Speed chart:

The speed chart depicts the transmission ratios. The structural diagram depicts only range ratio
so speed chart must be plotted to depict the transmission ratios
o Horizontal line corresponds to transmission ratio, i = 1. (no speed)
o Line inclined upwards corresponds to transmission ratio, I >1 (increase in
speed)
o Line inclined downwards corresponds to transmission ratio, i <1 (decrease
in speed)
 While plotting the speed chart it is desirable to have minimum
transmission ratio i.e maximum speed reduction in the last
transmission group. The remaining shafts run at relatively
higher speed and so subjected to less torques.
Ray Diagram (Or) Speed Diagram
A ray diagram is a representation of structural formula. It provides information such as speed in
each stage, the transmission ratio in each stage, The total number of speeds and its values.

• As seen in fig.
(a) the maxi speed and minimum speed both are higher for shaft. This requires smaller size
of shafts due to reduced torque.
(b) the maximum speed and minimum speed both are lower which requires lager size of
shaft due to increased torque.
(c) the middle situation. One will definitely prefer the version(b) , but if the machine cost of
shafts is not a criterion , then version(a) is preferred. No. of stages

Structural formula:
Kinematic Diagram:
A kinematic layout is a pictorial representation of gearbox, describing the arrangement of
gears. A kinematic diagram or kinematic scheme illustrates the connectivity of links and joints of
a mechanismor machine rather than the dimensions or shape of the parts. Often links are presented
as geometric objects, such as lines, triangles or squares, that support schematic versions of the
joints of the mechanism or machine.[1] A kinematic diagram is sometimes called a joint map or
a skeleton diagram.
• It provides information like
1. number of stages
2. number of shafts used,
3. number of gear pairs
4. and its arrangement.

Why structural formula/ structural diagram/ray diagram/ speed chart is chosen for
qualitative assessment of the speed layout?
1. To decide number of shaft
2. To decide number of gear on each shaft
3. To decide arrangement gears on each shaft
4. To calculate number of teeth

Gear box: Gearbox often referred as transmission is a unit that uses gears and gear
trains to provide speed and torque conversions from a rotating power source to another
device. Gearboxes are employed to convert input from a high speed power sources to low
speed (E.g. Lift, Cranes and Crushing Machine) or into a many of speeds (Lathe, Milling Machine
and Automobiles).
Classification of speed boxes:
1. On the basis of general layout:
i. Speed boxes built in the spindle head
ii. Speed boxes manufactured as separate unit
2. By the method of changing gear
i. Speed boxes with change gear
ii. Speed boxes with sliding gears
iii. Speed boxes with jaw clutches
iv. Speed boxes with friction clutches
Classification of feed boxes:
i. Speed boxes with change gear
ii. Speed boxes with sliding gears
iii. Feed boxes with cone and sliding key
iv. Feed boxes with tumbler(Norton) gear
Functions of gear box:
The transmission box which is also known as the gear box is the second element of the power
train in an automobile. It is used to change the speed and torque of vehicle according to variety
of road and load condition. Transmission box change the engine speed into torque when
climbing hills and when the vehicle required. Sometimes it is known as torque converter. Main
functions of a gear box is as follow:
1. Provide the torque needed to move the vehicle under a variety of road and load conditions.
It does this by changing the gear ratio between the engine crankshaft and vehicle drive wheels.
2. Be shifted into reverse so the vehicle can move backward.
3. Be shifted into neutral for starting the engine.

Working principle of gear box:

In a gear box, the counter shaft is mashed to the clutch with a use of a couple of gear. So the
counter shaft is always in running condition. When the counter shaft is bring in contact with the
main shaft by use of meshing gears, the main shaft start to rotate according to the gear ratio.

• When want to change the gear ratio, simply press the clutch pedal which disconnect the
counter shaft with engine and change connect the main shaft with counter shaft by another
gear ratio by use of gearshift lever.
• In an gear box, the gear teeth and other moving metal must not touch. They must be
continuously separated by a thin film of lubricant. This prevents excessive wear and early
failure. Therefor a gearbox runs partially filled with lubricant oil
Design procedure of gear box( sliding gear)
A. For designing a stepped drive
o Following informations are necessary
 Highest output speed
 Lowest output speed
 Number of steps (Z)
 Number of stages to achieve the required
number of speed
steps.
B. Break up of speed steps
o The number of steps (Z) should be so selected that it can be
broken into the multiples of 2 & 3. Thus, selected values of Z
are : 6,8,9,10,12,14,16 & 18.
C. Structural diagram
 It gives the information about
o Number of shafts in the speed box
o Number of gears on each shaft
o The order of changing transmission in individual groups to
obtain the desired speed.
o Transmission range
o Group characteristics

Comparison AP GP HP
Defination The difference The ratio of any two The diameter range
between any two successive spindle of workpiece served
successive spindle speeds is constant by spindle speed is
speeds is constant constant
Progression
Good in High spindle speed High spindle speed Low spindle speed
range range range
Poor in Low spindle speed Low spindle speed High spindle speed
range range range
Low rpm range Need to more steps Should brought still At satisfaction range
of speed closer
High rpm range Some values of speed Can be widened little Too wide apart
are redundant
Performance can be uneconomical Equally feasible in Can be uneconomical
at some range the whole rpm range at some range

Advantage of GP?
1. Optimum distribution of gear speeds
2. Constant loss of economic cutting speed
3. Better gear box design
Choose of materials depends on:
1. Material Properties:
a. Steel:
i. Higher strength under static and dynamic loading
ii. Damping occurs mainly in welds
iii. If welded joints are properly designed, the damping structure may
approach that of cast iron
 iv. Unit rigidity of steel under tensile, torsional and bending loads is
higher
b. Cast iron:
i. Higher inherent damping properties
ii. Has better sliding properties
2. Manufacturing problems:
a. Wall thickness:
i. welded structures made of steel can have much thinner walls( upto
50%) as compared to cast structure
ii. steels can have 10-12 mm thick plates are easy to manufacture but
are not cost effective
iii. thin walled steel structures have 3-6 mm thick walls which are thinner
than the walls of cast structure by 1.5-2 times. These are greater
economy of metal but difficult to manufacture
b. wall of different thickness can gbe welded more easily than cast
c. machining allowance for cast structures are generally larger than for weld
structures
d. a welded structure can be easily repaired and improves than cast structures
3. Economy:
a. Economy of metal:
i. Cost of pattern and welding fixtures
ii. Cost of machining
b. Steel should be preferred for simple, heavily loaded structures in small
numbers
c. Cast iron should be preferred for complex structures to normal loading
d. Lately, combined welded and cast structures are becoming popular.

A control system consist of:

1. A control member/ transmitter
2. A transmission( a set of elements and mechanism)
3. An operative member
Function of machine tool systems:
1. Changing the speeds and feeds
2. Providing the working and auxiliary motions in the desired sequence
The requirements of machine tool design:
1. Reliability against failure to respond
2. Fast respond
 3. Accuracy of the system
Automatic control system:
Base on changing speeds and feeds control system:
a. Control system with individual control
b. Control system with centralized control
i. Systems with simple centralized control
ii. Systems with preselective centralized control
iii. Systems with selective control

1. Mechanical automatic control system

a. Cam-controlled systems
b. Template controlled systems
2. Manual control system
a. Design of push button
i. Top surface slightly concave
ii. Pressing force .3 to 1.2 kgf
iii. Diameter 12-15 mm
iv. Movement of button 3 to 10 mm
v. Adjacent push button should be 6mm away
vi. The stop push button should be larger than rest, painted red and locadter
above the control panel( it can be operated by palm or the wrist, so its
dia should be 25mm and slightly convex)
b. Design of toggle switch: miniature lever which is used as a selector in light duty
electrical switching operations
i. Dia 3 to 12
ii. Long 12-25 mm
iii. Toggle movement 30 to 40 degree on either side of central position
iv. Button should be place in a horizontal row not vertical row
c. Design of knobs:
i. Small knobs are knurled and large knobs have serrations on their
periphery
ii. Bar knob:
1. Long: 25 mm(up to 70mm)
2. Thickness: not more than 25 mm
3. Adjacent knob distance: 25-75 mm
d. Design of cranks:
i. The torque is depend of lever arm length,l
 ii. Smaller cranks are suitable for low torque and high rpm and it gives high
accuracy
iii. Large cranks are suitable for high torques and low rpm
iv. Optimum height from floor should be 90mm
3. Electrical automatic control system
4. Adaptive control system: there are the three functions of adaptive control system
i. Monitoring
ii. Optimization
iii. Execution
b. Important sources of random variations of the cutting condition
i. Variation of depth of cut
ii. Variable work material hardness
iii. Variable wokpiece rigidity
iv. Deformation of machine tool elastic system
v. Tool wear
vi. Air gaps that interrupt the cutting
c. Classification of adaptive control system
i. Limit constraint adaptive control system
ii. Process optimization adaptive control system
Objective and aim of machine tool: General requirements of machine tool:
 Accuracy and precision  High productivity
 Productivity  High accuracy
 Safety and convenience  High useful life
 Workpiece dimension  Ease to manufacture
 Surface finish  Ease to operation
 MRR  Reliability
 Power consumption  Safety
 Tool life  Aesthetic looking
 High static stiffness
 Reliability
 Acceptable level of vibration
Methods of raising productivity:  High speed and feed low rate of wear
 Low thermal distortion
 High machining speed  Low design, development, repair, maintenance
 High feed rates and manufacturing cost
 Multiple cutting tools
 Automation
 High power density
 Selection of machine tool:
Classification of machine tool:
 Size of working envelope
1. According to size:  Tool capacity
i. Light duty  Type of tool holder
ii. Medium duty  Machine power
iii. Heavy duty  Type of machine control
2. According to method of actuation  Compactability with existing CAM
i. Manually operatied software
ii. Semi-automatic operated  No. of available machining axes
iii. Automatic automated Minimization of cost
3. According to purpose
i. General purpose machine tool 1. Simplicity of the product
ii. Special purpose machine tool 2. Standard material and component
3. Standard design of the product
iii. Limited purpose machine tool
4. Specify liberal tolerances
4. According to types of motion
5. Avoid process restrictiveness
i. Rotary cutting machine
1. Rotate workpiece General design rules for economic production:
2. Rotate cutting tool 1. Simplify the design
ii. Linear cutting machine 2. Design for Lower labor cost operations
1. Moving workpiece 3. Avoid generalized statement
2. Moving cutting tool 4. Minimum weight
5. According to feed 5. Use general purpose tooling
i. Axial feed machine 6. Avoid sharp corner
ii. Transverse feed machine General Recommendations:
6. According to level of accuracy
i. Normal accuracy 1. Avoid machining operations
2. Specify liberal tolerances
ii. Higher accuracy
3. Avoid sharp corner and points
iii. Super high accuracy
4. Use stock dimensions
7. According to degree of specification
5. Avoid interrupt cut
i. General purpose m/c tool 6. Avoid under cut
ii. Single purpose m/c tool 7. Avoid tapper and contour
iii. Specialized m/c tool 8. Avoid difficult to machine materials
iv. Special m/c tool 9. Design part so that standard cutters can
8. Degree of accuracy be used
i. Standard accuracy 10. Avoid relief space for burr formation
ii. Above standard accuracy
iii. High accuracy
iv. Precision machine tool
v. High precision machine tool
 Advantages Of Gear Drive:
Advantages of belt drives :  Positive drive and has more efficiency
1. Made from flexible material, it can be used for than belt
the shafts whose axes are note parallel. and rope drive.
2. Initial cost is low.  Operation of drive is simple and
3. Lubricant is not required. effective.

4. Noise is relatively less.  Life is more compared to other drives.

5. It is flexible member, it slips or break during  With one input speed, no. of output
overload and safeguards the machine. speeds
can be obtained by using suitable gear
Disadvantages Of Belt Drive; drive.
1. Drive is not positive as the belt slip over the
pulleys.  Safe and compact.

2. Oqupies relatively more space.  Constant velocity ration is obtained.

3. Speed ration can not be maintained because  Using different type of gears, power
of slipping of belt. can be
transmitted between shafts whose
4. Adjust the tension in the belt is require time to axes are
time. parallel, inclined or intersecting to
5. Life is relatively low each other.

Advantages of Chain drive; Disadvantages of Gear Drive:

1. Positive drive as there is no slip, hence 1. If the tooth geometry of the gear is
constant velocity ratio. not properly maintained, the drive
may get locked.
2. Occupies less space compared to belt drive.
2. Not preferred when very high speed
3. Life is more compared to belt drive. transmission is required.
4. Used for large center distance. 3. If lubrication arrangement is not
5. Transmission efficiency is larger than belt provided, it
drive. may produce noise.

Disadvantages Of Chain Drive:

1. Noisy compared to belt drive.
2. Initial cost is higher compared to belt drive
3. Initial cost is higher compared to belt drive
4. Adjustment in the center distance is
necessary.
5. Maintenance cost is higher & complex compared to belt drive.
 Design of guideways and power screw:
Major requirements of guideways must satisfy:
1. High accuracy and surface finish
2. High accuracy of travel
3. Durability
4. Low friction
5. Minimum possible variation
6. High rigidity
7. Good damping properties
Design consideration of slideways:
1. Effective lubrication without much difficulty
2. Provision for compensation of possible wear
3. High wear resistance

Open slideways: sliding velocity is high

Closed slideways: velocity is not high+ poor lubricant quality

Flat slideway V slideway Dovetail Cylindrical

slideway slideway
manufacture Easy to Difficult
manufacture
Mfg. Costly
inspection Easy More difficult
Require Adjusting Automatic
clearance Adjusting
clearance
Accuracy Greater; on
travel
Design Compact and
simple
Rigidity Low
Tolerance Extremely
stringent

Materials of slideways:

 Cast iron
 Low carbon steel
  Low allowed steel
 Gray cast iron : cheap don’t have good wear resistant
Plastic slideways:

 Advantage:
o Ease of manufacture
o Less friction
o Good anti-scoring and anti corrosive
 Disadvantage:
o Poor contact rigidity
o Poor structural stiffness
Methods of adjusting clearance in slideways
1. Flat strips that are not clamped after clearance adjustment
2. Flat strips that are clamped after clearance adjustment
3. Taper ribs
Design of hydrostatic slideways:

 Properties:
o High load capacity
o Low running friction
o High stiffness
o Good damping
o High uniformity, accuracy of feed and setting motions
 Disadvantage:
o Difficulty in fixing the moving member in a desired position