ME 4621: Machine Tools

Shamsuddin Ahmed, PhD

Professor, Department of Mechanical and Chemical
Engineering
IUT, OIC
Humor without Malice
 I man announced in a gathering, “I have good
news and bad news. The good news is, we
have enough money to pay for our new
building program. The bad news is, it’s still out
there in your pockets”.
 During a Q&A session, a scholar was asked, “Will
we get cigarettes in Paradise?” to which he replied,
“Maybe, but you’d have to go to Hellfire to light
it”.
 An engineer was fixing a bell outside a house. Nasrudin came by,
stopped and asked, "What is that thing?" "Fire alarm". "I've seen
them before, they don't work," said Nasrudin. "What do you
mean?" "The bell rings all right, but the fire burns just the same."

Quotable quotes
 “No one is born hating another person because of
the color of his skin, or his background, or his
religion. People must learn to hate, and if they can
 learn to hate, they can be taught to love, for love
comes more naturally to the human heart than its
opposite.”
- Nelson Mandela
 “The future depends on what we do in the
present.”
- Mahatma Gandhi
 The highest scale of Iman is the LOVE for ALLAH
SWT.
- Al-Qur’an
 There is nothing weightier in the scales (on the
Day of Judgment) than pleasant manners
– Muhammad (PBUH)

What is Engineering? Or, Who is an Engineer?

Engineering is a profession in which the
knowledge of mathematics and natural
sciences gained by study, experience, and
practice is applied with judgment to develop ways
and means to utilize, economically, the material
and forces of nature for the benefit of mankind
(ABET).
Engineering and Science
Science is concerned with quest of basic
knowledge. Engineering is concerned with the
application of scientific knowledge to the solutions
of problems and to the quest for better life.

Basic science is known as “knowing science”,

whereas engineering is known as “doing science”.
However, the development of science and
engineering often occur hand-in-hand. In some
cases, a scientist and an engineer might be the
same person.

Engineers and other professionals

 Engineers solve problems and use
mathematics
 Engineers analyze data
 Engineer design systems and produce
products. Design = analysis + synthesis

Engineers use resources (materials, machines,

men, money). They need to analyze lots of data
and come up with (mostly) tangible solutions.
Engineer comes from old French word in the form
of verb (’ingenier)
An engineer is one who seeks in his mind, who
sets his mental power in action, in order to
discover or devise some means of succeeding in a
difficult task he may have to perform. To be human
is to be an engineer.
Engineer => Art + Artefact => Design + how it
goes about
Key words for an engineer: change, resources,
best, and uncertainty.

Engineering method
Strategy for causing the best change in a poorly
understood situation within the available
resources.
Engineering process
The basic steps are as below:

1) Problem symptom (need expression)

2) Problem definition (scenarios, statements)
3) Statement of the desired outcome (objectives)
4) Analysis/experimentation on potential solutions
5) Synthesis of alternative solution
6) Decision (one alternative solution)
7) Solution (system or method)
Define manufacturing engineering. Why is it
important today?
Manufacturing Engineering is the process of
designing a product(s) and production process(es)
to produce the product(s). Manufacturing is an
industrial activity to transform (raw) materials and
information into goods/products, mainly by
machinery, normally on large scale and with
division of labor, for the welfare and satisfaction of
human needs.
Manufacturing is now the primary wealth-
generating activity for a nation. It is the backbone
of an industrial nation. Level of manufacturing is
related to economic health and standard of living
of the people. It has significant role in national
development – economic development and
employment. Service sector is enhanced by
increasing manufacturing activity.

MCE Machine 3-0 Credit 3.00

4621 Tools
Mechanical, electrical hydraulic and pneumatic
drives in machine tools. Bearings, slide ways,
structure and control of machine tools. Detailed
case study of engine lathe, turret lathe, milling
machine, grinding machine, and gear shaping
machine and gear hobbing machines, etc.
Installation and acceptance tests of machine tools.
Locating principles and locators, clamps, dies,
jigs/fixtures. Non-conventional Machine tools, NC,
CNC and DNC machine tools.
MCE 4622 Machine Tools Lab 0-1.5 Credit 0.75

Experiments and study based on MCE 4621.

Mechanical Drives
 Mechanism for transmission of motion and power
between a prime mover (electric motor) and part of
a machine.
 The mechanisms which are used to transmit the
required motion and power from one shaft to
another shaft are called mechanical drives.
 These drives are extensively used in automobiles,
workshops, processing and transport industry.

Types of Mechanical Drives

1. According to principle of operation
# Transmit power by means of friction such as Belt
drive and rope drive.
# Transmit power by means of engagement such as
chain drive and gear drive.
Factors for selection of drive
  Center distance
 Velocity ratio
 Shifting arrangement
 Maintenance ease
 Cost

Belt drives are used to transmit power between a drive

unit and a driven unit
 Basic Components
Load carrying section
Rubber compression section
Cover
 Types of belts
 (a) Flat belt
 It is mostly used in factories and workshops, where
a moderate amount of power is to be transmitted.
The distance between two pulleys is not more than
8 meters apart.
 (b) V –belt
 It is mostly used in factories and workshops, where
a moderate amount of power is to be transmitted.
The distances between two pulleys are very near to
each other.

Circular belt or rope belt

 It is mostly used in the factories and workshops,
where a greater amount of power is to be
transmitted. The distance between two pulleys is
more than 8 meters.
Open belt drive
Use: It is used when the driven pulley is to be rotated in
the same direction as the driving pulley.

Construction
In this driving pulley pulls the belt on one side and
drives it to the other side. So the tension on pulled side
will be more than other side. The tension on pulled side
is known as tight side and other side is known as slack
side.
Crossed belt drive
Use: It is used when the driven pulley is to be rotated in
the opposite direction to that of driving pulley.
Construction
 In cross belt drive the belt bents in two different
planes, it therefore wears rapidly.
Compound belt drive
Use: It is used when the distance between input and
output shaft is very large.

Belt size with sheave size

The size of the belt must match the sheave size. if they
do not match, then the belt will not make proper contact
with the sheave and will decrease the amount of load it
can transmit.
B
A

B A

Sheaves

V-belt and Pulley

Standard V-Belt

Cogged Belt

Joined V-Belt

Positive Drive Belt

Location of Idler
Shaft Speed

Driven Drive

12 6 in
inch dia.
dia.

rpm 1800
rpm
 DriveSheaveDiameterI nches  driveshaft_rpm
DrivenShaft_rpm 
Driven_sheave_diameter

Driven Sheave Diameter

Driven Drive

___ 6 in
inch dia.
dia.

900 1800
rpm rpm

DriveSheaveDiameterI nches  driveshaft_rpm

DrivenSheaveDiameter 
Driven_shaft_rpm

Belt Length
Driven Drive

12 inch 6 in
dia. dia.

35
Belt_lengt h  drive_diam eter  3.14  driven_dia meter  3.14  center_to_center  2
2 2

Belt Speed

Driven Drive

12 6 in
inch dia.
dia.

900 1800
rpm rpm

diameter  3.14  rpm

FPM 
12

Belt Maintenance
 Routine maintenance is essential if a belt drive is to
operate properly
 Never force belt onto sheave
 Belt should not ride on bottom of sheave.
 Check belt condition
 Belt alignment
  Tension
 Inspect sheaves and shafts
 Belt stretch

Tensioning V-belts Drives

 Too
tight

Slight Too
bow loose
Check tension

Preventive maintenance
  Check belt condition
 Check belt tension
 Identify sources of contamination
 Check sheave alignment
 Check sheave wear

Chain Drives
 Types of links
Self-forming teeth
Extended Pin

DRIVE DRIV
N ROLL E
GEA

Chain
Pitch
Advanatges
 No slippage
 More compact than belt
 Good for slow speeds
 Easier to install
 Not subject to deterioration
 Operates under wet conditions
 Less adjustment required
 Can drive several shafts
 Less costly than gear drives
Disadvantages
 Cannot be used where drive must slip
 Cannot except misalignment
 Noisy
 Causes vibration
 Needs frequent lubrication
 Small load capacity
 Shorter Service Live
Chain drive with long center distance
 Drive chain
Drive Sprocket Sprocket
Shaft speed

Driven Drive

12 T 6T

DriveSprocket_# teeth  driveshaft_rpm

DrivenShaft_rpm 
rpm 1800
DrivenSprocket_# teeth

Chain length calculation rpm

Driven Drive

12 T 6T

35
inches
 DriveSprocketTeeth  Pitch
ChainLength  
2
DrivenSprocketTeeth  Pitch
 CenterToCenter  2 
2

Chain speed

Driven Drive

12 T 6T

900 1800
rpm rpm
teeth  pitch  rpm
FPM 
12

Some chain drive example

Fork lift

Roller conveyor

Gear drives and friction drive

  A gear is a form of disc, or wheel, that has teeth
around its periphery for the purpose of providing a
positive drive by meshing the teeth with similar
teeth on another gear or rack.
In order to transmit a definite power from one shaft to
another shaft to the projection on one disc and recesses
on another disc can be made which can mesh with each
other. This leads to the formation of teeth on both discs
and the discs with teeth on their periphery are known as
"Gears".
Advantages
It is a positive drive (no slip) i.e. it transmits exact
velocity ratio from one shaft to another shaft.
It can transmit very large power.
High transmission efficiency.
Requires less space.
Reliable.
 Gear boxes
 Types
Automotive transmissions
Auxiliary transmissions
Transfer cases
Power takeoffs
Marine gears
Hydraulic drives
Industrial transmissions
Differentials
  Series trains
 Planetary gearing
 Speed reducers
Base mounted
Shaft mounted
 Speed increasers

Spur Gear
Use: When the axis of two shafts are parallel to each
other. These gears have teeth parallel to the axis of the
shaft.
Involute curve
Cord
Base
Circle
 Circle
involute

Circle

Pressure angle

Pressure
Angle
Pressure
angle

Pressure
angle

Rotation
Line of
action
 14 ½ ° 20°

Pitch diameter and Center distance

Pitch Pitch
Diameter Diameter
D2 D1

Center
Distance C
D1  D 2
C
2 D1  2C  D2 D2  2C  D1

Circular and diametrical pitch

Circular
Pitch

3.1416”

1 2 3 4 5 6 7 8 9 10
Names of gear parts
Pitch
Circle

Clearance
Addendum
Pitch
Circle
Dedendum Working Thickness
Whole depth Circular
depth pitch

Addendum Thickness
Pitch
Line

Dedendum Whole Circular

depth pitch

Gear-teeth terms
Backlash
Backlash

Pitch
Line
Helical Gear
In helical gears the teeth are at some angle called
helix angle with respect to axis of the shaft.
Rack and Pinion
It is a special case of spur gear in which one gear is
having infinite diameter called "Rack".
Use To transmit the rotary motion into reciprocating
motion or vice-versa.
Application
Lathe machine, drilling machine and measuring
instrument.

Bevel Gear
Use
 When power is required to be transmitted from one
shaft to another shaft which are intersecting to each
other then bevel gears are used. Generally, the
angle between two shafts is 90⁰.
 The bevel gears are of two types,
 Straight bevel gear
  Spiral bevel gear

Straight Bevel Gear

In straight bevel gears the teeth are formed straight on
the cones, and they are parallel to the axis of the gear
Spiral Bevel Gear
In a spiral bevel gear, the teeth are formed at an angle
with respect to its axis. The contact between two
meshing teeth is gradual and smooth from start to
end, as in case of helical gears.
Use
To transmit power from one shaft to another shaft
which are non parallel and non intersecting.
For low load transmission only since they have
point contact between mating teeth.

Worm Gear
Use
To transmit power from one shaft to another shaft
which are non intersecting and their axes are normally
at right angles to each other.
Application: Lathe machine to get large speed
reduction.