1
Introduction
• Beds, bases, columns and box type housings are called
“structures” in machine tools.
• In machine tools, 70-90% of the total weight of the
machine is due to the weight of the structure.
Functions of Machine Tool Structure & their Requirements
• Machine tool parts, such as beds, bases, columns, box-type
housings, over arms, carriages, table etc. are known as
structures.
Basic functions of machine tool structure
1. To provide rigid support on which various subassemblies
can be mounted i.e. beds, bases.
2. To provide housings for individual units or their
assemblies like gear box, spindle head.
3. To support and move the work piece and tool relatively,
i.e. table, carriage, tail stock etc.
• Design of machine tool elements is critical in tool
engineering.
1. They must withstand against applied external load.
2. Machine tool structure consists of bed, column,
housing.
3. Base of machine tool on which the guide-ways, slide-
way, spindle, carriage, etc. are mounted.
4. These elements must able to withstand higher
permissible load.
5. Ability of the structure or the bed to resist distortion
Stability & accuracy of the moving parts.
6. Wear resistance of the guide-way.
7. Freedom from residual stresses.
8. Damping of vibration.
• Machine tool structure must satisfy the following
requirements:
1. The initial geometrical accuracy of the structure
should be maintained for the whole life of the
machine tool.
2. All mating surfaces of the structure should be
machined with a high degree of accuracy to provide
the desired geometrical accuracy.
3. The shape & size of structure should not only provide
safe operation & maintenance of the machine tool
but also ensure that working stresses & deformation
should not exceed specific limits.
4. The selection of material & high static & dynamic
stiffness are the fundamental requirement to fulfill
above-mentioned requirement.
• Machine tool structure consists of bed, base, columns,
box type housings, over-arms, carriages, tables etc.
• The structures are divided into three categories according
to their functions :
1. Category 1: An element, upon which various
subassemblies are mounted.
• Example: bed and base.
2. Category 2: Elements consist of box type housings in
which individual parts are assembled.
• Example: Speed box housing, spindle head, etc.
3. Category 3: Elements consist of parts that are used for
supporting and moving the work-piece and cutting
tool.
• Example: Table, carriage, knee, tailstock, etc.
• Materials for Machine Tool Structure:
1. The commonly used material are cast iron & steel.
2. Earlier cast iron structures were widely used but due
to advances in welding technology, welded steels are
widely used now days.
• The selection of material for machine tool structure
depends upon
1. Material properties
2. Manufacturing Problems
3. Economy
1. Material properties
A. Cast iron has higher damping properties than steel.
B. Welded steel also shows good damping properties.
C. Cast iron has better sliding properties.
D. Steel has higher strength under static & dynamic
loading.
E. The unit rigidity of steel under tensile, torsional &
bending loads is higher than cast iron.
• Important material properties of relevance are:
1. Modulus of elasticity: For high stiffness it is necessary
to choose materials with a high value of E.
2. Specific stiffness: Material should have high specific
stiffness.
3. Damping: Cast iron has higher inherent damping
properties, damping in steel structures occurs mainly in
welds, if welded joints are properly designed, the
damping of steel structure may approach that of cast
iron.
4. Long-term dimensional stability: The machine tool
structural material must also have a good long-term
dimensional stability.
5. Coolant resistance: The material should be unaffected
by coolant.
6. Wear rate and frictional properties: Material should
have low wear rate and low coefficient of friction.
7. Thermal expansion coefficient: The material used
should have a reasonably low coefficient of expansion.
• If several composite materials are used, each should have
the same coefficient of expansion to avoid thermal
bending/distortion.
2. Manufacturing Problems:
A. Welded structures of steel have much thinner wall
thickness as compared to cast structure.
B. Walls of different thickness can be welded more easily
than casting it. Machining allowances for cast
structures are generally greater than for weld steel
structures.
C. Welded structure can be easily repaired as compared
to cast structure.
3. Economy
A. The selection of material for structure will also depend
upon its cost.
B. The weight of steel is lesser & but actual metal
consumption is higher than that of cast iron. Hence in
such cases the cost increases.
C. Holes are obtained with the help of core in the casting
structure but holes are made in welded steel structure
by machining. These will not only increase the
material cost but also increases labour cost.
D. Cost of patterns, welding fixtures, & cost of
machining are considered while selecting material for
structure.
Different Materials Used for machine tool structure
• As already stated, commonly used materials for machine
tool structure are cast iron and steel.
• While in recent times, granite and epoxy concrete are
also developed and used for structures.
1. Cast Iron: From early times cast iron has been the most
commonly used material for machine tool structures.
• It may be cast into complex and intricate shapes.
• It has fairly good damping properties and also has
reasonably good antifriction properties helped by the
graphite contained in it.
• It can be given very good long-term dimensional
stability by giving it a special long cycle stress relief
annealing treatment.
• It is easily machined and may be hand-scraped and
lapped to a high degree of accuracy.
• One major disadvantage is the time and cost taken to
produce a finished casting.
• Again care has to be taken at design stage to ensure no
abrupt changes in section thickness.
2. Mild steel weldments:
• since 1950’s mild steel weldments have been used more
and more as a machine tool structural material.
• They have a high stiffness and the strength is also high.
• It has lower weight compare to cast iron.
• If necessary, in mild steel structures thin wall sections
can be used.
• While with cast iron the wall thickness is limited by the
accuracy of casting.
Disadvantage of using mild steel for structure
• The material damping is low.
• manufacturing times are long.
• This material will rust, too.
• Long-term dimensional stability has not been verified to
the same degree as cast iron.
• Finally, combined welded and cast structures are
becoming popular, now days.
3. Granite:
• Granite is used for surface tables and measuring machine
structures.
• Its internal damping is better than that of cast iron.
• Its wear properties are good.
• It is reputed to be very stable dimensionally.
Granite has a number of disadvantages.
• It is becoming more and more scarce.
• It takes a long time to cut it out to size, grind and lap it to
shape.
• There are many types of granite, but most absorb water
and the surrounding air humidity affects its dimensional
stability and thus geometrical accuracy.
4. Epoxy concrete:
• It is a new material specifically developed over the past
two decades for high precision machine tool structure.
• It is the mixture of binding agent reaction resin and the
hardener together with carefully selected and mixed
aggregates.
• It is completely new technology as compared with those
of the materials mentioned above.
• Epoxy concrete offers great design freedom, similar to
cast iron.
• It has outstanding damping properties – better than
traditional concrete.
• It costs approximately the same as steel reinforced
concrete or even less.
• Epoxy concrete does not expand and contract with change
in humidity, as does ordinary concrete.
• The volume of the two beams with optimum l/b values will be in
the ratio
End of Chapter Four