Fundamentals of Machine Tools

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Fundamentals of Metal Machining and Machine Tools. Machining And Machine Tools. Theory of Elasticity. The value that machine tools added to these human talents is in the areas of rigidity constraining the toolpath despite thousands of newtons pounds of force fighting against the constraint , accuracy and precision , efficiency , and productivity.

With a machine tool, toolpaths that no human muscle could constrain can be constrained; and toolpaths that are technically possible with freehand methods, but would require tremendous time and skill to execute, can instead be executed quickly and easily, even by people with little freehand talent because the machine takes care of it. The latter aspect of machine tools is often referred to by historians of technology as "building the skill into the tool", in contrast to the toolpath-constraining skill being in the person who wields the tool.

As an example, it is physically possible to make interchangeable screws, bolts, and nuts entirely with freehand toolpaths. But it is economically practical to make them only with machine tools. In the s, the U. National Bureau of Economic Research NBER referenced the definition of a machine tool as "any machine operating by other than hand power which employs a tool to work on metal".

The narrowest colloquial sense of the term reserves it only for machines that perform metal cutting—in other words, the many kinds of [conventional] machining and grinding. These processes are a type of deformation that produces swarf. However, economists use a slightly broader sense that also includes metal deformation of other types that squeeze the metal into shape without cutting off swarf, such as rolling, stamping with dies , shearing, swaging , riveting , and others.

Thus presses are usually included in the economic definition of machine tools. For example, this is the breadth of definition used by Max Holland in his history of Burgmaster and Houdaille, [4] which is also a history of the machine tool industry in general from the s through the s; he was reflecting the sense of the term used by Houdaille itself and other firms in the industry. Many reports on machine tool export and import and similar economic topics use this broader definition. The colloquial sense implying [conventional] metal cutting is also growing obsolete because of changing technology over the decades.

The many more recently developed processes labeled "machining", such as electrical discharge machining , electrochemical machining , electron beam machining , photochemical machining , and ultrasonic machining , or even plasma cutting and water jet cutting , are often performed by machines that could most logically be called machine tools. In addition, some of the newly developed additive manufacturing processes, which are not about cutting away material but rather about adding it, are done by machines that are likely to end up labeled, in some cases, as machine tools.

In fact, machine tool builders are already developing machines that include both subtractive and additive manufacturing in one work envelope, [5] and retrofits of existing machines are underway. The natural language use of the terms varies, with subtle connotative boundaries. Many speakers resist using the term "machine tool" to refer to woodworking machinery joiners, table saws, routing stations, and so on , but it is difficult to maintain any true logical dividing line, and therefore many speakers accept a broad definition.

It is common to hear machinists refer to their machine tools simply as "machines". Usually the mass noun "machinery" encompasses them, but sometimes it is used to imply only those machines that are being excluded from the definition of "machine tool".

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This is why the machines in a food-processing plant, such as conveyors, mixers, vessels, dividers, and so on, may be labeled "machinery", while the machines in the factory's tool and die department are instead called "machine tools" in contradistinction. Regarding the s NBER definition quoted above, one could argue that its specificity to metal is obsolete, as it is quite common today for particular lathes, milling machines, and machining centers definitely machine tools to work exclusively on plastic cutting jobs throughout their whole working lifespan.

Thus the NBER definition above could be expanded to say "which employs a tool to work on metal or other materials of high hardness ".

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And its specificity to "operating by other than hand power" is also problematic, as machine tools can be powered by people if appropriately set up, such as with a treadle for a lathe or a hand lever for a shaper. Hand-powered shapers are clearly "the 'same thing' as shapers with electric motors except smaller", and it is trivial to power a micro lathe with a hand-cranked belt pulley instead of an electric motor.

Thus one can question whether power source is truly a key distinguishing concept; but for economics purposes, the NBER's definition made sense, because most of the commercial value of the existence of machine tools comes about via those that are powered by electricity, hydraulics, and so on. Such are the vagaries of natural language and controlled vocabulary , both of which have their places in the business world. Forerunners of machine tools included bow drills and potter's wheels , which had existed in ancient Egypt prior to BC, and lathes, known to have existed in multiple regions of Europe since at least to BC.

Clockmakers of the Middle Ages and renaissance men such as Leonardo da Vinci helped expand humans' technological milieu toward the preconditions for industrial machine tools. During the 18th and 19th centuries, and even in many cases in the 20th, the builders of machine tools tended to be the same people who would then use them to produce the end products manufactured goods. However, from these roots also evolved an industry of machine tool builders as we define them today, meaning people who specialize in building machine tools for sale to others.

Historians of machine tools often focus on a handful of major industries that most spurred machine tool development. In order of historical emergence, they have been firearms small arms and artillery ; clocks ; textile machinery; steam engines stationary , marine , rail , and otherwise the story of how Watt 's need for an accurate cylinder spurred Boulton's boring machine is discussed by Roe [8] ; sewing machines ; bicycles ; automobiles ; and aircraft.

Others could be included in this list as well, but they tend to be connected with the root causes already listed. For example, rolling-element bearings are an industry of themselves, but this industry's main drivers of development were the vehicles already listed—trains, bicycles, automobiles, and aircraft; and other industries, such as tractors, farm implements, and tanks, borrowed heavily from those same parent industries.

Machine tools filled a need created by textile machinery during the Industrial Revolution in England in the middle to late s. The increase in mechanization required more metal parts, which were usually made of cast iron or wrought iron. Cast iron could be cast in molds for larger parts, such as engine cylinders and gears, but was difficult to work with a file and could not be hammered. Red hot wrought iron could be hammered into shapes. Room temperature wrought iron was worked with a file and chisel and could be made into gears and other complex parts; however, hand working lacked precision and was a slow and expensive process.

The advance in the accuracy of machine tools can be traced to Henry Maudslay and refined by Joseph Whitworth. The process by which the master plane gages were produced dates back to antiquity but was refined to an unprecedented degree in the Maudslay shop.

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The process begins with three square plates each given an identification ex. The first step is to rub plates 1 and 2 together with a marking medium called bluing today revealing the high spots which would be removed by hand scraping with a steel scraper, until no irregularities were visible.

This would not produce true plane surfaces but a "ball and socket" concave-concave and convex-convex fit, as this mechanical fit, like two perfect planes, can slide over each other and reveal no high spots. The rubbing and marking are repeated after rotating 2 relative to 1 by 90 degrees to eliminate concave-convex "potato-chip" curvature.

Next, plate number 3 is compared and scraped to conform to plate number 1 in the same two trials. In this manner plates number 2 and 3 would be identical.

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Next plates number 2 and 3 would be checked against each other to determine what condition existed, either both plates were "balls" or "sockets" or "chips" or a combination. These would then be scraped until no high spots existed and then compared to plate number 1. Repeating this process of comparing and scraping the three plates could produce plane surfaces accurate to within millionths of an inch the thickness of the marking medium.

The traditional method of producing the surface gages used an abrasive powder rubbed between the plates to remove the high spots, but it was Whitworth who contributed the refinement of replacing the grinding with hand scraping. Sometime after Whitworth went to work for Maudslay and it was there that Whitworth perfected the hand scraping of master surface plane gages.

Fundamentals Of Machine Tools

In his paper presented to the British Association for the Advancement of Science at Glasgow in , Whitworth pointed out the inherent inaccuracy of grinding due to no control and thus unequal distribution of the abrasive material between the plates which would produce uneven removal of material from the plates. With the creation of master plane gages of such high accuracy, all critical components of machine tools i.

Important early machine tools included the slide rest lathe, screw-cutting lathe , turret lathe , milling machine , pattern tracing lathe, shaper , and metal planer , which were all in use before An important early example of something now taken for granted was the standardization of screw fasteners such as nuts and bolts. Before about the beginning of the 19th century, these were used in pairs, and even screws of the same machine were generally not interchangeable.