A machine is or device which converts some form of input into output,
e.g., Air coolers, Air conditioners and refrigerators etc., where the input is electric energy and the output is the cooling
effect.
On the other hand, machine tools are machines that produce the various articles. Thus, whereas, all the machine tools are
machines, but all the machines are not machine tools.
Most machine tools perform the following four functions:
1. Hold the job.
2. Hold the cutting tools.
3. Move one or both of these (rotary motion or reciprocating motion).
4. Provide a feeding motion for one of these.
General Purpose Machine Tools:
General purpose or universal machine tools are used for performing a great variety of machining operations
on a wide range of workpieces.
Used in small-lot production and repair work.
versatile machine tools are also called “Omniversal’’
Eg: plain turning lathes, turret lathes, milling machines, drilling machines, grinding machine etc.
Single Purpose Machine Tools:
These machine tools are designed to perform a single definite machining operation, e.g., broaching, thread
cutting, gear shaping and hobbing machines, machines for machining pistons, crank shafts, camshafts and for
turning the cam contours on camshafts etc.
Limited Purpose Machine Tools:
These machine tools are capable of a narrow range of operations on a wide variety of workpieces, e.g.,
automatic cutting off machines.
Production Machine Tools :
These are mainly used in batch and mass production and feature high power and rigidity. These machine
tools include : multi-tool lathes, single-and multi spindle automatics, and semi- automatic lathes, plunge-cut
cylindrical grinders, centreless, planer type milling machines, thread rolling machines for tap production,
numerically controlled machine tools etc.
Specialized Machine tools :
These are used for machining articles similar in shape but different in size. These machine
tools allow the machining of several surfaces in different planes. Their advantage is that they
are readily changed over from one job to another. This is done by mounting additional unit
heads, positioning them at an angle to a horizontal or vertical plane or other-wise. These
machines are used mainly in large-lot production.
Special Machine Tools :
These machine tools are designed and manufactured individually and are intended for
performing a certain definite operation in machining a certain definite workpiece. These
machine tools include : machines for sharpening round threading dies, for grinding relief
surfaces at the chamfer of round threading dies, for marking round threading dies and shank-
type tools, for threading by die taps, for grinding flutes on taps and reamers, tap chamfers,
flutes on twist drills etc. These machines find applications in large-lot and mass production.
The general purpose machine tools have the following characteristics: (i) Usually less
initial investment in equipment. (ii) Greater machine flexibility. (iii) Fewer machines may be
required. (iv) Less maintenance cost. (v) Less set up and debugging time. (vi) Less danger of
obsolescence.
The special purpose machines have the following characteristics: (i) Uniform product flow.
(ii) Reduced in-process inventory. (iii) Reduced manpower requirements. (iv) Reduced
factory floor space. (v) Higher output. (vi) Higher product quality. (vii) Reduced inspection
cost. (viii) Reduced operator skill requirements.
Motions in Machine Tools :
To obtain a finished workpiece on a machine tool, certain co ordinated motions must be
imparted to the work and the cutting tool. These motions are of two types : Primary,
Secondary and auxiliary motions. Primary motions consist of principal or cutting motions
and secondary consists feed motions. They serve the purpose of removing metal from the
workpiece. The speed of the principal motion depends on the optimum cutting speed, while
the speed of the feed motion depends on the required degree of surface finish.
Auxiliary motions help in the completion of the machining process and include such motions
as : handling and clamping the work in the machine, advance and withdrawn of the cutting
tool, engagement and disengagement of working motions, and changing their speeds etc.
Primary motions are power driven. Secondary motion may be manual or power driven.
Auxiliary motions may be either hand or power operated. On automatic machine tools,
practically all auxiliary motions are automated.
Principal motions are of three types : rotary, reciprocating or a combination of these. This
motion can be imparted either to the workpiece or to the tool. Rotary motion to work :
Lathes Rotary motion to tool : Milling, grinding and drilling machines. Both simultaneously :
In drilling small diameter holes. Reciprocating motion of tool : Shapers, slotters, broaching
machines etc. Reciprocating motion of work : Planers Feed motions may be : Continuous,
intermittent or compound. Continuous feed : lathes, milling, drilling machines etc.
Intermittent feed : Shapers, planers etc. Compound feed : Gear cutter for cutting helical
geacs. Combined feed : Cylindrical grinders.
Methods of Machining a Shape:
1. Forming. Here the shape of the tool is the finished shape of the workpiece and the tool is
called “Form tool” to finish the job, all that is necessary, in addition to the relative
movement required to produce the chip (primary motion) is to feed (plunge) the tool in
depth,
Other examples are : drilling, plunge cut method of cylindrical grinding and plunge cut
method of thread grinding.
2. Generating. Here, the required shape of the workpiece is obtained by combining several
motions that not only accomplish the chip forming process (primary action) but also
move the point of engagement (of the job and the tool) along the surface (called as feed
motion), e.g., in cylindrical turning on a centre lathe, the tool is set to cut a certain depth
of cut and then traverses along the job to produce the chips.
Other examples are : shaping and planning a flat, surface grinding, peripheral milling and
so on.
3. Combined forming and generating: Thread cutting, Taper Turning with a single point tool and
hobbing etc.