Machine Tool and Tool Design

ME 4207

CLASSIFICATION & CHOICE OF DRIVE

SYSTEM

Pronob Das
Lecturer
Dept. of Mechanical Engineering
Rajshahi University of Engineering &
Technology

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 1
 Content
❖ What is a Drive System?
❖ The Prime Mover.
❖ Classification of Drive System.
❖ Combined Drive System.
❖ Recommendations for the Design of a
Drive System.
❖ Mechanical drive: Frictional Element.
❖ Mechanical drive: Formed Element.
❖ Electrical Drive System.
❖ Selection of Electrical Drive System.
❖ Hydraulic Drive System.
❖ Pneumatic Drive System. Figure 1: The gears used to transmit power
❖ References. from an electric motor to the agitators of a
commercial mixer. Source: Courtesy of
Hobart, Inc.
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology 2
 What is a Drive System?
The drive system consists of a prime mover and speed
changing mechanism. The ultimate objective is to obtain
economic cutting speed under all conditions.

It should be:
➢ Less costly
➢ Easy to operate
➢ Demand less space &
➢ Able to absorb quickly the shocks.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 3
 The Prime Mover
a) The machine tool should have such a prime mover (usually
an electric motor), which can provided necessary speed
and power during the machining operation.
b) It should have good load characteristics, i.e. under load the
cutting speed should not cross certain limit.
c) It should be less costly, easily available and require
minimum maintenance.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 4
 Speed Changing Mechanism
Speeds are changed through gear boxes and other systems.
The basic characteristics of the speed changing mechanism
that should have:

1. It should have maximum efficiency and generate less heat

due to friction and other causes.
2. Take less time to change the speed.
3. Should not be complicated and costly.
4. Ability to absorb shock load.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 5
 Classification of Drive System
Frictional Element
(belt etc.)
Mechanical
Formed Element
(gear etc.)
Electrical +
Electronic
Machine Tool
Drive Elements
Hydraulic

Pneumatic

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 6
 Combined Drive System

Mechanical Electrical + Electronics Mechatronics

Electrical + Electronics Hydraulic + Pneumatic Fluidics

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 7
 Recommendations/ Choice/Basic Consideration

1.Variable cutting speed:

It should be possible to produce variable cutting speed
to match economic cutting condition.
2.Speed variation not significant:
There should not be any marked variation in the speed,
if the cutting speed suddenly changes.

3.Reversible cutting speed:

The cutting speed should be reversible. In operation like
thread cutting, the job or the tool is to be rotated in both
direction.
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology 8
 Recommendations/ Choice
4. Minimum start, stop and reverse time:
The transient time for starting, reversing or stopping the
drive should be minimum. This increases the actual productive
time of machine.

5. Lost energy:
The lost energy should not heat up the drive system or
machine tool beyond a reasonable limit. Otherwise the bearing
may be damaged and the accuracy of the machine tool may be
hampered.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 9
 Recommendations/ Choice
6. High Mechanical Efficiency:
The mechanical efficiency should be as high as
possible.

7. Availability of Technology and Material:

The designed material for the components should be
easily available. It should be possible to manufacture the
components economically with the available technology.

8. Minimum Production Cost:

The cost of production should be minimum.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 10
 Recommendations/ Choice
9. Dimensional constraints:
The machine tool has designed dimensions. The drive
system has to fit within the dimension.

10. Aesthetic aspects:

The machine tool designers are giving more and more
importance to the look of the machine in order to attract the
attention of the customers.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 11
 Mechanical Drive: Frictional Element

Figure : Quarter-twist belt drive: an idler guide

pulley must be used if motion is to be in both
direction

These figures are the examples of Mechanical

Frictional Element Drive
Sketch Courtesy: Shigley's Mechanical
Engineering Design 8th Edition
Figure : Variable-speed belt drives.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 12
 Mechanical Drive: Formed Element

Figure(b) : Simple gear train.

Figure(a): An assortment of gears. Figure(c) : Compound gear train

Source: Courtesy of Quality
Transmission Components

Figure (a), (b) & (c) are the examples of Mechanical Formed Element Drive

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 13
 PIV Drive
A stepless drive where the transmission of torque takes place infinitely
variable without slip is called PIV drive.

Working Principle:
▪ No slip
▪ Stepless drive
▪ Endless chain

*Why P.I.V drive is so called?

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 14
 PIV Drive system
Advantages
i. No slip in transmission system
ii. Maximum transmission of power
iii. Speed can be changed at running condition
iv. Any range of speed can be obtained
v. It can give constant cutting speed.

Disadvantages
i. Rapid wear

Applications: For speed variation in lathe m/c, printing m/c

etc.
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology 15
 Electrical Drive System: Classification

Machine Tool Drive

(Electrical Machines)

Central Drive Individual Drive

DC System AC System

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 16
Electrical Drive System: DC System

DC System Separately Excited Motor

Shunt Motor

Series Motor

Compound Motor

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 17
 Electrical Drive System: AC System

Single Speed Induction Motor Synchronous Motor

AC System

Electrical Shafting

Pole Changeable Frequency Changed

Multiple Speed
Motor Motor(Inverter)

Infinitely Variable
Ward Leonard Set
Speed

Stepper Motors

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 18
 Electrical Drive System: Selection
The selection of a motor as a machine tool drive depends on:

1. The starting characteristics.

2. The requirement of speed regulation.
3. The torque and the power characteristics with respect to the shaft
speed.
4. The cost economy.
5. The need to breaking(rapid stopping, inching etc.).
6. The dynamic( or vibration) characteristics.
7. The available electrical energy(for AC system power factor as well).
8. The efficiency, including the operating condition.
9. The robustness of the motor.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 19
 Central Drive
In this system every shop has a central electrical motor. Through the
overhead shaft the power is supplied to different machine tools.
Advantages:
1. Motor is more or less evenly loaded and has a maximum capacity
utilization.
2. Cost economy.

Disadvantages:
1. All the machine tools remain idle, if the motor is out of task.
2. The system does not allow very long distance transmission.
3. It creates space problem, because of line shaft and the belt drives.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 20
 Hydraulic Drive System
Hydraulic Motor
Oil

Prime Mover
(Electric Motor)

Hydraulic
Pump Sump

Fig.: A Schematic Diagram of a Hydraulic Drive System

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 21
 Advantages of Hydraulic Drive
1. Relatively small dimensions and weight for a design horsepower.
2. The possibility of simple and smooth speed reversion.
3. The speed and the feed can be varied infinitely within the range.
4. Quiet running.
5. Possibility of programme control and overload protection.
6. Possibility of high cutting and clamping forces.
7. Self lubricating effect.
8. Due to less inertia and cushioning effect, the elements of
hydraulic drive have long life.
9. Hydraulic power can be delivered to points, which are not
accessible to gears and mechanical drive elements.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 22
 Disadvantages of the Hydraulic Drive
1. The high accuracy of the parts and close fit of the assembly leads
to high cost of production.
2. Heating of the viscous medium due to throttling action.
3. Any leakage reduces the efficiency of the system drastically.
4. The compressibility of oil, however small, and the elasticity of
the oil carrying parts, specially long pipe lines, may seriously
affect the rigidity of the linkage and with it the dynamic property
of the machine and its elements.
5. It is not easy to repair hydraulic elements.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 23
 Hydraulic Pumps
Pumps

Constant Variable
Delivery Delivery

Axial Radial
Gear Pump Screw Pump
Arrangement Arrangement

Axial Piston Radial Piston

Vane Pump
Pump Pump

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 24
 Gear Pump

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 25
 Rate of Delivery and Power of Motor
The rate of delivery and power for 2 gear pumps can be calculated as:
𝜋 8𝑑𝑚𝑏𝑛
𝑄= . (l/min)
4 500
𝜋𝑇𝑚2 𝑏𝑛
= (l/min)
500
Where, Q = Theoretical supply rate (l/min)
d = pitch diameter (cm)
m = module (cm)
b = gear width (cm)
n = gear speed (rpm)
T = number of teeth of a gear
𝜂 = mechanical efficiency = 0.6-0.8
p = delivery pressure (atm.gage)
10𝑝𝑄
Power, 𝑃 = (hp)
60×75×𝜂

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 26
 Hydraulic Cylinder
Hydraulic cylinders are positive displacement reciprocating hydraulic motor converting the
energy of the fluid into the kinetic energy of pistons or of cylinders.

Oil under pressure (P) enters the cylinder from the left hand side and pushes the piston to the
right against the cutting force F and the oil pressure 𝑝𝑎 on the rod side of the piston. The
piston velocity is V and the fluid supply rate Q.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 27
 Cont….
𝜋 𝜋
Cutting force, 𝐹 = 𝐷2 𝑃 − 𝑑2 𝑝𝑎
4 4
4𝑄
Piston velocity, 𝑉𝑓 =
𝜋𝐷2
During the return stroke of the piston the fluid is supplied on the
right hand side (i.e. piston rod side).
𝑉𝑅 = Velocity of the piston during the return stroke
𝑄 4𝑄
=𝜋 2 2 = 2 2
𝐷 −𝑑 𝜋 𝐷 −𝑑
4
𝐷 4 1
If 𝑑 ≈ then 𝑉𝑅 =
, 𝑉
= 1 + 𝑉𝑓
2 3 𝑓 3
So, 𝑉𝑅 is 33% higher than 𝑉𝑓 .

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 28
 Pneumatic Drive System
Pneumatics is a section of technology that deals with the study
and application of pressurized gas to produce mechanical
motion.

Pneumatic drive systems are used extensively in industry are

commonly powered by compressed air or compressed inert
gases.

Pneumatics has applications in:

➢ Air motors and other pneumatic devices.
➢ Dentistry, construction, mining and other areas.
Department of Mechanical Engineering
Rajshahi University of Engineering & Technology 29
 Comparison to Hydraulics
a) Both pneumatics and hydraulics are applications of fluid
power.
b) Pneumatics uses an easily compressible gas such as air or a
suitable pure gas─while hydraulics uses relatively
incompressible liquid media such as oil.
c) Most industrial pneumatic applications use pressure of about
80 to 100 psi (550 to 690 kPa). Hydraulics applications
commonly use from 1000 to 5000 psi (6.9 to 34.5 MPa), but
specialized applications may exceed 10,000 psi (69 MPa).

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 30
 Advantages of Pneumatics
1. Simplicity of Design and Control: Machines are easily designed
using standard cylinders and other components, and operate
via simple on-off control.
2. Reliability: Pneumatic systems generally have long operating
lives and require little maintenance.
3. Safety: There is a very low chances of fire compared to
hydraulic oil. Newer machines are usually overload safe.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 31
 Speed Range

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 32
 Maximum and Minimum cutting and feed speeds

1000𝑉𝑚𝑎𝑥
Maximum spindle speed, 𝑛𝑚𝑎𝑥 = (rpm)
𝜋𝑑𝑚𝑖𝑛
1000𝑉𝑚𝑖𝑛
Minimum spindle speed, 𝑛𝑚𝑖𝑛 = (rpm)
𝜋𝑑𝑚𝑎𝑥

Where, 𝑉𝑚𝑎𝑥 = Maximum cutting speed (m/min)

𝑉𝑚𝑖𝑛 = Minimum cutting speed (m/min)
𝑑𝑚𝑎𝑥 = Maximum job diameter (mm)
𝑑𝑚𝑎𝑥 = Minimum job diameter (mm)
𝑛𝑚𝑎𝑥 𝑉𝑚𝑎𝑥 𝑑𝑚𝑎𝑥
The Speed range ratio, 𝑅𝑛 = = . = 𝑅𝑣 . 𝑅𝑑
𝑛𝑚𝑖𝑛 𝑉𝑚𝑖𝑛 𝑑𝑚𝑖𝑛
Where, 𝑅𝑣 = Cutting speed range ratio
𝑅𝑑 = diameter range ratio
For straight line cutting motion 𝑅𝑛 depends only upon 𝑅𝑣 , but For rotary
cutting motion, 𝑅𝑑 must be taken into consideration.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 33
 Economic Cutting Speed

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 34
 Saw Diagram for cutting speed
1000𝑉𝑢 1000𝑉𝑙
𝑛1 = =
𝜋𝑑1 𝜋𝑑2
1000𝑉𝑢 1000𝑉𝑙
𝑛2 = =
𝜋𝑑2 𝜋𝑑3
1000𝑉𝑢 1000𝑉𝑙
𝑛3 = =
𝜋𝑑3 𝜋𝑑4
……………………………
1000𝑉𝑢 1000𝑉𝑙
𝑛𝑛−1 = =
𝜋𝑑𝑛−1 𝜋𝑑𝑛
1000𝑉𝑢 1000𝑉𝑙
𝑛𝑛 = =
𝜋𝑑𝑛 𝜋𝑑𝑛+1
Therefore,
𝑛2 𝑛3 𝑛𝑛 𝑉𝑢
= = ….. =
𝑛1 𝑛2 𝑛𝑛−1 𝑉𝑙

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 35
 Continue….
From the equation, it is established that, the stepped speeds constitute a GP series with
𝑉
the progression ratio of 𝛷 = 𝑉𝑢.
𝑙
It is seen that the diameter range for lower spindle speeds is larger that of higher ones.

Two other methods for the distribution of the spindle speeds are:
a) Arithmetic progression
b) Logarithmic progression

a) Analysis of the geometric progression (GP) series

If V is the limiting cutting speed for a given set of cutting conditions and economy and 𝑉𝑗
is the corresponding actual cutting speed, because the speed, n corresponding to the cutting
speed, V is not available.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 36
 Continue……

The loss of cutting speed, 𝛥𝑉 = 𝑉 − 𝑉𝑗

𝛥𝑉
The relative speed loss, 𝐴 = . 100(%)
𝑉
𝛥𝑉 𝑛−𝑛𝑗
𝐴= = . 100(%)
𝑉 𝑛
Where, 𝑉 = 𝜋𝑑𝑛
𝑉𝑗 = 𝜋𝑑𝑛𝑗

Fig.: Analysis of speed loss in a stepped drive

Therefore, the maximum relative loss of cutting speed 𝐴𝑚𝑎𝑥 occurs when n approaches 𝑛𝑗+1 .
𝛥𝑉 𝑛𝑗+1 −𝑛𝑗 1 𝛷−1
𝐴𝑚𝑎𝑥 = = = 1−𝛷 = . 100%
𝑉 𝑚𝑎𝑥 𝑛𝑗+1 𝛷

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 37
 Cont……
Thus, it is evident that 𝐴𝑚𝑎𝑥 is constant over the whole range of speeds, if the
speeds are stepped in a G.P. series.

b) Layout of speeds in AP (Arithmetic Progression) series:

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 38
 References
1) M. Anwarul Azim, “Elements of Machine Tools”.
2) Schmid, Hamrock and Jacobson, “Fundamentals of Machine
Elements, 3rd ed.”.
3) Joseph Adward Shigley, “Mechanical Engineering Design, Eighth
Edition”.
4) www.Wikipedia.com
5) Other internet resources.

Department of Mechanical Engineering

Rajshahi University of Engineering & Technology 39