Machine Tool Design Assignment 2017

(You may find some repetitions of some questions)

Q1. (a) Name the various mechanisms that are used to convert rotary motion into linear
or translatory motion and give examples of application of those different mechanisms in
machine tools.
(b)What factors need to be considered while designing a lathe spindle for strength?
(c) Why and how the friction in between the worktable (slide) and the bed (guide) is
reduced in heavy-duty machine tools.
(d)State the working principle and the relative advantages of recirculating balls type feed
screws being used in modern machine tools like CNC milling machines.
Q2. (a) What factors need to be considered during designing the body or structure of any
machine tool?
(b)Why is grey cast-iron preferably used to make lathe beds?
Q3. (a) What are the effects and possible causes of vibration in machine tools?
(b) What are the various sources of vibrations? Explain any two of them briefly.
(c) State the purposes of mounting machine tools on proper foundations.
Q4. (a)What does machine tool chatter mean? How such chatter develops and can be
controlled?
(b) Discuss in brief the effect of vibration on the cutting conditions.
(c) How can vibration in centre lathes be reduced without sacrificing productivity and
product quality?
Q5. (a) What features and characteristics of a machine tool are checked and measured
during its: (i) Geometrical test, (ii) Kinematic test, (iii) Idle run and (iv) Full load-running
test?
(b) Describe the acceptance tests for lathes.
(c) Explain various instruments required for acceptance tests.
Q6. (a) Compare flexible automation with fixed automation with respect to their basic
working principle in machine tools, advantages, limitations and applications.
(b)State the purposes of incorporating automation in machine tools.
(c) Usually when, where and by whom machine tools are thoroughly tested?
(d)What are the differences between Machine tool inspection and Machine tool testing?
Q7. (a) With the help of a suitable sketch briefly describe the working principle of
hydraulic copying lathe or copy milling machines.
(b) Draw a neat sketch of the cam- controlled automatic system used in machine tools.
Explain its working principle.
Q8. (a) Explain how the machine tools are classified. Derive the expression for the
machining time of any operation in the machine tools.
(b) Discuss the general requirements of machine tool design.
(c) Explain how the selection of electric motor is made on the consideration of
overloading and heating.
(d) Derive an expression to find out the diameter of the spindle subjected to combined
bending and twisting.
Q9. (a) What is the function of pressure valves? Draw a neat sketch of a ball-type pressure
valve and explain its principle of operation.
(b) Draw the cross-section of milling machine column. Find out the total deflection at the
top of the milling machine column along with their limiting value.
(c) Discuss how the module of the gear is determined in machine tools.
Q10. (a) Explain in brief, with sketches, different gear transmission systems, used for
transmitting rotary motion.
(b) What do you mean by dynamic stiffness and magnification factor? Make the analysis
when the (i) amplitude of the exciting force is independent of the exciting frequency, and
(ii) amplitude of the exciting force depends upon the exciting frequency.
(c) Discuss the advantages of cone pulley drive in machine tools. What are its limitations?
Q11.
a) Draw the commonly used slide-way profiles.
b) What are the main elements of a machine tool drive?
c) How a milling machine is specified?
d) Define speed and feed regarding lathe operations.
e) Name the main elements of a shaper.
f) What is the chief advantage of using hydraulic drive in machine tools?
g) What is meant by machine tool testing?
h) What is the purpose of feed motion in machine tools?
i) What do you mean by machine tool elastic system?
j) Name the materials used for making spindles.
Q12. (a) What are the advantages of a step-less drive? Describe any one commonly
used mechanical step-less drive in machine tools.
(b) What are feed control devices? Why are they needed? Explain the feed control by
using limit switches.
(c) Define backlash and what are its after effects? How is backlash minimized in a lead
screw and nut drive?
Q13. (a) What is the importance of guide-ways in machine tools? Describe the main
types of slide- ways used machine tools.
(b) Explain the design considerations of a spindle to be used in a lathe.
Q14. (a) Discuss the design considerations of machine tool structures. What methods
are used for improving rigidity?
(b) Briefly explain the mechanical and electrical automatic control systems used in
machine tools.
Q15. Write notes on:
(a) Dynamic characteristics of the cutting forces.
(b) Feed mechanism used in milling machine.
Q16. (a) Explain machine tool consideration for two criteria (i) Manufacturing (ii)
economy
(b) Why is that machine tool structures are designed considering rigidity criteria and not
with the strength criteria?
(c) Explain the function of machine tool structure and discuss their requirement during
design.
Q17. (a) Explain the general requirement of machine tool.
(b) Explain why a profile of machine tool structure is important when designing a machine
tool.
(c) Name and discuss the various methods used to improve the rigidity of machine tool
structure.
Q18. (a) List the advantages of hydrostatic bearing.
(b) What are the main elements in the machine tool control systems?
(c) Why ergonomics is important in machine tool design?
(d) What are the functions of a machine control unit in a CNC machine tool?
Q19. (a) What is the effect of tool wear on cutting forces and surface finish?
(b) Describe the mechanism of crater wear of the tools.
(c) Show that in orthogonal cutting with zero rake tool, the ratio of shear stress () to the
specific cutting energy (Ps) is given by:

(d) Discuss the basic requirements of a good machine tool design.

(e) Explain what characteristics of grinding process makes different from turning/milling
operations.
Q20. (a) Discuss how one would select a suitable drive system for a machine tool. What
factors should be considered for this purpose?
(b) Describe the factors that should be considered while making a choice between group
versus individual drive.
(c) Briefly describe any four mechanisms that can convert rotary motion into translation.
Q21. (a) Describe the general requirements of an ideal all-gear drive design. Describe any
method used for speed changing in all-geared drive.
(b) Describe the advantages and disadvantages of using rigid and flexible couplings. Draw
a sketch of Oldham coupling and explain its working.
(c) Discuss the significance of machine tool layout. Write the layout formula for a knee-
type vertical milling machine.
Q22 (a) What is the effect of cutting speed, feed and depth of cut on machine tool life?
(b) Using an appropriate diagram, derive the following expression connected to machine
sin
tool orthogonal cutting process: r = ; where r is the cutting ratio, is the shear
cos( )
plane angle, and is the rake angle. Use this equation to determine the percentage increase
in chip thickness when the coefficient of friction is doubled from 0.2, and the rake angle
is 200.
(c) An orthogonal cutting operation is carried out under the following conditions: to = 0.1
mm, tc = 0.2 mm, width of cut = 6 mm, v = 2 m/s, rake angle = 150 and coefficient of
friction is 0.2, Fc = 600 N, and Ft = 300 N. Calculate the percentage of the total energy
that is dissipated in the shear plane.
Q23. (a) With the aid of an appropriate diagram state and describe the role of each of the
principal forces acting on the work piece during an orthogonal machining operation.
Which of the principal forces can be measured and how will they be measured? Why is it
important to have knowledge of the force components in machining operations?
(b) In a machining operation that approximates orthogonal cutting, the cutting tool has a
rake angle = 100. The chip thickness before the cut to = 0.50 mm and the chip thickness
after the cut tc = 1.2 mm. The measured cutting force and thrust force are: F c = 1600 N
and Ft = 1200 N. The width of the orthogonal cutting operation w = 3.0 mm. For this
machining operation if the cutting speed v = 2 m/s, determine the:
i) shear plane angle,
ii) shear strain,
iii) friction angle,
iv) coefficient of friction,
v) shear strength of the work material,
vi) cutting power, and
vii) Specific energy.
viii) Increase in temperature above ambient temperature of 200C if the volumetric
specific heat for the work material = 3.0 x10-3 J/mm3/C, and thermal diffusivity =
50x10-6 m2/s (or 50 mm2/s).
Q24 (a) What are the causes and effects of vibrations? What do you understand by
vibration isolation? Use a graph to discuss the difficult encountered when using dampers
to isolate vibrations
(b) A uniform shaft 100mm diameter is held in a lathe machine chuck, A, at one end and
supported at the other end but free to rotate. The shaft carries two rotors B and C which
are to be machined. The shaft plus the chuck and the two rotors can be considered as a
three-mass torsional system. If IA= IB = 620 Kg-m2 and IC = 300 Kg-m2, sketch the system
and then determine:
i) The length BC if AB = 800 mm;
ii) The torsional stiffness of the shaft BC to make the first natural frequency 6 Hz;
iii) The corresponding second natural frequency.
Assume G = 80 GN/m2
Q25. (a) (i) Explain three types of machine tool vibrations and their causes. How can
vibration be controlled in a machine tool?
(b) Describe the adverse effects of vibrations and chatter in machining.
(d) Explain the application of hydrostatic bearings.
(e) Describe the purpose of machine tool spindle,"
Q26. (a) Discuss design of machine tool spindle subjected to combined bending and
twisting.
(b) Explain the following statements:
(i) Stick slip motion in guides
(ii) Chatter in machine tools
(c) Explain the force analysis of lathe guideways.
Q27. (a) Discuss objects and procedure for acceptance tests for machine tools and explain
any two instruments used for it.
(b) Explain standard acceptance test charts for a lathe.
(c) Describe various elements of control systems for machine tools.
(d) Describe aesthetic and ergonomics as applied to machine tools with suitable examples.
Q28. (a) Mention the factors affecting stiffness of a machine tool structure and explain
the methods of improving it.
(b) Compare welded and cast structure with respect to the application in machine tool
structures.
(c) Classify the guides used in machine tools.
(d) Explain the design procedure of slideways based on Stiffness
Q29. (a) Explain the method of determining the 'dynamic characteristics' of a machine
tool structure using experimentation.
(b) Discuss the effects of forced vibration on the performance of a machine tool.
(c) Explain the importance of aesthetics and ergonomics on the design of machine tools.
(d) Discuss various static measurements carried out for the acceptance tests of machine
tools.
Q30. Write brief notes on the following:
(a) Classification of machine tools
(b) Required properties of materials for machine tools
(c) Elements of hydraulic transmission
(d) Aim of feed rate regulation
(e) Choice of different sections of machine tools structures
(f) Functions of machine tools control systems
(g) Standardization of machine tools
(h) Chatter in machine tools
(i) Factor influencing the dynamic stability of machine tools
(j) Advantages of modular design.
(k) Kinematic structure of machine tool
(l) Explain speed structure-analysis.
(m) Difference between rigidity and compliance of a machine tool.
(n) Modular design
Q31. a) In CNC machine an antifriction ball guideways are used to reduce frictional
resistance of sliding movement. The slide has to support total load of 4000N. The
effective number of load sharing balls, is 16, and the ball diameter is 7mm. The
Poissons ratios for the arterial used for ball and guideways are 0.35 and 0.32
respectively and the modulus of elasticity for both the materials is 21 x 10 6 N/cm2.
Calculate the maximum specific pressure on each ball and the contact deformation of
the ball if contact compliance cosfficient Cb = 2.2 m/Kg
b) Explain the recirculating ball slideways used in machine tools.
Q32. a) Explain the terms static rigidity and dynamic rigidity of machine tools. How
can they be improved?
b) What do you understand by instability of the machine tool?
c) Explain the dynamic deflection with respect to excitation produced during machining
operation and its effect on stability.
Q33. a) Derive an expression for limited width of the cutting tool, under the threshold
conditions of stability and instability of the machine tool for machining operation.
b) What do you understand by adaptive control? Explain the principle and its operation
in controlling machining time.
c) Explain the adaptive control optimization and adaptive control constraints with their
advantages and limitations.
Q34. (a) Define the Factor of Safety. State the considerations to be considered when selecting factors of
safety. Why should the factor of safety be right?
b) A cantilever beam made of cold drawn carbon steel of circular cross-section (as shown in the figure
below) is subjected to a load which varies from P to 3P. Determine the maximum load that this member
can withstand for an indefinite life using a factor of safety as 2. The theoretical stress concentration
factor is 1.42 and the notch sensitivity is 0.9. Assume the following values: Ultimate stress = 550 MPa;
Yield stress = 450 MPa; Endurance limit = 250 MPa; Size factor = 0.85; Surface finish factor = 0.90

Q35. (a) Explain the following terms about the design of machine members subjected to variable
loads:
i) Endurance limit,
ii) Size factor,
iii) Surface finish factor, and
iv) Notch sensitivity.
(b) The bending stress in a machine shaft fluctuates between a tensile stress of 360MN/m2 and a
compressive stress of 275MN/m2. If the yield stress of the shaft is to be between 50% and 80% of the
ultimate tensile strength, the endurance strength = 0.5 Ultimate strength; and factor of safety = 2.0;
determine the minimum ultimate tensile strength of this shaft to carry this fluctuation indefinitely
according to: (i) Goodman's formula, and (ii) Soderberg formula;
(c) A simply supported shaft with a span of 600mm is subjected to a point cyclic load at its mid span.
The load varies from a minimum value of 40 KN to maximum value of 60 KN. The load direction is
transverse to the shaft axis. Find the diameter of the shaft, if the Ultimate strength = 650MN/m2, the
Yield strength = 500MN/m2 and the Endurance strength = 400MN/m2. Assume a factor of safety = 2, a
factor of size effect = 0.85 and a factor of surface finish = 0.80.
Q36. (a) Design a column for a drilling machine, if column height is 1.25 meters, maximum torque =
6.6 Kgm, feed force = 400 kg. Distance of drill center from column face (throat) = 250 mm.
(b) Design an anti-friction roller guideway, with 4 faces, if the load on the guideway
(Fy) = 400 kg, weight of saddle and work (W) = 80 kg, and feed force (Fx) = 40 kg. Hardened and
ground guideways are to be used. Saddle length = 350. The saddle operates at a cutting speed of 20
m/min. Find the frictional force for (a) open, and (b) closed guideways. Permissible pressure [p] = 0.08
kg/mm2.