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Machine Design - Fundamentals

The document provides information on machine tool design fundamentals including mechanics, forces, springs, friction, bearings, screws, and dynamics. It discusses key concepts like the laws of equilibrium of forces, parallelogram law of forces, action and reaction forces, stiffness of springs, cutting forces, efficiency of screw threads, and calculation of impact and inertia forces. The document also covers considerations in machine design like marketing, costs, manufacturing, and maintainability.

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0% found this document useful (0 votes)
125 views31 pages

Machine Design - Fundamentals

The document provides information on machine tool design fundamentals including mechanics, forces, springs, friction, bearings, screws, and dynamics. It discusses key concepts like the laws of equilibrium of forces, parallelogram law of forces, action and reaction forces, stiffness of springs, cutting forces, efficiency of screw threads, and calculation of impact and inertia forces. The document also covers considerations in machine design like marketing, costs, manufacturing, and maintainability.

Uploaded by

raghunath670743
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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MACHINE TOOL DESIGN - MECHANICAL

MACHINE DESIGN – FUNDAMENTALS


DESIGN

• Marketing Considerations
• Cost Considerations
• Design Approach - Analysis
• Functional Characteristics - Aesthetics,
Safety
• Manufacturing Considerations
• Assembly Characteristics - Ease Of assembly
• Maintainability
Mechanics

• We need to understand the working of the machines


through mechanics
• We should know how forces are generated on the machines
and how they are transmitted.
• How the machines are subjected to forces in movements,
impact etc.
FORCE

Force is defined by :
• Magnitude
• Point of Application
• Direction
Law Of Equilibrium Of Forces

Two Forces can be in Equilibrium only if they are


• Equal in magnitude
• Opposite in Direction
• Collinear in action
Parallelogram Law of Forces

B D D

A C A C

(a) (b)
Law Of Action and Reaction

 For every action there is an equal and


opposite reaction w
w

A
Ra

(a) (b)
FORCES IN A WEDGE

F=10

Fb
FRICTION

P P

F
F
F=*R

R N =tan() R N
(a) (b)
SELF RELEASING TAPER (7/24)

Fb Fa

Fa=35
Fb
Fa Fb=35

F
SELF LOCKING MORSE TAPER (MT4)

NORMAL REACTION FORCES Fa AND Fb


FOR APPLIED FORCE F IN UPWARD DIRECTION

Fb=192.6
Fb Fa
F Fa=192.6

FORCE F REQUIRED IN DOWNWARD DIRECTION


TO OVERCOME FRICTIONAL FORCE

f f
Fb F Fa
MORSE TAPER IN TAILSTOCK CENTER
CLAMPING FORCE IN COLLET

Fr

Fp=2400

Fp

Fc
BEARING REACTION

F
Rb
Ra
STIFFNESS OF SPRINGS

K=K1 K=K1+K2

ELASTIC ENERGY
Deflection

=1/2*K*h²
h

Applied force
F=K*h
1/K=1/K1+1/K2
CUTTING FORCES

 Chip Cross-section a= d*f


f
 Tangential Force Ft
=chip c/s *Sp. Cutting force
=a *Fs
 Torque=Force *radius =
Fx
Ft*D/2
 Power in KW =T*N/975
SCREW JACK
EFFICIENCY OF SCREW THREAD

Input Work = =2xxTx


Output Work = Force * Pitch
Input Work * efficiency = Output Work
2xxTx = Force * Pitch
 = Helix Angle of
thread
 =Tan-1(  )

TAN()
f
Efficiency =
TAN( +)
LOCK NUT
Forces acting on a slide

*X X

*X
X
a
 Taking moments about point O  In the limiting condition- 2* *X =F
 F*a =X*L/2+X*L/2 (The two
F  2**F*a/L=F
moments of *X cancel each other
 If =0.15 , 0.3*a/L=1
 X=F*a/L
 It is self locking if a>L/0.3
KEY FORMULAE

• Kinetic Energy of Linear Motion =1/2*m*v²


• Kinetic Energy of Rotational Motion = 1/2*I*²
• Elastic Energy=1/2*k*h²
CALCULATION OF IMPACT FORCE
IN BALL SCREW

 Kinetic Energy = 1/2*m*v²=1/2*k*h²


 1/k=1/k1+1/k2+1/k3
 k1 =Stiffness of Ballscrew shaft
 k2 =Stiffness of Ballscrew nut
 k3 =Stiffness of Ballscrew Bearings
 Impact force =k*h
CALCULATION OF IMPACT FORCES

• Motive Force
• Inertia Force
MOTIVE FORCE

• MOTOR TYPE : FANUC C6


• a) Continuous Load Torque Rating Tc =6N-m
• b)Peak Load Torque Rating=10*Tc =60N-m
• c)Peak Load Torque of motor and controller=4*Tc= 24N-m
• d)Peak Load Torque With Overload Tripper =1.5*Tc
• Motive Force at each Condition is Calculated by: 2**T*=F*p ,
F=2**T*/ p
INERTIA FORCE

• Kinetic energy of Moving Slide and Turret = 1/2*m*v²


• Kinetic Energy of Rotating elements i.e., Ball Screw Shaft =
1/2*I*²
• Ib= 3Ld /(32*g) , =2**n/60
• c)Kinetic Energy of Motor = 1/2*Ir* ²
• Ir=Rotor inertia
TOTAL KINETIC ENERGY

• Without Overload Tripper =KE of Linear Motion+KE


of Ballscrew Rotation +KE of Motor
• With Overload Tripper = KE of Linear Motion+KE of
Ballscrew Rotation
• Here we do not consider Motor Inertia because the
overload tripper will not allow the load due to motor
(motor force+inertia force) to exceed it’s preset
value
ELASTIC ENERGY

• Elastic Energy =1/2*k*h² where k is given by


1/k=1/Knut+1/Kshaft+1/Kbrg+1/Ksp
• Knut=0.8*K(Fao/(0.1*Ca))*
• Kshaft=A*E/L For different values of L
• Kbrg from Catalogue
• Ksp =Calculated Radial Stiffness for X-Axis and Axial Stiffness
for Z-Axis
Thermal deformation

100 kg
Tension force Tension
force

50 kg X 50kg

Expansion  11microns / mlength / deg


Dynamics

• General equation of motion ma= F


• Equation of dynamic equilibrium X-0 =0
Work Energy and Power

• Work = Force * distance moved 1 NM= 1 joule


• Energy=Capacity to do work
• Power = It is the time rate at which the work is done.
• 1 watt= 1 joule/sec=1 NM/sec
• 1000Watts = 1 Kw or 735.5watts= 1 HP
THANK YOU

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