ADDIS ABABA SCIENCE AND TECHNOLOGY

UNIVERSITY
COLLEGE OF ELECTRICAL AND MECHANICAL
ENGINEERING
DEPARTMENT OF ELECTROMECHANICAL
ENGINEERING

MACHINE TOOL DESIGN AND NUMERICAL

CONTROL

CHAPTER TWO- DESIGN SPEED & FEED RATE OF

MACHINE TOOLS
 2.1 Working and Auxiliary motions in machine tools

The relative movement between the WP and cutting edge

can be obtained either by:
The WP, the cutting tool or by a combination of the
motion of the WP and Cutting tool

These motions are called working motion and further

classified as:
Drive motion or Primary cutting motion
Feed motion
Working motion of some machine tool
Working motion of some machine tool
• Working motion in machine tools are generally of two
types: rotary and Translatory

1. For lathes and boring machines

Drive motion- rotary motion of work piece
Feed motion- Translatory motion of cutting tool in the axial
or radial direction.
2. For drilling machines
Drive motion- rotary motion of drill
Feed motion- Translatory motion of drill
3. For milling machines
Drive motion- rotary motion of the cutter
Feed motion- Translatory motion of the work piece
4. For shaping, planning and slotting machines
Drive motion- reciprocating motion of cutting tool
Feed motion- intermittent Translatory motion of work piece.
5. For grinding machine
Drive motion- rotary motion of the grinding wheel
Feed motion- rotary as well as Translatory motion of the work
piece.

Beside the working motion, a machine tool also has provision

for auxiliary motion.

Examples of auxiliary motion in machine tools are:

 Clamping and unclamping of the work piece
 Idle travel of the cutting tool to the position from where cutting
is to proceed.
 Changing the speed of drive and feed motion.
Engaging and disengaging of working motion, etc…..

Parameters defining working motions of a machine

tools
The working motion of the machine tool are
numerically defined by their velocity.
The velocity of the primary cutting motion or drive
motion is known as cutting speed.
Velocity of feed motion is known as feed.

The cutting speed is denoted by v and measured by

m/min.
Feed is denoted by s and measured in the following units:
1. mm/rev in machine tools with rotary drive motion.
 E.g., lathes, boring machine, etc….
2. mm/tooth in machine tool using multiple tooth cutters.
 E.g. milling machine
3. mm/stroke in machine tools with reciprocating drive
motion.
e.g. shaping and planning machine
4. mm/min in machine tools which have a separate power
source for feed motion.
e.g. milling operation
 Terminologies of machine tool working motion

Cutting Speed: is given in surface feet per minute (sfpm)

& the speed at which the metal is removed by the tool from
the work piece, expressed in meters per minute.

Feed: the distance, the tool advances for each revolution

of
the work piece, measured in the direction of the feed
motion, It is expressed in mm/rev.

Depth of cut: It is the penetration of the cutting tool into

the work-piece in a single cut, & expressed in mm
 Procedures for Selection of Speed, Feed, & Depth of Cut:

Use the preceding speed, feed, & depth of cut figures as a

basis for these choices. Useful tool life is influenced most by
cutting speed. The feed rate is the next most influential
factor in tool life, followed by the depth of cut.

When the depth of cut exceeds approximately 10 times the

feed rate, a further increase in depth of cut has little effect
on tool life. In selecting the cutting conditions for a turning
or boring operation, the first step is to select the depth of
cut, followed by selection of the feed rate & then the cutting
speed.
The machinist or machine operator will know if the selected
speed, depth of cut, & feed are more than the given machine
can tolerate & can make corrections accordingly.
Calculation of the working motions

1. Cutting speed:- Machine tool with rotary primary

cutting motion, the cutting speed is determined by the
relationship:
 d is dia. of the work piece (lathe machine) or cutter
(milling machine), in mm
 n is rpm of work piece or cutter
Lathe operation
To calculate the required power and metal removal rate
 Cont …
Parameters Working Motion of Machine Tools:
V = π dm nw /1000 ;
Turning Where d , is the diameter of the machined surface &
: m
nw , is rotational frequency of the work piece
Ex1: Determine the cutting speed of a turning operation if
the rotational frequency is 75 rpm & the diameter of the
machined surface is 90 mm. Solution: V = π dm nw
/1000
V= π 75rpm*90mm/1000
V = 21.2 m/min
Ex2: Calculate the rotational frequency RPM setting for a Lathe
machine to turn Ø 50mm. Grey C.I work-piece with throwaway
carbide insert tool. The feed is 0.38mm/rev. The depth of cut is
3.8mm & the recommended cutting speed is 60 m/min.
Solution: RPM setting (Rotational Frequency):
V = π dm nw /1000
60m/mim = π*50mm*nw /1000
nw = (1000*60)/(π *50)
14 = 381.8 rpm
Ex3: Determine the power required to cut a cylindrical
shaft Ø 50 mm on lathe when the cutting conditions
are as follows; cutting speed =18 m/min, feed =0.26
mm/rev, depth of cut =0.058 cm, specific power ps= 3.7
kw for removing one cubic cm per min, efficiency of
motor η = 80%)
Solution: Rotational frequency
V = π dm nw /1000
nw = (1000*18)/(π *50) =114.65 rpm
Metal removal rate: Zw = πfapnw (dm +ap)
=π*0.026*0.058*114.65*(5+0.058)
= 2.7cm3/min
Power required at the tool:
Pm=Ps *Zw =3.7kw*2.7cm3/min =10 KW
Motor power required:
Pe = pm /m = 10/0.8 = 12.5HP
15
 TYPICAL LATHE OPERATION:
Quiz:
1. Determine the rotational frequency as well as the metal removal
rate of machining for turning operation with the following
conditions; Cutting speed = 50 m/min; Diameter to be turned = 75
mm; Depth of cut = 2.5 mm; Feed = 0.25 mm/rev.

2. A mild steel rod of Ø 60 mm is machined on a lathe with a single

point cutting tool. Find the motor power using the following data.
Cutting Speed = 90 m/min, Feed = 0.5 mm/rev, Depth of Cut = 2.54
mm, specific power ps= 3.7 kw for removing one cubic cm per min,
Efficiency of motor η = 50%.

16
 Parameters Working Motion of Machine Tools:Cont …
Principal Cutting
Horizontal, Slab on knee type milling
Operations: machine:
Milling Operations:
Horizontal or slab milling: The feed f, which is equal to the distance
moved by the work-piece during one revolution
of the tool, is given by: f = Vf/Nt
Where: Nt, is the rotational frequency of the cutter, &
Vf , is the feed speed of the work-piece.
The cutting seed V,
d c nt
v
1000

Metal removal rate: Z w  ae a p v f

The power Pm & the power efficiency Pe

required to perform any machining operation:
Pm = ps Zw; Pe = pm /m

Where: Pm, is the power required,

Ps , is the specific power.

17
Principal Cutting
Operations:
Milling Operations: Vertical Vertical, Face or End milling machine:
milling:
The feed f, which is equal to the distance
moved by the work-piece during one
revolution of the tool, is given by:
f = Vf/Nt ; Vf=f *Nt
Where: Nt, is the rotational frequency of the cutter, &
Vf , is the feed speed of the work-piece.
FACE MILLING: Cutter Ø larger than width of
work-piece

Metal removal rate:

Z w  ae a p v f

18
 Milling: V = π dc nt /1000 ; Where dc, is the diameter of the cutter &
nwt , is rotational frequency of the tool
Ex1: For a slab milling operation determine the rotational
frequency setting for a 100 mm dia HSS cutter machining grey
cast iron at a cutting speed of 15m/min & feed is 58 mm/min,
depth of cut is 15mm, width of work-piece is 50mm, the cutter has
8 teeth. Determine feed per tooth & metal removal rate.
Solution:
Rotational frequency: V = π dc nt /1000
15m/min= π * nt *100mm/1000
nt = 47.7 rpm
Feed per minute: Feed =58mm/min
Feed per revolution: 58/47.7 = 1.2mm/rev
Feed per tooth: 1.2/8= 0.15mm/tooth
Metal removal rate: Zw = ae ap Vf
Vf = f * nt =1.5cm*5cm*276.6cm/min
=58*47.7 = 2075cm3/min
=2766.6mm/min
19
 TYPICAL MILLING OPERATION:
Quiz 2:
1. The feed of an 6-teeth face mill cutter is 0.4 mm per tooth at 280 rpm.
If the depth of cut is 5 mm & width of cut is 100mm, calculate the
power required at the cutter & at the motor. (Specific power ps= 0.05
HP/cm3/min & η = 80 %).

2. Determine the power required for a milling cutter to take a cut 100
mm wide 3 mm deep at 75 mm/min feed for an alloy steel. Cutter
diameter is 100 mm & cutting speed is 15 m/min. (Specific power ps=
0.03 HP/cm3/min & η = 60 %).

3. For a horizontal milling operation determine the following a) RPM

setting, b) Metal Removal Rate, c) Feed per tooth. Data Given: Cutter
Diameter= 90mm; Depth of cut = 6.5 mm; Width of cut = 38 mm; No.
of teeth in the cutter = 12.

20
2. 2. REGULATION OF SPEED & FEED RATE:
Aim of speed & feed rate:
Machining operation parameters: Speed, Feed & Depth of
cut. Ensure minimum cost of machined surface.
C = Cmt + Cnpt + Ctc + Ct
Where:

21
 The provision of regulating the spindle RPM &
feed rate is an essential requirement of machine
tool to ensure economic machining of work-
pieces of different materials & Size by cutting tools
of different shapes & composition.

Design of Speed Box

Principle of designing speed boxes, Gear boxes

are employed for stepped regulation of the RPM.
22
VARIOUS LAWS OF STEPPED REGULATION:

In stepped regulation of speed only certain value of the

spindle RPM are available on the machine tools.
Criterion for choosing the discrete steps, Two extreme
available n1 & nZ spindle RPM.
The same number of Z intermediate steps may be placed
in number of ways.
The various series of RPM value have diff. operational
characteristics.

•Let us analyze 4 cases & select the most suitable law of

speed range distribution:

Arithmetic, Geometric, Harmonic & Logarithmic progression

23
1. The RPM Values Constitute an Arithmetic
Progression:
The diff b/n adjacent RPM value is constant:

Where a=common diff of the arithmetic

progression
N12 = n1 + 11a
a = 375-30/11
= 31.4
For particular V the maximum selected cutting condition
the dia range of work-piece that can be machined by a
particular spindle RPM value nx can be determined as:

Hence the dia. Range

served by this particular
RPM is:

24
 Stepping of Speeds According to Arithmetic
Progression:
Let n1, n2, … , nz be arranged according to arithmetic

progression. Then n2 – n1= n3 – n2 = constant

For an economical cutting speed v0, the lowest speed vl is

not constant; it decreases with increasing diameter.

25
Speed stepping according to arithmetic progression.
 Let us calculate the RPM value & dia. Range served by each
RPM for the following conditions n1=30RPM, nz=375RPM,
number of speed steps Z=12, V=20m/min. these value are
tabulated below in table.Table1: Dia. Range for diff. rpm values
in arithmetic progression.

26
 Suppose we start machining a wp of dia. 212mm. For
cutting speed of V=20m/min, the value n1=30rpm will
correspond to optimum cutting.
Before we change over to the next higher rpm value of
n2=61.4, we must remove 108.3mm of metal from the dia.
During all passes except the first one, we would be
machining uneconomically as the actual cutting speed
would be less than the permissible value.
On the other hand in changing over from an rpm value of
n11=344 to n12=375, we have to reduce the wp. dia. only by
1.6mm. We could actually remove more than this
allowance in one pass.
It follows from the above analysis that in the high rpm
range some value of speed steps are redundant, whereas in
the low rpm range there is clearly a need to add more steps
b/n the calculated value.
27
EX.1 Let us calculate the RPM value & dia. Range served by
each RPM for the following conditions n1=20RPM,

nz=250RPM, number of speed steps Z=8, V=13.3m/min.

Formulate a table: dia. Range for diff. rpm values in

arithmetic progression
RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=

28
 2. The RPM Values Constitute a Geometric
Progression:

Stepping of Speeds According to Geometric

Progression
The percentage drop from one step to the other is
constant & the absolute loss of economically expedient
cutting speed δv is constant all over the whole
diameter range. The relative loss of cutting speed
δvmax/v0 is also constant.
 = (nZ /n1)
1/(z-1)

= (n12 /n1)1/(12-1)
= (375 /30)1/(11)
29 = 1.26
 Stepping of Speeds According to Geometric
Progression:
The percentage drop from step to step δn decreases as the speed
increases. Thus the speeds are not evenly distributed & more
concentrated & closely stepped, in the small diameter range
than in the large one.

Speed stepping according to geometric progression.

30
 Let us calculate the RPM value & dia. Range served by each
RPM for the conditions n1=30RPM, nz=375RPM, number of
speed steps Z=12, V=20m/min. these value are tabulated
below in table2.
Table2: Dia. Range for diff. rpm values in geometric
progression

31
 Cont…

Before we change over from a speed n1=30rpm to n2=37.5rpm

an allowance of 42mm must be machined from the wp dia.

In changing over from n11=300rpm to n12=375rpm, we have to

take 4.2mm or a depth of cut of 2.1mm which can be easily
accomplished in one pass.

We thus see that in order to make the machine tool

performance equally feasible in the whole rpm range, the
low rpm value should be brought still closer while the
high rpm value can be widened a little.
32
 Cont…
EX.2 Let us calculate the RPM value & dia. Range served by
each RPM for the f0llowing conditions n1=20RPM,
nz=250RPM, number of speed steps Z=8, V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in
geometric progression

RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=

33
3. The RPM Values Constitute a Harmonic
Progression:
The HP is developed from the basic idea that the dia. range
served each rpm of the progression is equal. i.e.

= 2.75x10-3

The harmonic progression can

be written as follows:

C= 1/nx – 1/nx+1
=1/n1 – 1/n1+1
= 1/30 – 1/32.7
= 0.00275229
34
 The value of rpm & dia. range for the same data used in the
previous examples are tabulated in table3.
Table3: Dia. Range for diff. rpm values in harmonic
progression

35
It may be seen that in order to change from n11=183rpm

to n12=375rpm, the wp dia. must be reduced from 35mm

to 17mm.

On a slender wp of 35mm, a large depth of cut can’t be

taken as this would lead to the deformation of the wp.

It may be concluded that in harmonic progression the

rpm value in the high range are too wide apart, making
this
36
range uneconomical for exploitation.
 EX.3 Let us calculate the RPM value & dia. Range served by
each RPM for the following conditions n1=20RPM,
nz=250RPM, number of speed steps Z=8, V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in
Harmonic progression

RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=

37
4. The RPM Values Constitute a Logarithmic
Progression:
In this progression the dia. range is a function of the
dia.
Where: M is known as the location
coefficient; generally p=0.5.

38
 The logarithmic progression can be written as
follows

39
 For a given value of n1, nz & Z it is difficult to develop
the logarithmic progression as this has to be done by
successive trials with different values of M.
For instance

Knowing d2 the next dia. Is found as

In this manner d12 can be found for two values of M.

say M=1.0 & 0.5. As it is known that d12=17mm, the
correct value of M is found by linear interpolation.
The logarithmic progression for the data of previous
ex. Is given in table4. It would be developed for a
value of M=0.88.

40
 The value of rpm & dia. range for the same data used in the
previous ex. are tabulated in table4. It has been developed for
a value of M=0.88.
Table4: Dia. Range for diff. rpm values in logarithmic
progression

41
 EX.4 Let us calculate the RPM value & dia. Range served by
each RPM for the following conditions n1=20RPM,
nz=250RPM, number of speed steps Z=8, V=13.3m/min.
Formulate a table: dia. Range for diff. rpm values in
logarithmic progression

RPM  dx mm dx mm
N1 =
N2 =
N3 =
N4 =
N5 =
N6 =
N7 =
N8=

42
 A comparison of the rpm value of table2-4 reveals that in
the low as well as high rpm range the value of table4 lie
b/n the values of table2&3.
It may be thus concluded that from the point of view of
the operational efficiency of the machine tool,
logarithmic progression is most suitable. The efficiency
of geometric progression if poorer in the low rpm range,
whereas that of the harmonic progression is poorer in the
high rpm range.
Despite the major shortcoming discussed above,
geometric progression is commonly used in machine tool
drives owing to the following advantages:
1. Constant loss of economic cutting speed in the whole
rpm range
2. Constant loss of productivity in the whole rpm range
3. Better design feature
43
Geometric progression is commonly used in machine tool
drives owing to the following advantages:
1. Constant loss of economic cutting speed in the whole rpm range:
Suppose the spindle rpm value constitute: n1, n2, n3, …, nj, nj+1
Consider optimum cutting speed lie b/n nj & nj+1

Obviously, of the two rpm nj & nj+1, we select the one which gives a cutting speed
closer to Vopt. The diff. b/n the actual & optimum cutting speed is known as the
loss of economic cutting speed & hence the loss of economic cutting speed is
maximum when the optimum cutting speed lie at the middle of two speeds
provided by nj & nj+1

It may concluded that in order that (Vj)max may be constant & j must be
44
 2. Constant loss of productivity in the whole rpm
range:

The productivity of a machining operation can be

expressed as the surface area of metal removed in unit
time. i.e. by the quantity:
Where: V= the cutting speed,
m/min
S = the feed, mm/rev

____ =V

For a constant value of feed s & depth of cut t, the

productivity of machining operation is constant in the
whole rpm range.

45
 Cont…
3. Better design features:
When all the rpm value of a spindle are obtained from a single transmission,
i.e. by changing gears only b/n two shafts, then any of the series discussed
above can be utilized for designing the speed box.
If the rpm value are changed by mounting a new pair of gears on the shaft
every time, then changing of speeds becoming time-consuming,
inconvenient & economically infeasible. If the rpm values are obtained
by mounting gear pairs of the transmission ratio the dimension of the
speed box becoming too large.
These consideration underline the fact that speed steps in a speed box
should be obtained not through a singe transmission b/n two shaft but
through a group of transmission b/n a number of shaft.
This feature can be realized in an actual speed box design only if the rpm
value lie in a geometric progression.

46 Tuesday, February 1, 2022

 Cont…
The Initial Information Required for Designing a
Speed box: Selection of Range of Ratio:
Essential information before start designing stepped
drive:
1. The highest out put rpm, nmax
2. The lowest out put rpm, nmin
3. The number of steps Z into which the range b/n
nmax & nmin is divided
4. The number of stages in which the required
number of speed steps are to be achieved.
An important parameter in designing
speed boxes is the range ratio:

The very wide speed range is generally neither

practicable nor economically feasible. The value R v
should therefore, be kept within reasonable limits.
47 Tuesday, February 1, 2022
 Cont…
The range of dia. Should be selected & reveals that a ratio
of:
covers more than 85% of the wp., while
6 covers 92% of the wp.
After selecting the proper values of Rv & Rd, then the range
ratio Rn is determined. Typical values of Rn for some groups
of machine tools are given in table5:
Table5: typical range ratio value for some machine tools.

48 Tuesday, February 1, 2022

 Cont…

A variety of cutting tools of diff. shapes &

compositions are used on general-purpose machine
tools, & therefore, Rn values are relatively large.

On the other hand, in grinding machines the

grinding wheel diameter generally varies in the range
Rd<2 & the wheel material being the same, Rn values
are small.

Low Rn value in the range of Rn=5-10 are also

characteristic of special purpose machine tools.

The Rn value calculated on the basis of conditions

discussed above should be increased about 25% to
provide for future progress in machining techniques,
49 cutting tool materials & design. Tuesday, February 1, 2022
 Stepped Regulation of Feed:
Design of Feed Box:

In machine tools the feed motion in generally obtained through

following kinematics train:
1. The driving member, it may be driven by the spindle through gear,
belt or chain transmission in lathe & drilling, or may be powered by
an independent motor as in milling machine;
2. The device for engagement & reversing the feed mechanism;
3. The feed box;
4. The single transmission which provide heavy speed regulation;
5. The traction device which is generally a screw & nut or rack & pinion
transmission;
6. A rapid travers mechanism which is generally powered by a separate
motor & is kinematically linked to the feed mechanism immediately
after the single gear transmission.

50 Tuesday, February 1, 2022

The accuracy of the kinematic train of the feed box is
determined by its function.
• Productivity & accuracy in turning, drilling, boring
are not high
• Generating obtain profile thread, gear, worm cutting
In a majority of machine tools stepped feed regulation is
employed b/c economically viable step-less methods of
feed regulation are not available.
The machining time of
the an operation is in
general calculated from
the expression
The productivity of the machine tool, which may
be described as the length of machined surface
per unit time.
Let Qopt of the machine tool corresponding to the
nopt & sopt, which lie b/n spindle speeds nj & nj+1 &
51
feed rate s & s Tuesday, February 1, 2022
Thank you