Machine Tools & Automation

Robotics and Automation

Milling is a manufacturing process in which

excess material from the work piece is
removed by rotating multipoint cutting tool.

Plain or Slab milling

End Milling
Slot milling

A
robot
is
a
reprogrammable,
multifunctional manipulator designed to
move materials, parts, tools.
An artificial agent acting as a substitute for
human labour.
A
robot
basically
consists
of
manipulators(links and joints), guided by
sensors, driven by actuators, and controlled
through programmed software to perform a
specific task

Material transfer Machine loading-Material Handling

Spot Welding
Arc welding
Painting and Coating
Process operations
Assembly
Inspection and Testing

Automation: It is defined as the set of

technologies of carrying out a process or
procedure without human assistance and
achieves performance superior to manual
operation.
Auto-self, Matos-Moving

Applications:
Industries, agricultural appliances, Mining, Highway
systems, Waste management, Household appliances,
online shopping and banking. Booking tickets for plane
and train

 Computers
Controllers
Actuators
Sensors
Software

Fixed automation or Hard automation.

Programmable
automation
or
automation.
Flexible automation.

soft

Programmable
Automation

Variety

Flexible
Automation
Fixed
Automation

Quantity

Sequence of processing (or assembly) operations

is fixed by the equipment configuration
Typical features:
Suited to high production quantities
High initial investment for custom-engineered
equipment
High production rates
Relatively inflexible in accommodating product
variety

Capability to change the sequence of operations

throug
reprogramming
to
accommodate
different product configurations
Typical features:
High investment in programmable equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in
product configuration
Most suitable for batch production
Physical setup and part program must be
changed between jobs (batches)

System is capable of changing over from one job

to the next with little lost time between jobs
Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of
products
Medium production rates
Flexibility to deal with soft product variety

1.
2.
3.
4.

5.
6.
7.
8.
9.

To increase labor productivity

To reduce labor cost
To mitigate the effects of labor shortages
To reduce or remove routine manual and
clerical tasks
To improve worker safety
To improve product quality
To reduce manufacturing lead time
To accomplish what cannot be done manually
To avoid the high cost of not automating

37

38

Shortage of labor
High cost of labor
Increased productivity
Competition
Safety
Reducing manufacturing lead time
Lower costs in the long run

39

Process to perform fixed and repetitive

operations using mechanical machinery to
produce a high volume of similar parts.

Assembly line and chemical industry-automobile

Advantages

Material Handling
High production at faster rate
Low unit cost
Disadvantages
High initial investment
Not flexible for the product change
Only for specific products to produce in larger volume.

It is programmed to change the sequence of

operations to accommodate different product
configurations.
The sequence of operation is controlled by a
program, which is set of coded instructions that can
be read and interpreted by the system.
NC machine tools, industrial robots,
Advantages:
Flexible to deal with design variations
Suitable for batch productions
Disadvantages:
High investment
Lower production rate

It is a process that adopts both computer

programs and programmed operating systems.
It is used to produce variety of parts with no time
lost for change overs from one part style to the
next.
Flexible manufacturing systems: Industrial robots

Advantages

Continuous production with varied combinations

Flexible for product design variations
Disadvantages:
Medium rate of production
High investment cost
High unit cost

Power: Process & automation

Program: Instruction-work cycle program

Part program

Control system
Closed loop
Open loop

Numerical control is the method of automation of machine tools or

other equipments that are operated precise programmed
commands coded alphanumeric data which are encoded on
punched paper tape or an alternative storage medium

CNC is an advanced form of the NC system where the machine

control unit is a dedicated microcontroller instead of a hard wired
controller, as in conventional NC.