ABCs of Machine Tool Design

About the Book

First and foremost, this book is written for professionals who are engaged in machine design and development. This book can also serve as a reference for advanced, practical, real-world information on machine design. Any legacy or innovative design needs general design information to make the machine more productive and efficient. This book presents a logical connection between design principles and system engineering principles. Throughout the book, I have laid out specific uses and calculations that the author has used throughout their professional career. Machine Tool Design is an art baked into Systemic Engineering Disciplines. Efficient and innovative designs are created when education and experience are combined. System engineering is required to develop a machine that operates efficiently over its desired life without unwarranted, uninterrupted failures, i.e., that maintains machine functionality at minimum life-cycle cost throughout the machine's desired life. System Engineering includes requirements analysis, cost analysis, safety analysis, and system analysis to achieve the lowest life cycle cost.
The art dictates the shape, color combinations, ergonomics, and form of the machine or the aesthetics of the product. The product must be human-friendly to reduce operational fatigue throughout the machine's desired life. The primary objective of this write-up is to connect system design and analysis for machine tool components. Design, analysis, and testing have been integrated to create a highly productive design for various types of machines required in the industry. The book connects fundamental concepts of machine design to the design of machine components to satisfy customer requirements. System design calls for analysis of the system and its components to satisfy customer requirements at an affordable cost. The customer defines the quality. During system analysis, components need to be designed and analyzed using forces, stress, and strains. The life of any element depends on the stress it is subjected to during operation. Fatigue Analysis, material strength analysis, deflection analysis, and safety analysis need to be performed to optimize the design. The final design needs to be verified and validated using static and endurance tests.
The contents of this book reflect the author’s experience in machine tool design and analysis over more than four decades in industry. The contents are so broad and diverse that it is not possible to cover all the topics in a single book. The analysis is primarily drawn from the author’s calculation notebooks and reprinted to reduce the book's cost. The focus depends on the systemic analysis of machine tool components. The contents of this book do reflect the author’s experiences with machine tool designs. The purpose of this book is to introduce design and analysis concepts to beginners in machine design so that they can understand and grasp the subject very easily and logically. The chapters are arranged so that the ideas are developed gradually and systematically as the designer progresses through this book. The earlier chapters should help the designers understand the next chapter more leisurely. Engineering symbols have been used as they are commonly used in the industry. The symbols have been defined before any component analysis is explained. Overall, the book contains the basics of machine design methods and processes that can be applied explicitly to machine tool component design and analysis. The book also contains machine design theories, design process, analytical techniques, and failure theories required for component design.
The book provides examples of component and system design using real-world examples from various machines. The book has twenty-two chapters in total. The contents include system engineering ideas, system modelling methods, spindle design and analysis, gear analysis, and reliability analysis, as they relate to the design of machine tools in industry. It also includes foundation design and welding design as related to the machine design and development. A very brief discussion on component fatigue analysis and vibration analysis has also been included. Examples in each chapter have been drawn from the author’s experiences as much as possible. To familiarize readers with both MKS and English units in calculations, examples include both the units the author has used in the past, as and when necessary. To make the content more usable and valuable to designers, the topics of reliability, foundation design, and welding processes have been discussed. The author has found that several fastener designs and the selection of materials to optimize a design are critical considerations for designers.
The spindle design and bearing selection procedures have also been included in the book. The inclusion of several chapters was decided to improve the designer’s understanding of component design and to increase the use of system analysis in all designs. Most of the chapter’s content has been reviewed by some of my students, and their comments and suggestions have been incorporated. The author remains thankful to those who have helped me to complete the voluminous work.

About the Author

Jyoti Mukherjee is an Ex-adjunct professor of the Mechanical Engineering department of the University of Arizona and Ex-Chair Professor of the Industrial Engineering Department of the Indian Institute of Technology, Kharagpur, India. He has over 40 years of experience in teaching industrial engineers and practicing machine tool design in various companies and educational institutions, such as Warner and Swasey, Cleveland, USA; Hardinge Brothers, Elmira, New York; Makino Machine Tool Company, Japan; Tata Engineering & Locomotive Company, Jamshedpur, India; and Ford Motor Company, Dearborn, Michigan, USA. He is also the author of another book titled “System Engineering for Machine Tool.” In addition, the author has about 14 international patents related to machine tool design. He is also a consultant for Machine Tool Design and Development worldwide. He was awarded Bachelor of Engineering (B.E) from Calcutta University in India, a Master of Technology (M.Tech) from IIT Kharagpur, India; an Master of Business Administration (MBA) in Operation Management, from Syracuse University, New York; a Post Graduate Diploma in Business Management (PGDBM) from Xavier’s Labor Relation Institute, Jamshedpur, India; a master of science degree (M.Sc.) from MIT, Cambridge in System management, and a Doctor of Engineering (Dr. Engg.) from Cleveland State University, Cleveland, Ohio. He has been a licensed Professional Engineer in the state of Ohio since 1978.