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Murad Kondratyev
Murad Kondratyev

The Ultimate Guide to Machine Tool Design and Numerical Control by N.K. Mehta

Machine Tool Design And Numerical Control is aimed at students who are pursuing undergraduate courses in engineering. It covers the fundamental principles of machine tool design, and the use of numerical control for automation of machine tools.

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Machine tools are devices that are used to shape metals and other material. These tools are used for grinding, drilling, boring, cutting and other processes that are used to shape metals. Numerical control involves using control devices that can automate the operations of the machine tools in industrial environments. These machines can be manual or completely automated. Over the last few decades, the trend has been towards the use of Computer Numerical Control (CNC) devices that are fully automated control machines.

Machine Tool Design And Numerical Control covers the subject of designing machine tools and controlling them through different kinds of numerical controllers. The material in this book is divided into nine chapters. The book begins with an Introduction to Machine Tool Drives and Mechanisms. This chapter covers the general principles of machine tool design. The second chapter covers the Regulation of Speed and Feed rates in machine tools. It explains feed boxes, gear box design and kinematics of machine tools.

The third chapter looks at the Design of Machine Tool Structures. This chapter goes into the functions that a tool needs to perform and the design criteria that defines the structure of such tools. It also looks at the various structural elements of the machine tool like ribs and stiffeners. The next chapter focuses on the Design of Guide Ways and Power Screws. It examines the functions and types of guideways and the design of power screws. The fifth chapter is on the Design of Spindles and Spindle Supports.

The sixth chapter covers the Dynamics of Machine Tools. It discusses the machine tool as a closed loop system where the Machine Tool Elastic System and the Cutting Process (MTES & CP) interact with each other. It also goes into various cutting force models and stability analysis. The next chapter begins the coverage of Control Systems in Machine Tools. It examines manual and automatic control systems. The eighth chapter discusses Numerical Control of Machine Tools. It covers manual and computer aided part programming. The final chapter covers the Extensions of Numerical Control. It looks at Computer Numerical Control (CNC) machine tools and Direct Numerical Control (DNC) machine tools, with special focus on CNC systems.

As a design manager, I am acutely aware of how important it is to have the right tools at hand to help complete a project. After all, it is my job to design some of the most powerful and accurate portable machine tools for use in plant maintenance and production processes around the world.

While the powerful and sophisticated CAD software is the bread and butter tool for our trade, good machine designers shouldnt rely on software alone. I could not be without the humble sketchpad, calculator, and pencil. Almost all of our initial designs are hand-drawn before they make it to the 3D CAD system.

In my opinion, the team at SolidWorks really grasps what machine designers need and have packaged it into user-friendly interface. The additional features such as the cost estimate and quoting tools help us deliver projects on budget, while files we export can easily be turned in to stunning 3D animations such as this:

Literally, hard machining describes machining of parts having hardness over 45 HRC. Besides its advantages like high metal removal rate, easiness of adapting to complex part geometries, possibility of dry cutting; this operation, which can substitute grinding in most cases, has some disadvantages. One of them is the significant increase of surface roughness due to tool wear even when the tool life limit is not exceeded. In this study, considering hard turning praxes, higher depths of cut (0.5 to 1.0 mm) were examined when dry turning AISI D2 cold work tool steel, through-hardened to 62 HRC. TiN coated mixed ceramic inserts (Al2O3 + TiCN) were employed in the operations. Relationship between surface roughness and cutting parameters (cutting speed, feed and depth of cut) was modeled and analyzed using a Box-Behnken response surface methodology (RSM) design. A linear model best described this relationship. Despite the higher depths of cuts, the surface roughness values achieved were comparable to those in grinding operations. Finally, the optimal values of cutting parameters for minimum surface roughness were predicted.

Dr. Cihat Ensarioglu is currently a research assistant at the Department of Mechanical Engineering in Uludağ University, Bursa, Turkey. He received his BSc, MSc and PhD degrees in Mechanical Engineering from the same university in 2003, 2007 and 2014, respectively. His research interests are machining, machine tools, materials and production methods.

Prof. Mustafa Cemal Cakir is currently Professor in the Department of Mechanical Engineering of Uludağ University, Bursa, Turkey. He received his BSc degree from the same university in 1982 and he graduated with MSc from Technical University of İstanbul, Turkey in 1984. He received his PhD degree in Mechanical Engineering from University of Bath, UK, in 1989. His research interests are machining, manufacturing automation, CAD/CAM, machine tools, production methods, and design for manufacturability and assembly.

Prof. Ali Oral is currently Professor in the Department of Mechanical Engineering of Balikesir University, Balikesir, Turkey. He received his BSc and MSc degrees from Uludağ University in Mechanical Engineering in 1988, 1991, respectively. He received his PhD degree in Mechanical Engineering from Balikesir University in 1997. His research interests are machining, tool wear, machine tools and CAD/CAM.


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