hold dimensions because of the deflections of the boring bar due to
cutting forces.
c. Interrupted internal surfaces should be avoided.
(2)Fundamentals of Machine Tools
In many cases products form the primary forming processes must undergo
further refinements in size and surface finish to meet their design specifications. To
meet such precise tolerances the removal of small amounts of material is needed.
Usually machine tools are used for such operation.
In the United States material removal is a big business-in excess of $ per year,
including material, labor, overhead, and machine-tool shipments, is spent. Since 60
percent of the mechanical and industrial engineering and technology graduates have
something connection with the machining industry either through sale, design, or
operation of machine shops, or working in related industry, it is wise for an
engineering student to devote some time in his curriculum to studying material
removal and machine tools.
A machine tool provides the means for cutting tools to shape a workpiece to
required dimensions; the machine supports the tool and the workpiece in a controlled
relationship through the functioning of its basic members, which are as follow:
(a) Bed, Structure or Frame. This is the main member which provides a basis for,
and a connection between, the spindles and slides; the distortion and vibration under
load must be kept to a minimum.
(b) Slides and Sideways. The translation of a machine element (e.g. the slide) is
normally achieved by straight-line motion under the constraint of accurate guiding
surfaces (the slideway).
(c) Spindles and Bearings. Angular displacements take place about an axis of
rotation; the position of this axis must be constant within extremely fine limits in
machine tools, and is ensured by the provision of precision spindles and bearings.
(d) Power Unit. The electric motor is the universally adopted power unit for
machine tools. By suitably positioning individual motors, belt and gear transmissions
are reduced to a minimum.
(e) Transmission Linkage. Linkage is the general term used to denote the
mechanical, hydraulic, pneumatic or electric mechanisms which connect angular and
linear displacements in defined relationship.
There are two broad divisions of machining operations:
(a) Roughing, for which the metal removal rate, and consequently the cutting
force, is high ,but the required dimensional accuracy relatively low .
(b) Finishing, for which the metal removal rate, and consequently the cutting
force, is low, but the required dimensional accuracy and surface finish relatively high .
It follows that static loads and dynamic loads, such as result form an unbalanced
grindingwheel, are more significant in finishing operations than in roughing
operations, The degree of precision achieved in any machining process will usually be
influenced by the magnitude of the deflections, which occur as a result of the force
acting.