The 163 series lathe was designed by the Ryazan Machine Tool Plant back in 1953. The production of this model continued for a long time, as it has unique technical and operational qualities. And the machine is still used to perform work in specialized workshops.
Design features of the machine
The 163 Series was originally designed to perform a wide range of turning operations and is therefore considered a universal machine. This was reflected in its layout and structural elements.
The arrangement of components in the equipment is classic. There are polished guides on the surface of the bed. They are equipped with a carriage with a tool holder, which has a cutting tool feed mechanism. The main drive is carried out by the operation of an electric motor, which is connected to the gearbox using a belt drive. To regulate the spindle rotation speeds in the gearbox, you can change the clutch of the transmission gears.
Machine 163 has the following design features and performance qualities:
- variety of operations performed. Using this equipment you can do turning, boring, and form metric threads on the surface of cylindrical workpieces. As additional function the manufacturer has provided the ability to perform drilling;
- the ability to activate the processing mode at high spindle speeds. In this case, not only cutters with standard characteristics are installed, but also special models;
- the caliper has a device for mechanical displacement. Thanks to this, the machine can turn conical parts.
To implement rapid displacements of the caliper in the longitudinal and transverse directions, the design has two electric motors. This reduces processing inertia and improves the quality of turning work. However, prior setup is required before activating these modes.
The pitch adjustment during thread formation is carried out by changing the pairs of gear wheels in the gearbox. Additionally, it is necessary to adjust a similar parameter for the guitar of the machine.
Description of technical characteristics
For lathe Model 163 is characterized by ease of operation. Achieving optimal results in processing workpieces is possible only after studying its technical characteristics and operating rules for this equipment.
Like all equipment of this class produced in the mid-20th century, the lathe has quite large dimensions, which are 353 * 152 * 129 cm. This is explained by its versatility and the ability to perform a wide range of operations. The weight of the installation is 4050 kg.
To accurately analyze the capabilities it has, you should study its main technical characteristics. They are as follows:
- The maximum permissible dimensions of processed parts depend on the method of their installation. Above the bed this parameter cannot exceed 63 cm, above the support – 35 cm;
- the length of the workpiece cannot be greater than 140 cm;
- the spindle head has a hole with a diameter of 70 mm;
- the spindle can rotate at a frequency from 10 to 1250 rpm;
- the number of spindle head speeds depends on the direction of rotation. For forward movement, this parameter is 22, for reverse movement – 11;
- the number of feeds of the cutting slide, longitudinal and transverse carriage is 32;
- rapid displacements are carried out at a speed of 3.6 m/min (longitudinal) and 1.3 m/min (transverse).
The electric motor power for the main drive is 13 kW. But besides this, when calculating maximum load on the electrical network, the characteristics of auxiliary power plants. Their total power is 2.2 kW. They also include electric pumps that ensure the functioning of the lubrication system and coolant supply.
The functionality of the 163 machine includes thread forming operations various types: metric, pitch and inch. Before performing this work, install the appropriate pair of gears in the gearbox.
Equipment operating rules
Reading the instructions is prerequisite for effective and safe work on machine 163. However, it should be taken into account that the model has not been produced for a long time and therefore the actual characteristics may differ from the passport ones.
At the first stage of work, it is necessary to check the components and assemblies of the equipment. This includes analyzing the condition of the gearbox, electric motors and checking the linear dimensions of the headstock and tailstock, tool slide and caliper. Then the components are lubricated according to the attached instructions.
To ensure safe operation of the machine, the following conditions are observed:
- availability of good lighting;
- briefing workers before work;
- correct installation of the machine on special supports or a prepared platform;
- application of funds personal protection: work clothes, safety glasses.
Only after this can you begin turning operations.
The video shows an example of how a 163 screw-cutting lathe processes a steel workpiece:
stanokgid.ru
163 machine characteristics
Specifications:
Model 163 machines are designed to perform a variety of turning and screw cutting work on ferrous and non-ferrous metals, including turning cones, cutting metric, modular, inch and pitch threads. The rigid design of the machine, the high spindle speed limit (1250 rpm) and the relatively high drive power (13 kW) make it possible to use it as a high-speed machine using high-speed steel cutters and hard alloys. The use of a step increasing mechanism makes it possible to increase feeds: at spindle speeds up to 80 rpm - 16 times, at spindle speeds
The largest diameter of the workpiece above the bed, mm 630 The largest diameter of the workpiece above the support, mm 340 The diameter of the rod passing through the hole in the spindle, mm 65 The distance between centers, mm 1400 The height of the centers, mm 315 The longest turning length, mm 2520; 4500 Limits of spindle revolutions per minute 5:-: 500 Limits of longitudinal feeds, mm/rev 0.20:-: 3.05 Limits of transverse feeds mm/rev 0.07:-: 1.04 Cutting threads: metric, pitch in mm 1:-: 192 inch, number of threads per 1” 24 – ? modular, pitch in modules 0.5p - 48p pitch, in diametric pitches 96 - 7/8 Main electric motor power, kW 14 Machine dimensions, mm (length, width and height) 3530 X 1520 X 1290 Machine weight 4050
Buy this machine without intermediaries:
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Screw-cutting lathe 163
The 163 screw-cutting lathe is designed for processing parts such as shafts, disks, turning external cylindrical surfaces, facing, boring various holes, cutting threads with both a cutter and a tap and die, rolling corrugated surfaces.
The machine can process relatively large-sized parts from various materials (ferrous and non-ferrous metals).
The screw-cutting lathe 163 is a high-speed universal machine that allows the use of high-speed modes using cutters made of high-speed steel and carbide (VK, TK) at the upper limits of the spindle rotation speed.
It is used in conditions of individual and small-scale production.
- 1M63;
- 1M63F306;
- 1M63M;
- 1M63NG;
- 1M63NP;
A. Guitar replacement gears;
B. Headstock;
B. Four-jaw chuck;
G.Movable steady rest;
D.Cutter head;
E.Support;
J. Fixed rest;
Z. Tailstock;
I. Cabinet for electrical equipment;
K. Stanina;
L. Drive for accelerated movement of the caliper;
M.Machine apron;
N. Tray for collecting coolant and chips;
O. Machine feed box
- Gearbox control handle;
- Knob for adjusting normal or increased thread pitch;
- Reverse handle when cutting left or right threads;
- Pull handle;
- Rack and pinion engagement;
- Handle for turning and fixing the tool holder;
- Handle for mechanical movement of the carriage;
- Button for enabling rapid movement of the caliper;
- Handle for reversing longitudinal and transverse movements of the caliper;
- Fixing the tailstock quill;
- Flywheel for manual movement of the quill;
- Voltage switch;
- Turning of cones or cylinders;
- Manual carriage movement;
- Turning on and reversing the spindle;
- Turning on the uterine nut;
- Manual movement of the caliper;
- Enabling mechanical movement of the caliper;
- Manual longitudinal movement of the caliper;
- Turning on and reversing the spindle;
- Starting the main electric motor;
- Turning on the lead screw or shaft;
- Handle for setting the required pitch and feed for thread cutting;
- Selecting the type of thread to be cut
photo: kinematic diagram of screw-cutting lathe 163
The following basic movements can be distinguished in the operation of the machine:
- Main movement or cutting movement;
- Auxiliary movement or feed movement;
- Movements of helical surface formation
The main movement is the rotation of the spindle with the workpiece being processed. The drive shaft of the gearbox receives rotational motion from the main electric motor through a V-belt drive. Using a disc friction clutch, gears 40 and 45 are connected to shaft 1. Shaft 2 receives torque through a moving gear block B with two different gears. From shaft 2, rotational motion is transmitted to shaft 3 through a triple movable gear block. On average, the gear block engages and rotation is transmitted directly to the machine spindle 6.
Auxiliary movement is the rectilinear reciprocating movement of the caliper in the longitudinal and transverse directions.
The feed movement is carried out directly from the spindle through gears 60-60 when the moving block is shifted to the right position.
The central shaft 19 of the apron receives rotational motion from the roller through gears 24-44, an overrunning clutch, shaft 18 and a worm gear 3-36.
Turning on, off and reversing the longitudinal feed is carried out using an electromagnetic friction clutch.
The movement of the formation of a helical surface is a rectilinear reciprocating movement of the caliper kinematically associated with the rotation of the spindle for cutting various threads.
The movement is borrowed from the spindle head through gears 60-60 or from shaft 4 through a large pitch link with gears 60-24-48-60.
When cutting metric and inch threads, replaceable gears (guitar) are installed according to the Sp scheme, and for modular and pitch threads - Wed
Using two handles, all speeds on the machine are switched.
Handle 1 controls the movable blocks of gear wheels B1 and B2, and handle 27 controls the triple block B3 and double block B4
By moving handle 1 through shaft 26 and gears 25-8, the crank pin 9 with disk 7 on which the end crank groove is located is rotated. It includes a roller 6 of a two-arm lever 5. The second end of the lever 5 is connected with a slider 32 to a fork 31, which, in turn, moves along a round guide 30. The roller 31 moves the triple movable block B2
The double movable block B1 is moved by a fork 11, which, in turn, moves along round guides using a crank pin 9 and a slider 10.
photo: gear shift mechanism
Video: screw-cutting lathe 163www.metalstanki.com.ua
Screw-cutting lathe 163
Screw-cutting lathe 163 is an old modification of the more modern machine model 1M63 - one of the most common in the territory former USSR a machine that allows turning of medium and large sized parts. The machine was exported to many countries around the world. Screw-cutting lathes model 163 have proven themselves to be reliable and unpretentious, not requiring special attention.
Purpose
The screw-cutting lathe 163 is designed for processing cylindrical, conical and complex surfaces - both internal and external, as well as for cutting threads. To process the end surfaces of workpieces, a variety of cutters, reamers, drills, countersinks, as well as dies and taps are used.
Designation of screw-cutting lathe 163
The alphanumeric index of the screw-cutting lathe 163 means the following: number 1 is a lathe; number 6 – indicates a screw-cutting lathe, number 3 – maximum radius for processing the workpiece (315 mm).
| Technical characteristics of the machine 163 | Options |
| The largest diameter of the workpiece installed above the bed, mm | 700 |
| Machining diameter above the bed, mm | 630 |
| Machining diameter above the support, mm | 350 |
| Distance between centers | 750 - 10 000 |
| Maximum length of the part installed in the recess of the frame, mm | 900 |
| Diameter of cylindrical hole in spindle, mm | 105 |
| DIN flanged spindle end | 11M |
| Number of spindle speed steps | 22 |
| Spindle speed limits, rpm | 10 - 1 250 |
| Accelerated longitudinal movement of the caliper, m/min | 5,2 |
| Accelerated lateral movement of the caliper, m/min | 2 |
| Main drive motor power | 15 kW |
| Maximum weight of the workpiece in centers, kg | 3 500 |
| Overall dimensions of the machine (L x W x H), mm | 2,950 - 12,470 x 1,780 x 1,550 |
| Machine weight, kg | 4 200 - 13 200 |
New screw-cutting lathe 163
This is an old modification of a more modern machine model - one of the most common machines in the territory of the former USSR, which allows turning parts of medium and large sizes. The machine was exported to many countries around the world. Screw-cutting lathes model 163 have proven themselves to be reliable and unpretentious, not requiring special attention.
Purpose
It is designed for processing cylindrical, conical and complex surfaces - both internal and external, as well as for thread cutting. To process the end surfaces of workpieces, a variety of cutters, reamers, drills, countersinks, as well as dies and taps are used.
Designation of screw-cutting lathe 163
The alphanumeric index of the screw-cutting lathe 163 means the following: number 1 is a lathe; number 6 - indicates a screw-cutting lathe, number 3 - maximum radius for processing the workpiece (315 mm).
| Technical characteristics of the machine 163 | Options |
| The largest diameter of the workpiece installed above the bed, mm | 700 |
| Machining diameter above the bed, mm | 630 |
| Machining diameter above the support, mm | 350 |
| Distance between centers | 750 - 10 000 |
| Maximum length of the part installed in the recess of the frame, mm | 900 |
| Diameter of cylindrical hole in spindle, mm | 105 |
| DIN flanged spindle end | 11M |
| Number of spindle speed steps | 22 |
| Spindle speed limits, rpm | 10 - 1 250 |
| Accelerated longitudinal movement of the caliper, m/min | 5,2 |
| Accelerated lateral movement of the caliper, m/min | 2 |
| Main drive motor power | 15 kW |
| Maximum weight of the workpiece in centers, kg | 3 500 |
| Overall dimensions of the machine (L x W x H), mm | 2,950 - 12,470 x 1,780 x 1,550 |
| Machine weight, kg | 4 200 - 13 200 |
New screw-cutting lathe 163
1. Description of the modernization object
1.1 General description group of machines to which the selected machine belongs, purpose and scope of their application
A lathe is a machine for processing by cutting (turning) workpieces made of metals and other materials in the form of bodies of revolution. Lathes are used for turning and boring cylindrical, conical and shaped surfaces, cutting threads, trimming and machining ends, drilling, countersinking and reaming holes, etc. The workpiece receives rotation from the spindle, the cutter - the cutting tool - moves along with the slide of the support from the lead shaft or lead screw, which receives rotation from the feed mechanism.
The turning group of machines includes machines that perform various turning operations: roughing, chamfering, boring, etc.
A significant share of the machine park consists of lathes. It includes, according to the ENIMS classification, nine types of machine tools, differing in purpose, design layout, degree of automation and other characteristics. The machines are designed primarily for processing external and internal cylindrical, conical and shaped surfaces, cutting threads and processing the end surfaces of parts such as rotating bodies using a variety of cutters, drills, countersinks, reamers, taps and dies.
The use of additional special devices on machines (for grinding, milling, drilling radial holes and other types of processing) significantly expands the technological capabilities of the equipment.
Lathes, semi-automatic machines and automatic machines, depending on the location of the spindle carrying the device for installing the workpiece blank, are divided into horizontal and vertical. Vertical machines are designed mainly for processing parts of significant mass, large diameter and relatively short length. The most famous lathes in Soviet times are 1K62 and 16K20.
The Model 163 screw-cutting lathe is a high-speed universal machine designed for performing a variety of turning and screw-cutting work, including turning cones with mechanical feed and cutting all common types of threads: metric, modular, inch and pitch.
The rigid design of the machine, the high upper limit of spindle speeds and the relatively large drive power make it possible to use it at high speeds using carbide cutters and tools made of modern high-speed steels. The machine can process relatively large-sized parts made of ferrous and non-ferrous metals. The machine is intended for use in individual and small-scale production.
Main components and accessories of the machine (Fig. 1.1). A - guitar of interchangeable wheels; B-headstock with gearbox; B-four-jaw chuck; G - movable steady rest; D - four-position tool holder; E - caliper; F - fixed steady rest; 3 - tailstock; I - cabinet with electrical equipment; K - bed; L - drive for rapid movements of the caliper; M - apron; N - tray for collecting coolant and chips; O-feed box.
Controls. 1 - gearbox control wheel; 2-handle for adjusting to a normal or increased thread pitch and for dividing when cutting multi-start threads; 3 - control handle for the reversing mechanism for cutting right- and left-hand threads and doubling the feed; 4 - selection control handle; 5 - button for turning the rack and pinion gear on and off; 6 - handle for turning, fixing and securing the four-position tool holder; 7 - handle for turning on and off the mechanical movement of the upper part of the caliper; 8 - button for enabling rapid movements of the caliper; 9 - handle for turning on, off and reversing the longitudinal and transverse movements of the caliper; 10-handle for securing and releasing the tailstock quill; 11 - handwheel for manual movement of the tailstock quill; 12 - voltage switch; 13 - switch for turning cones or cylinders; 14 - handle for manual movement of the upper part of the caliper; 15 and 21 - handles for turning on, turning off and reversing spindle rotation; 16 - handle for turning the uterine nut on and off; 17 and 22 - push-button stations for starting and stopping the main electric motor; 18 - handle for manual transverse movement of the caliper; 19 - button for turning on and off the mechanical transverse movement of the caliper; 20 - handwheel for manual longitudinal movement of the caliper; 23 - handle for turning on the lead screw or lead shaft; 24 and 25 - handles for setting the required thread pitch or feed amount; 26 - handle for selecting the type of thread or feed.
Movements in the machine. Cutting movement is the rotation of the spindle with the workpiece. Feed movements - rectilinear translational movement of the caliper in the longitudinal and transverse directions, and the upper part of the caliper - at an angle to the axis of rotation of the spindle; rectilinear translational movement of the tailstock together with the support along the axis of rotation of the spindle. The movement of the formation of a helical surface is a rectilinear translational movement of the caliper in the longitudinal direction, kinematically related to the rotation of the spindle. Auxiliary movements - fast mechanical and manual adjustment movements of the caliper in the longitudinal and transverse directions and at an angle to the axis of rotation of the spindle, manual linear movement of the tailstock quill, manual periodic rotation of the four-position tool holder.
Figure 1.1 - Machine model 163
1.2 Technical characteristics of the selected machine
Height of centers in mm…………………………………………….315
Largest diameter of the workpiece in mm
above the bed…………………………………………………….630
above the bottom of the caliper………………………………….340
The diameter of the hole in the spindle in mm…………………………….70
Distance between centers in mm……………….……….1400, 2800
Number of spindle rotation speeds………………………….…24
Limits of spindle revolutions per minute………………10-1250
Number of caliper feed rates………………………………40
Limits of caliper feed rates in mm/rev
longitudinal…………………………………….………0.10-3.20
transverse………………………………….………….0.04-1.18
Limits of feed rates of the vertical part of the caliper in mm/rev…………………………………………………………………………………0.033-1
Speed of rapid longitudinal movements of the caliper in m/min………………………………………………………………………………….…..3.6
Power of the main electric motor in kW……………………14
1.3 Description of the kinematic diagram of the machine
From shaft II, rotation is transmitted to shaft III through a triple movable gear block B 2 with six different speeds. In the middle position of the triple movable gear block B 3, rotation from shaft III is communicated directly to spindle VI. In the other two positions of block B 3, the movement is transmitted to shaft IV and then through gears 24-96, shaft V and the double movable gear block B 4 to spindle VI.
As can be seen from the speed graph (Fig. 1.3), the spindle has 24 different speeds, from 10 to 1250 rpm. When rotating in reverse, the spindle has only 12 speeds, from 18 to 1800 rpm.
The minimum number of spindle revolutions per minute n min is determined from the expression
n min = 14500.985 
≈ 10 rpm.
The feed movements are borrowed directly from the spindle through gears 60-60 when the double movable gear block B 5 is shifted to the right. When feeding, only two positions of the movable gear block B 6 are used: middle, when gears 28-56 are engaged, and right, when gears 42-42 are engaged.
The left position of block B 6 shown in the diagram is used for cutting left-hand threads.
The feed box receives rotation from shaft VIII through replaceable wheels. When feeding, the replacement wheels are installed according to the C n scheme, and the clutches M 1 and M 2 are activated in the feed box. Then the rotation from shaft VIII is transmitted to the running roller XVII through replaceable wheels 63-56-88-63, shaft IX, coupling M 4, shaft XI, one of the blocks B 7 -B 10, shaft X, coupling M 2, shaft XII, block B 11, shaft XIII, coupling M 4 or bust 30-60 and 30-60, shaft XIV, gears 37-53 and shaft XVI.
The central shaft XIX of the apron receives rotation from the drive shaft through gears 24-44, overrunning clutch Mo, shaft XVIII and worm gear 3-36.
The longitudinal feed is switched on, switched off and reversed by an electromagnetic double-sided friction clutch M 92. The movement from the central shaft XIX is transmitted to the apron by gears 55-55 or 52-26-52, coupling M 92, shaft XXVI, gears 22-66, shaft XXVII and rack and pinion 12-rack t = 4 mm.
Before shaft XXII, which receives rotation from the central shaft XIX through gears 55-55 or 52-26-52, coupling M 91, shaft XX and gear 63-17-20, the kinematic chain of transverse feed and feed of the upper part of the caliper is common. The transverse feed is activated by shifting the movable gear 17. In this case, the transverse lead screw receives rotation from shaft XXII through gears 20-17.
The feed from the upper part of the caliper is activated by the M 6 clutch. In this case, the movement is transmitted from shaft XXII by bevel gears 31-31, shaft XXIII, gear 30-30-30-30, shaft XXIV, bevel gears 25-25 and clutch M 6 to lead screw XXV.
When cutting threads, the movement is borrowed either directly from the spindle through gears 60-60, as in feed, or from shaft IV through the pitch increasing link with gears 60-24-48-60.
For cutting metric and inch threads, replacement wheels are installed according to scheme C p (63-56-88-63), and for cutting modular and pitch threads - according to scheme C p (63-56 and 37-88-53).
With couplings M 1 and M 2 turned off (as shown in the diagram), inch and pitch threads are cut. For cutting metric and modular threads, couplings M 1 and M 2 are included. The XV lead screw receives rotation from the feed box when the M 5 clutch is engaged.
Rapid movements of the support in all directions are carried out by a 1 kW electric motor installed on the apron of the machine. Rotation from the electric motor is transmitted by gears 20-33 to shaft XVIII and further along kinematic feed chains.
The M 0 overrunning clutch allows for rapid movements without turning off the working feed.
The longitudinal feed dial JI is driven from shaft XXVII by means of gears 75-37-149. The last wheel has internal teeth.
Manual movements of the remaining working parts of the machine are carried out by handles directly attached to the lead screws of the corresponding gears.
Figure 1.2 - Kinematic diagram of the machine model 163
Figure 1.3 - Speed graph of the model 163 machine
2. Review of existing mechatronic modules
2.1 Classification of mechatronic motion modules
Mechatronic motion modules currently used in production machines and new generation vehicles can be divided into four groups.
High-speed modules with maximum rotation speeds from 9,000 to 250,000 min-1 and power from 0.1 to 30 kW for metal-cutting machines, woodworking machines, drilling machines printed circuit boards, compressors, etc.
These modules use air and electromagnetic bearings. The main advantages of manufactured electrospindles on magnetic bearings:
absence of mechanical contacts and, as a result, wear;
the ability to use higher (compared to traditional designs) speeds;
little vibration, no friction and reduced heat loss;
the ability to change the rigidity and damping characteristics of the system;
ability to work in vacuum and harmful environments;
environmental cleanliness.
Low-speed modules with maximum rotation speeds from 4 to 300 min-1, torque from 10 to 2500 Η m and positioning accuracy up to 3" for rotary tables of machine tools, measuring machines, electronic engineering equipment, robot units and multi-purpose tool heads.
Modules of this type can be successfully used in electric bicycles, wheelchairs, electric motorcycles, scooters and other light vehicles. The technical characteristics of some transport MMDs, for example, electric bicycles and wheelchairs, significantly exceed the characteristics of the world's best manufacturers. Thus, the weight of the wheelchair is 30% less, and the range without recharging the battery is 50% more than that of imported analogues.
Linear motion modules with forces from 10 to 5000 Η and speeds up to 32 m/s for drives of metal-cutting machines, industrial robots and measuring machines, as well as for locking devices for gas and oil pipelines.
Digital electric drives with brushless synchronous and asynchronous motors with power up to 10 kW with torque from 1 to 40 N m and high attitude moment to weight for feed drives of high-performance machine tools and robots, textile and woodworking machines, fan drives, pumps, etc. The control unit for such drives is created on the basis of intelligent power circuits and is built into the housing or terminal box of the electric motor.
2.2 General information and technical characteristics of existing mechatronic motion modules
To create modern motion systems and technological machines, a variety of mechatronic motion modules are required. The requirements for the developed forces, accuracy and speed of movements are dictated by the features of the technological operation, and the requirement to minimize the size of the mechatronic motion module is dictated by the need to integrate it into the technological machine. An attempt to synthesize a mechatronic motion module from commercially produced components can lead to technically and economically ineffective solutions. Therefore, it is more rational to design a specialized module that most fully meets the service purpose of the machine.
Technical characteristics of mechatronic modules can be divided into the following groups:
Basic electromechanical characteristics (in nominal, maximum and intermittent operating modes):
for rotational motion modules - power, torque, rotation speed (max., min.), discrete angular movement;
for linear motion modules - power, force, speed of movement (max., min.), discreteness of linear movement.
Basic technological characteristics- geometric and design dimensions (spindle cone, max., stroke length of the linear mechanism, rotary table diameter, etc.).
Additional technological characteristics - the presence of a device for supplying coolant to the cutting zone, the presence of a device for clamping and releasing the fastening of a tool or part, the presence of built-in forced cooling devices, the presence of devices for monitoring the geometry of the workpiece, etc.
3. Design part
3.1 Ball screw calculation
To calculate the parameters of a ball screw (BSC), it is necessary to determine the maximum transmission force. To do this, when upgrading the linear movements of a lathe support, we calculate the mass of the support.
Based on the dimensions of the machine support, determined approximately from general view machine and dimensions given in the technical specifications, the mass of the support is equal to:
m soup = 
,
V soup, G soup, D soup - respectively the height, depth and length of the machine support, V machine, G machine, D machine - respectively the height, depth and length of the machine;
K z.sup - the coefficient of filling the volume with the caliper;
To z.machine - the coefficient of filling the volume of the machine; machine - weight of the machine.
B soup = 800 mm, G soup = 1420 mm, D soup = 612 mm, K g. soup = 0.4;
H of the machine = 1680 mm, D of the machine = 1420 mm, D of the machine = 3530 mm, K of the machine = 0.5;
m machine = 4060 kg.
m soup = 
= 
= 268 kg.
In the case of modernization of a lathe, the mass of the moving mechanism (support, turret and, in fact, the tool) is equal to:
m ∑ = m soup +m rev.heads. +m instr. ,
m soup = 268 kg;
m rev.heads = 5 kg;
m instr. = 3 kg.
m ∑ = 268+5+3 = 276 kg.
During horizontal movement of the moving mechanism, the friction force arising in the sliding supports, F tr (N), is equal to:
F tr = m ∑ ∙g∙f c ,
where is the acceleration of gravity, g = 9.81 m/s 2,
f c - sliding friction coefficient, f c = 0.15.
F tr = 276*9.81*0.15 = 406 N.
The maximum transmission force, F load (N), for horizontal movement, provided that the technological force F techn when processing the part is approximately 200...300% of the friction force, is equal to:
F load = F tr +F techn = (3÷4)∙F tr,
Ftr = 406 N.
F load = (3÷4)∙F tr = 1421 N.
3.2 Calculation of geometric parameters of the ball screw
To determine the geometric parameters of the mechanism links, we first set some values to a first approximation.
The screw stability condition is determined by the formula:
n y = J calc ∙q∙E y /F load ∙I 2 r.g.
where y is the safety factor, for vertical screws = 4; load - maximum transmission force = 1421 N; r.g. - working length of the nut (taken equal to 2-4 pitches of the screw), mm;
q - screw fastening coefficient =40;
E y - modulus of elasticity of the first type of screw material = 2.1*10 11 Pa; calculated - the moment of inertia of translationally moving masses reduced to the propeller, mm 4.
The angular velocity of the nut (screw) is determined by the formula:
ω = π∙n/30,
n - engine shaft speed = 750 rpm.
ω = 3.14∙750/30 = 78.5 rad/s.
The ball screw gear ratio is determined by the formula:
U VP = ω/ν,
ν - linear speed of the screw (nut) = 0.0669 m/s.
U VP = 78.5/0.0669 = 1174 m -1 .
The thread pitch is determined by the formula:
P = 2∙10 3 ∙π/U VP ∙K,
K is the number of thread starts (usually ball screws are made single-start, i.e. K=1).
P = 2∙10 3 ∙3.14/1174 = 5.35.
The result of calculating the thread pitch, obtained in mm, is rounded to the nearest standard number from the series: 1; 1.5; 2; 2.5; 3; 4; 5; 6; 8; 10; 12; 16; 20; 24. Therefore, P = 5.
The resulting thread pitch value is used to determine the working length of the nut l р.г.
The moment of inertia of the translationally moving masses reduced to the screw (shaft) is equal to, mm 4:
J calc = n y ∙F load ∙I 2 r.g. /q∙E y ,
where r.g. = 5.
J calc = 4∙1421∙25. /40∙2∙10 11 = 142100/80∙10 11 = 1.77∙10 -8 mm 4 .
The average screw diameter is determined by the formula:
d av = 
= = 2.45*10 -4 m.
Using the formula, we obtain the value of the screw diameter in meters,
for the convenience of further work, we convert into millimeters and round to the nearest larger standard value from the series: 3.5; 4; 4.5; 5; 6; 8; 10; 12; 16; 20; 25; 32; 40; 50; 63; 80; 100
Therefore d av = 30 mm.
d w = k r ∙P,
Kr - thread pitch coefficient equal to 0.6.
d w = 0.6∙5 = 3 mm.
We determine the angle of elevation of the helix at the average radius of the lead screw using the formula:
ψ = arctan (P∙K/π∙d 0),
where 0 is the diameter of the circle on which the centers of the balls are located (Figure 1.4); d 0 is considered equal to d cf.
ψ = arctan (5/3.14∙30) = 3.03°.
Figure 1.4 - Ball screw geometry
The reduced rolling friction angle is determined by the formula:
P k = arctg (2∙f k /d w ∙sinβ),
where k is the reduced coefficient of rolling friction (for hardened screw surfaces HRC > 58 and steel balls with hardness HRC > 63, f k = 0.007...0.01 mm);
β is the angle of contact of the balls with the screw and nut; for a circular groove β =30°.
P k = arctg (2∙0.01/3∙0.5) = 0.76°.
Efficiency of the screw pair:
ƞ VP = tg ψ / tg (ψ+P k),
ƞ ch = 0.05 / 0.06 = 0.83.
The development length of the working part of the helical ball groove is determined as:
lp. k. = l r.g. /sinψ,
l r.g - working length of the nut = 5.
lp. k. = 5/0.05 = 100 mm.
Estimated number of balls:
Z p = l p . k. /d w = 100/3 = 34.
The length of the nut is determined using the formulas:
lp. k = Z p * d w = 34*3 = 102 mm.
l r. g = l p.k * sinψ = 102*0.05 = 5.1.
Gap between screw (nut) and ball:
Δ/2 = 0.04∙d w = 0.04*3 = 0.12.
The groove radius (the radius of the screw and nut thread profile) is determined by the formula:
r w = 0.51∙d w = 0.51*3 = 1.53 mm.
Screw inner diameter:
d in = d av -2∙r w - Δ/2 = 30-2*1.53-0.12 = 26.82 mm.
Screw outer diameter:
d n = d in +2∙h 1,
where 1 is the depth of the thread profile of the screw and nut; h 1 = (0.3…0.35) d w = 1.
d n = 26.82+2∙1 = 28.82 mm.
3.3 Calculation of geometric parameters of the ball screw nut
Displacement of the thread profile in the radial direction, mm:
B’ = *cosβ = (1.53 - 1.5)*0.86 = 0.026 mm.
Inner diameter of the nut, mm:
D in = d cp +2*( B’) = 30+2*(1.53 - 0.026) = 33 mm.
Nut outer diameter, mm:
D n = D in - 2h 1 = 33 - 2 = 31 mm.
Diameter of the circle along which the balls contact the nut, mm:
D k = d cp + 2r f *cosβ = 30 + 3.06*0.86 = 32.63 mm.
Outer diameter of the nut when the return channel is located in it, mm:
D = 1.3*D h +2d w +10 = 1.3*33+6+10 = 59 mm.
Outer diameter of the nut when the return channel is located outside the nut, mm:
D = 1.3*D in = 1.3*33 = 43 mm.
3.4 Test calculation of transmission based on contact stresses
Contact strength condition:
σ H max = 0.245*n p * 
≤ [σ]H,
σ H max - maximum contact stress, MPa;
[σ] H - permissible contact stresses, MPa (for screw surfaces of a screw and nut with hardness HRC≥53 and balls with hardness HRC≥63, permissible contact stresses are [σ] H = 3500...5000 MPa);
r w - ball radius, r w = d w /2 = 1.5 mm;
r in - internal radius of the screw, r in = d in /2 = 13.41 mm;
E y = (2…2.5)*10 5 MPa;
F AΣ - total axial force,
F AΣ = F load + F n,
F n - preload force, F n = (0.25…0.35) F load; p is the load coefficient, determined depending on the ratio of the main curvatures A/D according to Table 1.
Table 1 - Value of coefficient n p
The Euler critical force value is calculated by the formula: s - safety factor (assuming s = 3); µ - coefficient depending on the method of fastening the screw (in the modernized machine, both ends of the screw will be rigidly sealed, which corresponds to the coefficient µ = 0.5); l - length of the loaded (unsupported) section of the screw, l = 2000 mm Static stability is ensured if the following condition is met: The required condition is met, therefore, the screw passes the static stability test. 3.6 Test calculation of the propeller for dynamic stability
The limiting frequency n of ball screw rotation is regulated by two factors: the critical rotation frequency ncr and the linear speed of the ball. The latter, in turn, is limited by the factor: As a result of the course project, the following conclusions were made: Mechatronic motion module (MMM) is a module that allows you to ensure the movement of mechanical control objects along one controlled coordinate. MMDs are classified as follows: high-speed modules, low-speed modules, linear motion modules, digital electric drives. Mechatronic modules for linear and rotational movements of processing machines make it possible to eliminate intermediate mechanical converters and transmissions, increase accuracy, speed, and reduce losses. The use of a data bank of mechatronic modules makes it possible to reduce the modernization of equipment to a simple selection of modules according to specified parameters and significantly simplify design calculations. mechatronic kinematic lathe 1. V.I. Anuriev “Handbook of mechanical engineering designer”. T.1 - M.: Mechanical Engineering, 1992 2. V.I. Anuriev “Handbook of mechanical engineering designer”. T.2 - M.: Mechanical Engineering, 1992 V.I. Anuriev “Handbook of mechanical engineering designer”. T.3 - M.: Mechanical Engineering, 1992 4. O.D. Goldberg, Ya.S. Gurin, I.S. Sviridenko “Design electric machines" - M.: Higher. school, 1984 Androsov A.A., Spichenkov V.V., Andryushchenko Yu.E. “Fundamentals of machine design: Textbook / DSTU”, Rostov n/a. 1993 6. A.G. Kosilova, R.K. Kosilov “Handbook of mechanical engineering technologist”. T.1 - M.: Mechanical Engineering, 1986
List of sources
The 163 series lathe was designed by the Ryazan Machine Tool Plant back in 1953. The production of this model continued for a long time, as it has unique technical and operational qualities. And the machine is still used to perform work in specialized workshops.
Design features of the machine
The 163 Series was originally designed to perform a wide range of turning operations and is therefore considered a universal machine. This was reflected in its layout and structural elements.
The arrangement of components in the equipment is classic. There are polished guides on the surface of the bed. They are equipped with a carriage with a tool holder, which has a cutting tool feed mechanism. The main drive is carried out by the operation of an electric motor, which is connected to the gearbox using a belt drive. To regulate the spindle rotation speeds in the gearbox, you can change the clutch of the transmission gears.
Machine 163 has the following design features and performance qualities:
- variety of operations performed. Using this equipment you can do turning, boring, and form metric threads on the surface of cylindrical workpieces. As an additional function, the manufacturer has provided the ability to perform drilling;
- the ability to activate the processing mode at high spindle speeds. In this case, not only cutters with standard characteristics are installed, but also special models;
- the caliper has a device for mechanical displacement. Thanks to this, the machine can turn conical parts.
To implement rapid displacements of the caliper in the longitudinal and transverse directions, the design has two electric motors. This reduces processing inertia and improves the quality of turning work. However, prior setup is required before activating these modes.
The pitch adjustment during thread formation is carried out by changing the pairs of gear wheels in the gearbox. Additionally, it is necessary to adjust a similar parameter for the guitar of the machine.
Description of technical characteristics
The Model 163 lathe is easy to use. Achieving optimal results in processing workpieces is possible only after studying its technical characteristics and operating rules for this equipment.
Like all equipment of this class produced in the mid-20th century, the lathe has quite large dimensions, which are 353 * 152 * 129 cm. This is explained by its versatility and the ability to perform a wide range of operations. The weight of the installation is 4050 kg.
To accurately analyze the capabilities of the 163 screw-cutting lathe, you should study its main technical characteristics. They are as follows:
- The maximum permissible dimensions of processed parts depend on the method of their installation. Above the bed this parameter cannot exceed 63 cm, above the support – 35 cm;
- the length of the workpiece cannot be greater than 140 cm;
- the spindle head has a hole with a diameter of 70 mm;
- the spindle can rotate at a frequency from 10 to 1250 rpm;
- the number of spindle head speeds depends on the direction of rotation. For forward movement, this parameter is 22, for reverse movement – 11;
- the number of feeds of the cutting slide, longitudinal and transverse carriage is 32;
- rapid displacements are carried out at a speed of 3.6 m/min (longitudinal) and 1.3 m/min (transverse).
The electric motor power for the main drive is 13 kW. But in addition, when calculating the maximum load on the electrical network, the characteristics of auxiliary power units should be taken into account. Their total power is 2.2 kW. They also include electric pumps that ensure the functioning of the lubrication system and coolant supply.
The functionality of the 163 machine includes operations for forming threads of various types: metric, pitch and inch. Before performing this work, install the appropriate pair of gears in the gearbox.
Equipment operating rules
Reading the instructions is a prerequisite for efficient and safe operation of the 163 machine. However, it should be taken into account that the model has not been produced for a long time and therefore the actual characteristics may differ from the passport specifications.
At the first stage of work, it is necessary to check the components and assemblies of the equipment. This includes analyzing the condition of the gearbox, electric motors and checking the linear dimensions of the headstock and tailstock, tool slide and caliper. Then the components are lubricated according to the attached instructions.
To ensure safe operation of the machine, the following conditions are observed:
- availability of good lighting;
- briefing workers before work;
- correct installation of the machine on special supports or a prepared platform;
- use of personal protective equipment: work clothes, safety glasses.
Only after this can you begin turning operations.
The video shows an example of how a 163 screw-cutting lathe processes a steel workpiece:
The 163 screw-cutting lathe was developed in 1956 at the Ryazan Machine Tool Plant and was produced in various modifications for sixteen years. Currently, this company produces its modernized version under the symbol 1M63N. From the early sixties to the end of the eighties, lathe 163 under the symbol 1D63 was also produced by the Tbilisi Machine Tool Plant named after. Kirov.
Ryazan and Tbilisi lathes have the same technological characteristics, but they differ in some design features, which depend, among other things, on the year of manufacture.
Specifications
Like most turning equipment, the 160th screw-cutting lathes were produced in two modifications, in which the maximum length of longitudinal processing differed by a factor of two. In the standard version, the center-to-center distance is 2800 mm, and the turning length is 2520 mm. In the shortened version - 1400 and 1260 mm, respectively.
The maximum turning diameters (according to the passport) for this machine are:
- above the guides - 630 mm;
- above the carriage - 350 mm.
The through hole in the spindle in early models was Ø70 mm, later it was increased to 80 and 90 mm. The diameter of the three-jaw chuck is 320 mm. The rated power of the spindle drive motor is 14 kW.
Operating rules
When installing and operating the 163 screw-cutting lathe, the user of this equipment must follow the instructions set forth in Chapters 1 and 2 of its Operating Manual. They include the following sections:
- safety precautions;
- installation, installation and first start-up procedure;
- setup and operating modes;
- adjustment;
- lubrication system;
- specification of wearing parts.
The procedure for commissioning and operating machine 163 does not differ from similar turning equipment. The only thing that attracts attention is the very detailed instructions on setup and operating modes.
Purpose and scope
Screw-cutting lathe mod. 163 is a large-sized turning equipment that was created for processing rotating bodies weighing up to two tons. It has a vibration-resistant design and a high-power electric motor, which allows turning with large cutting depths. The machine is capable of performing the entire range of technological operations typical of universal turning equipment, including turning spiral surfaces and long cones.
Model 163 was used in mechanical engineering (and is still used) for single and small-scale production of large-sized parts. In addition, many repair departments of enterprises operating large-sized production equipment were equipped with these machines. One of its most important advantages is high speed fast strokes of the cutting tool (for this a separate electric motor is installed on it), which significantly reduces the time of auxiliary transitions and, accordingly, the total processing time of the part.
Workspace dimensions
Geometric limitations on the possibility of processing a part are determined technical characteristics turning equipment, the main ones being the center-to-center distance, as well as the height of the central axis above the guides and support carriage. For lathe 163 these values are 1400, 630 and 350 mm, respectively.
In addition, the workpiece turning area above the guides is limited by the dimensions and maximum strokes of the support, as well as the processing capabilities without a back stop. Another parameter that directly limits the size of processing is the maximum permissible weight of the workpiece (for this machine it is equal to two tons).
Design features of the machine
The peculiarity of screw-cutting lathes of the 163rd series is that they were produced at different machine-tool enterprises. For this reason, they have some discrepancies in the design of individual components and assemblies.
Of the basic differences between the Ryazan and Tbilisi machines, it should be noted that the former had both prismatic guides, while the latter had one prismatic and the other flat. The operating instructions and passports of 163 machines have many variations, which sometimes creates big problems when repairing this equipment.
Location of main components
The 163 lathe has a standard layout for this type of equipment. Its structural basis is a cast iron frame, on the upper plane of which there are two prismatic guides (for Tbilisi machines - one prismatic, one flat). On its left side there is a headstock with a spindle assembly, and on the right side there is a tailstock with a retractable quill.
The main working body of the machine is a cross-shaped support with a tool holder, which moves along the guides using the lower slide. The main engine of the Ryazan machine is located outside, and the Tbilisi machine is located inside the headstock housing. The movement to the caliper is transmitted using a lead screw and a lead shaft from the feed box, which is installed inside the headstock. The tailstock moves along the guides manually and is fixed to them with four bolts.
Location of controls
All the main controls of the 163 lathe are located on the left side. On the upper part of the headstock housing there are handles for controlling the operation of the spindle, below them there are handles for controlling feeds and thread parameters, and on the right side of the shaft there is a spindle reverse lever.
The controls on the apron consist of a manual steering wheel, a slide feed button, a high speed button, a high speed and feed joystick, a start and stop button for the main engine. On the support there are controls for rapid movements and feeds of the slide, and on the tool holder there is a lever for turning and fastening the tool. The tailstock is equipped with a travel flywheel and a quill fixation lever.
Kinematic diagram
The kinematic diagram of the 163 lathe consists of several interconnected components, the main ones of which are the following kinematic chains:
- control of operating modes and spindle rotation speed;
- thread cutting;
- longitudinal and transverse feeds;
- high-speed movements of the caliper.
The beginning of the kinematic diagram is the drive pulley of the gearbox friction shaft.
Gear shift mechanism
On the 163 lathe, the spindle rotation speed is set by two handles: rotating and rotary. With the help of the first, the movable gear blocks are controlled, while the set spindle rotation speed is indicated on the dial of this handle. The rotary handle is designed to lock the selected gear transmission.
Electrical diagram
IN electrical diagram lathe 163, the manufacturer of this equipment identifies the following individual circuits:
- main switch and door lock;
- power supply for control elements;
- main spindle;
- coolant system drive;
- feeds and movements of the carriage and support.
Control circuits AC powered by a voltage of 110 V, DC - by a voltage of 24 V. Asynchronous motors are powered from an alternating three-phase voltage of 380 V, and electromagnetic couplings - from a constant 24 V.
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