Presentations/Jury
Project
Seminar/Workshop
Mid-Terms 1 30
Final 1 40
Percentage of In-Term Studies 60
Percentage of Final Examination 40
TOTAL 100
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Reference Books
M.P. Groover PRINCIPLES OF MODERN MANUFACTURING John Wiley.

Helmi A. Youssef, MACHINING TECHNOLOGY: MACHINE TOOLS AND OPERATIONS CRC Press, 2008

Hassan El-Hofy

P.H. JOSHI MACHINE TOOLS HANDBOOK: DESIGN AND OPERATION McGRAW-HILL EDUCATION, 2015

N.K. MEHTA Machine Tools Design And Numerical Control [3 ed.] MC GRAW HILL INDIA, 2013

G.C. SEN PRINCIPLES OF MACHINE TOOLS New Central Book Agency, 2011

A.BHATTACHARYYA

A. B. Chattopadhyay Machining and Machine Tools [2 ed.] Wiley India Pvt. Ltd. 2017
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REFERENCE BOOKS (TURKISH)

Erhan ALTAN LECTURE NOTES / DERS NOTLARI

Faruk AKÜN MACHINE TOOLS (VOL 1-2)/ İTÜ Yayınları, 1973-1978

TAKIM TEZGAHLARI (CİLT 1-2)
MUSTAFA AKKURT MACHINING SCIENCE AND TECHNOLOGY, CNC MACHINE TOOLS AND Birsen Yayınevi, 2009
PRODUCTION AUTOMATION /
TALAŞ KALDIRMA BİLİMİ VE TEKNOLOJİSİ CNC TAKIM TEZGAHLARI VE ÜRETİM
OTOMASYONU
H. Oktay BODUR MACHINE TOOLS / Birsen Yayınevi, 1984
TAKIM TEZGAHLARI
Faruk MENDİ DESIGN OF MACHINE TOOLS / Gazi Kitapevi, 1999
TAKIM TEZGAHLARI TASARIMI
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Evaluation
Activities Number Percentage of Grade

Attendance/Participation
Laboratory
Application
Field Work
Special Course Internship (Work Placement)
Quizzes/Studio Critics 1 10
Homework Assignments 1 20
Presentations/Jury
Project
Seminar/Workshop
Mid-Terms 1 30
Final 1 40
Percentage of In-Term Studies 60
Percentage of Final Examination 40
TOTAL 100
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Introduction
Description of Machine Tool

Operation : It is a shaping process of metal or other rigid materials, usually by

cutting, boring, grinding, shearing or other forms of deformation.

Machine tool: It is a machine (power-driven machine) to carry out material

removal process by cutting unwanted section of material,which is called chip, by
using sharp cutting edged tool in.

Power driven machine which is capable of producing various shapes in metal by

using various sources.

Power driven machine which is capable of producing various shapes in metal by

cutting away the surplus material (called chip) using sharp cutting tool.

Other names : Machining, Material Removal Process, Chip Removal Process etc.
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Introduction
Machine tools are machines that give special forms to the
materials in desired shapes and tolerances.

These can be metal forming, machining, welding, casting

machines or plastic processing machines, non-traditional
manufacturing machines etc.

As a device of production, the use of machine tools has begun

since history of humanity. However, with the beginning of the
Industrial Revolution in Europe (I. Industrial Revolution) at the
beginning of the 19th century, machine tools showed a rapid
development with their current meaning.
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Introduction - History
The most significant developments in manufacturing methods are observed in the “Industrial Revolution” which
developed in England after 1870. With the industrial revolution, societies are oriented towards a rapidly
expanding mechanization. Within this period, technological inventions gradually increased the production, while
the physical effort spent on production was gradually reduced. In particular, the inventing of steam engine is a
technological revolution in the manufacturing industry. In this period, manpower was replaced by machines.

Towards the end of 19th century, the principles of manufacturing technologies were introduced and serial
manufacturing (2nd Industrial Revolution) started.

The great development in the field of machine tools started with the introduction of numerical controlled (NC)
machine tools in the 1950s. First of all, CNC (computer numerical control) and then DNC (direct numerical control)
machine tools were developed by equipping these NC machine tools with computers. Thus, production at the
optimization level was performed.

At this stage, robot systems were started to be used (3rd Industrial Revolution) to create robot factories
(unmanned factories) by using software including CAD/CAM systems as well as equipment.
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Introduction - History

Industrial revolutions throughout history;

1. Steam machine used in mechanical machine tools to use the steam power efficiently.

2. Production line development by Henry Ford's production line design and starting the use of
electricity in mass production.

3. Programmable machine tools caused mechanical and electronic technologies to be replaced by

digital technology in production in the 1970s.

4. Industry 4.0 is an industrial strategy plan that is expected to start the 4th Industrial Revolution.
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Shaping/cutting in the machine tools is the results of

relative motions created between the workpiece and
the cutting tool.
In this respect, motions can be divided into three
groups;
(1) Main (cutting) motion,
(2) Feed motion and
(3) Auxiliary (adjustment) motion.

Various machining methods are presented by

performing these motions with the cutting tool
and/or the workpiece.
 MAK4462 - MACHINE TOOLS

Introduction - History

Industrial revolutions throughout history;

1. Steam machine used in mechanical machine tools to use the steam power efficiently.

2. Production line development by Henry Ford's production line design and starting the use of
electricity in mass production.

3. Programmable machine tools caused mechanical and electronic technologies to be replaced by

digital technology in production in the 1970s.

4. Industry 4.0 is an industrial strategy plan that is expected to start the 4th Industrial Revolution.
MAK4462 - MACHINE TOOLS

Shaping/cutting in the machine tools is the results of

relative motions created between the workpiece and
the cutting tool.
In this respect, motions can be divided into three
groups;
(1) Main (cutting) motion,
(2) Feed motion and
(3) Auxiliary (adjustment) motion.

Various machining methods are presented by

performing these motions with the cutting tool
and/or the workpiece.
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Introduction - History
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Classification

Machine tools can generally be classified into 4 main groups;

1. Machine tools that remove chips (Machining)

2. Machine tools that do not remove chips (presses, etc.) (Chipless Manufacturing Processes)
3. Machine tools that are used in the processing of plastic materials (extruders),
4. Machine tools that are used in the material processing with physical and chemical methods
(non-traditional manufacturing methods).
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Classification of Machine Tools

A- According to the geometrical shapes of the workpieces

B- According to the number of the workpieces
C- According to the functions of the machines
D- According to the types of control
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Classification of Machine Tools
CLASSIFICATION OF MACHINE TOOLS IN MACHINING
According to the According to the
According to the Functions of the According to the Types of
Geometrical Shapes of Number of the
Machine Control
the Workpiece Workpiece
Machining cylindrical
Simple Lathes Manual
surfaces
Mechanical
Machining flat surfaces Universal Milling machine tools Automatic
NC
Making holes Production Drilling machine tools

Machining profiles Special Shaper/planer

Transfer Sawing machine tools

Numerical
Grinding machine tools
controlled
Modular Broaching machine tools

Super finish machine tools

Gear cutter machine tools

Thread cutter machine tools

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Classification of Machine Tools

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Classification of Machine Tools

According to the number of workpieces

1.Simple Machine Tools

2.Universal Machine Tools (general purpose)
spindle chuck tool-post tail-stock tail-stock wheel
3.Production Machine Tools (special purpose)
4.Special Machine Tools (limited purpose)
5.Transfer Machine Tools

carriage wheel carriage cross-slide wheel

lead-screw 6.Numerical Controlled Machine Tools
7.Modular Machine Tools
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Classification of Machine Tools

According to the functions of the machines

•Lathes
•Drilling Machine Tools
•Milling Machine Tools
•Shaper / Planer / Slotter
•Grinding Machine Tools
•Sawing Machine Tools
•Broaching Machine Tools
•Gear Cutter Machine Tools
•Thread Cutting Machine Tools
•Grinding Machine Tools
•Super Finish Machine Tools (Honing / Lapping / Polishing)
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Classification of Machine Tools

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Boundary Diagram of Machine Tools

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Classification of Machine Tools

Machine tools, in general, can be broadly classified according on the following basis:

1. According to primary machining operations

(a) Turning: lathes.
(b) Drilling: drilling machines.
(c) Shaping: shaping machine.
(d) Milling: milling machine.
(e) Boring: boring machines.
(f) Broaching: broaching machines.
(g) Grinding: grinding machines.

2. According to nature of cutting motion

(a) Rotating workpiece: all types of lathes.
(b) Rotating tool: drilling machine, milling machine, boring machine, grinding machine, hobbing machine, etc.
(c) Reciprocating tool: shaping machine, slotting machine, gear shaping machine and broaching machine.
(d) Reciprocating job: planing machine.
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Classification of Machine Tools

3. According to the basic purpose of use

a) General purpose: wide ranges of tools, jobs and operations (e.g., centre lathes).
b) Single purpose: only one or very few operations (e.g., roll turning lathe, facing lathe, relieving lathe, etc.).
c) Special purpose: a definite number and type of operations repeatedly done on single type of blank (e.g., finish
machining of bevel gear, blanks, cylinder blocks of IC engines, gear box housing, etc.).

4. According to degree of automation

(a) Non-automatic: centre lathes, shaping machines, drilling machines, etc.
(b) Semi-automatic: capstan lathe, turret lathe, copying lathe, relieving lathe, etc.
(c) Automatic: single spindle automatic lathe, Swiss type automatic lathe, transfer machine, CNC milling, machining
centre, etc.

5. According to type of automation

(a) Fixed automation: automatic lathe, transfer machines, etc.
(b) Flexible automation: CNC turning machine, CNC milling machine, machining centre, CNC grinding machine, etc.
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Classification of Machine Tools

6. According to size or capacity
(a) Heavy duty: large, bulky horizontal and vertical lathes, boring mills planing machines, etc. of power above 11 kW
(roughly).
(b) Medium duty: widely used centre lathes of power 2.2–11 kW.
(c) Small and mini: table top lathes of power less than 1.1 kW.
(d) Micro lathe: table top very small lathes (length smaller than 300 mm) such as Swiss type automatic lathes being
used mainly for turning parts of wrist watch and similar small products.

7. According to type of blank

(a) Chucking type: vertical lathes, turning centre, etc.
(b) (b) Bar type: capstan lathe, single spindle automatic lathe, etc.
(c) Housing type: horizontal boring machine, CNC milling and machining centre.
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Classification of Machine Tools

8. According to precision
(a) General: centre lathes, milling machine, drilling machine, etc.
(b) Precision and high precision: Swiss type automatic lathes, grinding machines, jig boring machine, etc.

9. According to number of spindles

(a) Single spindle: centre lathes, drilling machine, milling machines, single spindle automatic lathe, etc.
(b) Multiple-spindle: multiple-spindle (4, 6 or 8) automatic lathes, drilling machine, etc.

10. According to configuration

(a) Horizontal: lathes in general, horizontal boring machine and broaching machine.
(b) Vertical: vertical lathe, vertical boring machine, vertical broaching machine, gear shaping machine, etc.