National Institute of Advanced Manufacturing Technology

(Formerly National Institute of Foundry and Forge Technology)

(Deemed to be University under distinct category under MoE, Government of India)
Ranchi- 834 003, Jharkhand India

Unit 1- Introduction

Why automation, Current trends, CAD, CAM, CIM; Rigid automation: Part handling, Machine tools. Flexible
automation: Computer control of Machine Tools and Machining Centers.

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1. Why automation? and current trends

The word manufacturing has Latin origin and it has been derived by using two word that is manus in Latin and
factus in Latin. Manus means by hands in English and factus means to make or to do. The automation word has
the origin from Greek. The basic word is automatos and the meaning of the word automatos in English is acting
by itself.

1.1 Automation in the manufacturing industry is important for many reasons, including

 Increased Efficiency and Productivity: Automation streamlines manufacturing processes, reducing human
errors and increasing production speed. This leads to higher productivity levels, improved cycle times, and
efficiency gains.
 Cost Reduction: Process Automation can lead to significant cost savings in the long run. Though the initial
investment may be high, the reduced need for manual labor, minimized material waste, and optimized energy
consumption lowers operational costs.
 Enhanced Product Quality: Automated systems can consistently perform tasks with high precision and
accuracy, ensuring uniform product quality. This consistency results in fewer defects and improved customer
satisfaction.
 Improved Safety: Repetitive and hazardous tasks can be assigned to automated machines, protecting
workers from potential injuries. This not only enhances the safety of the workforce but also reduces insurance
costs and associated liabilities.
 Better Data Collection and Analysis: Automation facilitates real-time data monitoring and collection.
Manufacturers can use this data to gain valuable insights into their processes, identify areas for improvement,
and make data-driven decisions to optimize performance.
 Flexibility and Customization: Modern automation systems are designed to be adaptable to different
manufacturing needs. They can be reprogrammed and reconfigured to produce various products, enabling
faster transitions between production lines.
 Reduced Lead Times: Automated processes can significantly reduce manufacturing lead times. Quicker
production and assembly times mean products can reach the market faster, giving companies a competitive
advantage.
 Environmental Sustainability: Process automation can contribute to sustainability efforts by optimizing
resource utilization, minimizing waste generation, and reducing energy consumption. This eco-friendly
approach helps manufacturers to be more environmentally responsible.
 Employee Skill Development: Contrary to the fear that automation may eliminate jobs, it often leads to a
shift in job roles. Employees can be upskilled to operate and maintain automated systems, focusing on
higher-value tasks that require problem-solving and creativity.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 1.2 Challenges in implementing automation in manufacturing

 High Initial Investment: The substantial upfront cost is one of the most significant hurdles in adopting
manufacturing automation. The required machinery, sensors, robotic systems, and software can be
expensive, especially for small and medium-sized enterprises (SMEs). Organizations must carefully analyze
the return on investment (ROI) and long-term benefits to justify the initial capital expenditure.
 Integration with Existing Infrastructure: Manufacturers often have legacy systems and equipment not
designed with automation. Integrating new automated processes with existing infrastructure can be complex
and require additional modifications or retrofits to ensure compatibility and smooth functioning.
 Workforce Reskilling and Training: Automation can lead to changes in job roles and responsibilities. As
tasks are automated, employees must acquire new skills to manage and maintain the automated systems
effectively. Training the existing workforce or hiring new skilled personnel can be challenging and time-
consuming.
 Complexity and Technical Expertise: Automation systems can be intricate, involving advanced
technologies like artificial intelligence, machine learning, and complex programming. Implementing and
maintaining these systems requires a skilled technical workforce with robotics, software development, and
data analytics expertise.
 Interoperability and Standardization: Different automation technologies and equipment from various
vendors may need to work seamlessly in a manufacturing environment. Lack of standardization can lead to
compatibility issues and difficulties in creating a unified and efficient automation ecosystem.
 Security and Cyber Threats: As manufacturing facilities become more connected through the Industrial
Internet of Things (IIoT) and automation, they also become susceptible to cyber threats. Safeguarding critical
data and intellectual property and preventing unauthorized access becomes paramount, necessitating robust
cybersecurity measures.
 Change Management and Organizational Culture: Introducing automation can disrupt the existing work
processes and create resistance among employees who fear job displacement or unfamiliarity with new
technologies. A well-planned change management strategy and a positive organizational culture that
promotes innovation and adaptation are essential to overcome these challenges.
 Maintenance and Downtime Concerns: Automated systems require regular maintenance and updates to
ensure optimal performance. Sudden breakdowns or downtime due to technical issues can severely impact
production, making efficient maintenance procedures crucial.
 Regulatory Compliance: In regulated industries, implementing automation may require adherence to
specific standards and compliance with safety regulations. Ensuring the automated processes meet all legal
and safety requirements can be demanding.
 Scalability and Flexibility: Manufacturers must consider the future scalability of their automation systems
to accommodate changes in production demands and technological advancements. Ensuring the automation
setup remains flexible enough to adapt to evolving business needs is a constant challenge.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 1.3 Current trends in automation

 Machine learning
A trending technology that allows machines to learn processes without human intervention.
 Hyperautomation
A recent trend in artificial intelligence that combines methods and technologies like machine learning,
robotic process automation (RPA), and low-code platforms.
 Robotic process automation (RPA)
A technology that's gaining momentum across industries, including medical, food and beverage,
manufacturing, and personal and home appliances.
 Cloud-based RPA
A new frontier in automation that can help businesses achieve higher levels of efficiency and cost savings.
 Edge computing
An automated way to get closer to cloud-like compute power with better latency issues.
 Internet of things (IoT)
A technology that is currently on a trend, but has vulnerabilities to network-based disruptions and attacks.
 AI-powered test automation tools
A buzz in automation that will impact the software development lifecycle.

2. CAD, CAM, CIM

Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) are integral components of
Computer Integrated Manufacturing (CIM), which represents a comprehensive approach to streamline and
automate the entire manufacturing process. CIM connects all the functional areas of manufacturing, from design
to production, using digital and computer-controlled systems to enhance efficiency, reduce costs, and improve
product quality. The roles of CAD and CAM in this framework are crucial, as they facilitate seamless transitions
from the design phase to the manufacturing stage, optimizing the production process in various ways.

(a) Role of CAD in CIM

CAD refers to the use of computer systems to assist in the creation, modification, analysis, or optimization of a
design. It plays a critical role in the initial phases of product development within CIM. The key roles of CAD in
CIM include:
 Design Efficiency and Flexibility: CAD systems allow engineers and designers to create detailed 2D or 3D
models of a product with high precision. These models can be easily modified and analyzed, allowing for
rapid design iterations and enabling quicker responses to design changes. The flexibility of CAD ensures
that multiple design versions can be tested before committing to production.
 Integration of Engineering and Design: CAD systems incorporate simulation and analysis tools, such as
Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD), to test and validate designs. This
integration of engineering and design ensures that potential flaws are detected early, reducing the risk of
costly modifications during manufacturing.
 Collaboration and Communication: CAD files can be shared and worked on collaboratively by teams
across different locations, promoting collaboration among designers, engineers, and manufacturers. This
results in better communication and understanding across departments within the CIM system, aligning
design with manufacturing capabilities.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
  Documentation and Data Management: CAD systems generate detailed documentation for manufacturing
processes, including geometric dimensions and tolerances, material specifications, and assembly
instructions. This data is critical for ensuring that manufacturing systems produce components according to
design specifications.

(b) Role of CAM in CIM

CAM refers to the use of computer software to control machine tools and related machinery in the
manufacturing process. It bridges the gap between CAD and actual production. The key roles of CAM in CIM
include:
 Automated Manufacturing Processes: CAM systems translate CAD designs into precise instructions for
computer numerical control (CNC) machines, robotic arms, and other automated systems. This automation
ensures that products are manufactured with consistent quality and minimal human intervention, reducing
errors and increasing efficiency.
 Optimization of Machining Operations: CAM systems optimize machining paths and tool movements to
reduce production time and material waste. By using algorithms that determine the most efficient way to cut
or shape materials, CAM enhances productivity and minimizes costs.
 Customization and Flexibility in Production: CAM allows for mass customization, enabling
manufacturers to produce unique variations of products without needing to redesign the entire production
line. This flexibility is particularly important in industries with rapidly changing consumer demands, as it
allows for quicker production cycles and more adaptive manufacturing processes.
 Integration with Quality Control: CAM systems can incorporate feedback from sensors and quality control
systems, allowing for real-time adjustments to machining operations. This integration helps maintain product
quality and ensures compliance with design specifications.

3. Types of automation
Automation systems are classed into three different types of automation:

 Fixed automation
 Programmable automation
 Flexible automation

3.1 Fixed automation

It is a type of automation where the process of manufacturing stays fixed by the way it is configured, following a
fixed sequence of automated processes. An example of this is flow production, where products are continuously
being made. This is often also known as “hard automation”. Fixed automation can be expensive to set up initially
due to the equipment required, but in return, it provides high production rates. However, it is relatively inflexible
when it comes to making changes to the product. This is relatively useful for many companies who use automation
to create food products of one type and variant. It allows them to effectively produce that item and package it in
bulk.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 Advantages of fixed automation include:

 High levels of production

 Consistent quality in production
 Low cost per unit produced

Disadvantages of fixed automation include:

 High initial cost

 Difficult to accommodate changes

This type of automation is best suited for: High demand and generic products that require no change. Coca
Cola continues to use this automation in their factories. As seen above, this allows for the production of large
quantities of the soft drink, allowing Coca Cola to meet the high demands of their classic soft drink.

3.2 Programmable automation

Programmable automation allows the production equipment and automation to be altered to changing needs. This
is done by controlling the automation through a program, which can be coded in certain ways for the automation
to change the sequence of automation. It’s used more commonly in low to medium levels of production, often
being most suitable for batch production.
Programmable automation will often be used by factories who make different variants of foods. This allows them
to make batches, from a few dozen to potentially thousands at a time, of one product. If the product needs
changing, it simply needs to be reprogrammed.

Advantages include:

 Flexibility to change products if needed

 Suitable if batch production is required.

Disadvantages include:

 Expensive for equipment

 Lower production levels
 Often time-consuming to change products

This type of automation is well suited for: Low/Medium demand and occasional changes in products.

3.3 Flexible automation

Flexible automation, also known as “soft automation”, is similar to programmable automation, although a little
more complicated. Essentially, flexible automation enables the production of different types of products without
losing time when reprogramming.
A flexible automation system can produce various combinations of products efficiently without having to separate
them into different batches, as required in batch production. This type of automation tends to have medium levels
of production.

Advantages include:

 Flexibility of products
 No time lost with new changes to production

Disadvantages include:

 High custom machinery/automation cost

 Higher cost per unit

There are essential differences in establishing flexible automation from programmable automation. A flexible
automation system will be able to change the physical setup as well as programs, with no loss in time and
productivity.
Altering the part programme is usually done by coding the program offline on a computer and then transferring it
to the automated system.
This type of automation is best suited for: Medium demand and constant changes/large variety in products.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 4. Part handling in automation
Part handling is a crucial component of automation, influencing the efficiency, precision, and reliability of
manufacturing processes. In automated systems, part handling involves the movement, orientation, and
transportation of components between different stages of production. It is essential for feeding parts into machines,
moving them between workstations, and ensuring the correct alignment for subsequent operations. Effective part
handling systems are key to reducing manual labor, minimizing errors, and improving productivity in automated
production lines.

4.1 Principles of part handling

 Consistency and Repeatability: Automated systems must handle parts in a consistent and repeatable
manner to ensure uniform quality. Consistent part positioning and movement reduce variability and defects.
 Precision in Part Orientation: Many operations require accurate part orientation. Automated systems like
robotic arms or vision-guided equipment ensure parts are correctly aligned for processes like assembly or
inspection.
 Speed and Efficiency: Automation aims to improve the speed of part handling to increase productivity
without compromising accuracy. High-speed conveyors and fast robotic systems are key for reducing cycle
times.
 Flexibility and Adaptability: Part handling systems must adapt to variations in part size, shape, and weight.
Flexible systems, such as adaptive robots and adjustable conveyors, accommodate diverse parts without
frequent reconfiguration.
 Minimization of Human Intervention: Reducing manual handling lowers labor costs, improves safety, and
minimizes errors. Automated systems are designed to function with minimal human input, requiring only
occasional supervision or maintenance.
 Safety: Safety mechanisms, such as sensors, light curtains, and emergency stops, are essential to protect
workers and ensure safe interaction with automated systems.
 Error Detection and Recovery: Automated systems integrate sensors and vision systems to detect misaligned
or damaged parts, ensuring errors are corrected in real-time or halting operations to prevent further issues.

4.2 Benefits of automated part handling

 Increased Productivity: Automation allows for continuous, high-speed operation, leading to faster
production rates and reduced cycle times. Systems like conveyors and robotic arms can handle large volumes
of parts efficiently, minimizing bottlenecks and maximizing throughput.
 Precision and Accuracy: Automated systems provide precise and repeatable handling of parts, reducing
human error. This is crucial in industries requiring high accuracy, such as electronics and automotive
manufacturing, where even small misalignments can result in defects.
 Cost Reduction: By reducing the need for manual labor, automation lowers labor costs and minimizes the
risk of workplace injuries. Although the initial investment in automation equipment is high, the long-term
savings from reduced labor and fewer errors outweigh the costs.
 Improved Safety: Automated systems handle hazardous or heavy parts, minimizing the risk of injury to
workers. Equipment like robotic arms and AGVs can perform dangerous tasks safely, while safety features
such as sensors and emergency stops enhance overall workplace safety.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
  Consistency and Quality Control: Automation ensures consistent part handling, improving product quality.
Systems perform repetitive tasks without fatigue, maintaining high levels of precision and uniformity, which
is critical in industries with stringent quality standards.
 Flexibility and Scalability: Modern automation systems are highly flexible, capable of handling various
part sizes and shapes. They can be reprogrammed for new tasks, making them adaptable to changes in
production requirements and scalable for future growth.

4.3 Types of Part handling systems

Various part handling systems are designed to suit different applications and industries. They can be broadly
categorized into:

i) Conveyor Systems
Conveyors are a fundamental part of many automated systems and are used to transport parts from one station to
another. They come in various types, including belt conveyors, chain conveyors, and roller conveyors.
 Belt Conveyors: These are commonly used for moving parts between workstations. They are reliable,
cost-effective, and can handle a wide variety of products in terms of size, weight, and shape.
 Chain Conveyors: Ideal for handling heavy loads, chain conveyors are frequently used in industries like
automotive and aerospace.
 Roller Conveyors: These systems use a series of rollers to move parts, often found in warehouses and
assembly lines for lightweight materials.
Conveyor systems are highly flexible and can be integrated with sensors, robotic arms, and vision systems to
increase their efficiency. They are suitable for moving parts over long distances and across multiple stations in
large production lines.

ii) Robotic Arms

Robotic arms are one of the most versatile components in part handling systems. They are programmed to pick
up, move, and place parts with high accuracy and speed.
 Pick-and-Place Robots: These robots are used for handling small parts and are commonly found in the
electronics industry for placing components on circuit boards.
 Articulated Robotic Arms: These are more advanced and are used for tasks requiring greater dexterity,
such as welding, painting, or assembly in industries like automotive and aerospace.
Robotic arms can be equipped with specialized end-effectors, such as grippers, magnets, or vacuum cups,
depending on the type of part being handled. Their precision and repeatability make them essential for applications
that require delicate or precise handling.

iii) Automated Guided Vehicles (AGVs)

AGVs are mobile robots used to transport parts and materials in factories and warehouses. They are equipped with
navigation systems and can move autonomously along predefined paths or adapt to real-time changes in the
environment.
 Laser-Guided AGVs: These use laser sensors to navigate through the production environment, ensuring
accuracy and collision avoidance.
 Vision-Guided AGVs: Equipped with cameras and vision processing software, these AGVs can make
decisions based on visual cues, such as the location of a part or an obstacle.
AGVs are used in industries that require material handling over large distances or across different production
zones, such as automotive manufacturing and distribution centers.

iv) Vibratory Bowl Feeders

These systems are commonly used to orient and feed small parts in high-volume production environments.
Vibratory bowl feeders work by vibrating the parts so that they move in a controlled manner, typically along a
circular track, until they are properly aligned for the next operation.
 Advantages: They are suitable for handling small parts that require precise orientation and are commonly
used in the pharmaceutical, electronics, and automotive industries.

v) Palletizing Systems
Palletizers are automated systems used for stacking parts or products onto pallets for storage or transport. They
can be classified as robotic palletizers or conventional palletizers.
 Robotic Palletizers: Use robotic arms to stack products on a pallet based on predefined patterns.
 Conventional Palletizers: Use conveyors and mechanical arms to arrange products for palletizing.
Palletizing systems are particularly useful in industries like food and beverage, packaging, and logistics, where
speed and accuracy in stacking are essential.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 4.4 Challenges in Part handling

 Part Variability: In many industries, parts come in different shapes, sizes, and weights, which can pose a
challenge for automated systems. For example, a conveyor system designed for one part may not be suitable
for another. This requires flexibility in part handling systems, which can be achieved through advanced
sensing, vision systems, and reconfigurable machinery.
 Orientation and Alignment: Many automated operations require parts to be oriented or aligned in a specific
way for subsequent processes, such as assembly or inspection. Improper alignment can result in defects,
rework, or equipment damage. This makes precise orientation systems, such as vision-guided robots and
vibratory feeders, essential in part handling.
 Space Constraints: In some production environments, space is limited, which makes it challenging to design
and implement efficient part handling systems. Manufacturers must optimize the layout of conveyors, robots,
and storage systems to maximize floor space while maintaining high throughput.
 Safety: Ensuring the safety of human workers around automated part handling systems is crucial. Safety
measures, such as light curtains, sensors, and emergency stops, are essential to prevent accidents and ensure
that human-machine interaction occurs safely.

5. Computer control of Machine Tools/ CNC

Computer Numerical Control (CNC) refers to the automation of machine tools through the use of computers that
execute pre-programmed sequences of machine control commands. Unlike manual machining, where an operator
controls the machine, CNC allows for precise, automated machining of complex designs, enhancing speed,
accuracy, and consistency.
CNC systems are widely used in manufacturing processes for tasks such as cutting, drilling, milling, and turning.
These systems can control various types of machinery, including lathes, mills, routers, and grinders. The process
begins with creating a CAD (Computer-Aided Design) model of the part or product, which is then converted into
G-code, the CNC programming language. This code contains instructions for the machine, guiding its movements
along different axes to cut or shape the material accordingly.

The CNC machine depends on digital instructions made by CAD and CAM software to function optimally. The
CAD software makes the design, while the CAM converts the CNC design to a G-code which the CNC machine
can read.

5.1 Basic Elements of CNC Machine System

Below are elements or parts generally found in a CNC machine system:

 Information input/output devices include disk drives, special information devices, keyboards, and computers.
 Internet connection which could include Ethernet, HSSB (High-speed data transmission port), Processing
LAN, RS 232C port, and other networks
 External mechanical shaft control unit, such as exchange bench, unloading, and loading robot, the drive shaft
of the tool magazine
 Feed servo drive and motor unit
 Spindle motor and drive unit
 CNC control unit (numerical control part)
 PMC controller
 Feedback and position measurement unit of the machine
 Input and output unit of the control signal of the machine’s power cabinet

5.2 Different Types of CNC Machines

(i) Mill CNC Machine

CNC milling machine types remove material from a workpiece and precisely shape it to the required specifications
using high-speed cutting tools. Furthermore, milling machine cutter types come in a wide variety and serve various
functions. A few common examples include end mills, reamers, face mills, taps, and drills.
However, the size it can machine depends on the enclosure size housing the machine and the highest distance the
cutting tools can travel.

(ii) Lathe CNC Machine

The way CNC lathe machines operate is by rotating the material of the workpiece about a primary axis. The lathe
cutting tools remove the material from the workpiece and shape it as needed.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 CNC lathe machines are perfect for various tasks, including swiss machining, drilling, knurling, turning, and
sanding. CNC machines in this category have applications in producing automobile parts, camshafts, crankshafts,
musical instruments, gun barrels, baseball bats, and furniture.
However, due to the way this machine manufactures products, it is better to make symmetrical parts.

(iii) Drilling CNC Machine

The Drilling machine is one of the most popular CNC machines found in most CNC machine shops. Furthermore,
the drilling CNC machine uses a specialized cutting tool called drill bits or drill. It is ideal for drilling holes in
materials that hold screws, aesthetic requirements, or secondary assembly purposes.
Drilling CNC machines have applications in automobile manufacturing, astronautics, shipbuilding, mold making,
engineering machinery, furniture making, and other wood works.
One major limitation of the machine is the dimension of the hole it can create. It is challenging to create holes that
are deep or large enough without specialized drill bits.

(iv) Grinding CNC Machine

This machine uses a grinding wheel to remove materials from a workpiece. The grinding machine types function
primarily for sanding, polishing, or finishing. The material used for making the grinding wheel could be ceramic-
blend or diamond. However, you should know that diamond grinding wheels often provide high-quality secondary
finishing.
However, this CNC grinding machine removes materials from a workpiece at a very slow rate. This is why it finds
use primarily as a finishing or smoothening machine.

(v) Laser Cutting CNC Machine

This CNC machine shapes products or parts using a highly focused laser beam. The laser beam cuts through the
materials regardless of their conductivity to create the desired product or shape. Additionally, laser-cutting CNC
machines have applications in three major industries: aerospace, automobile, and medical.
However, one of the limitations of a laser cutting CNC machine is the 2.75 inches maximum thickness of the
material you can cut with it.

(vi) Plasma Cutting CNC Machine

A CNC plasma cutting device produces a very precise cut. It ionizes the air and melts the material in its path using
an electrical discharge arc (similar to a plasma torch). The procedure only works with electrically conductive
materials since it involves an electrical arc.
The plasma-cutting is a popular machine used in large-scale industries and hobbyist shops. It aids in industrial
construction, automotive repair and restoration, and scrapping operations.
However, these machines produce tremendous heat as they cut materials by melting them. This heat often affects
the surface finish of the cut material, resulting in heat-affected zones.
Another limitation is that this machine has a restrictive range of materials it can cut, as it only cuts through metals
and other conductive alloys.

(vii) Waterjet Cutting CNC Machine

This machine cuts through materials using a thin jet of water. CNC water jet cutting is one of the most adaptable
processes due to its capacity to cut through any material.
Waterjet cutting machine is quite versatile, as it can shape rubber, leather, fiberglass, nappies, circuit boards, foam,
paper, ceramic, glass, stone, and sheet metal.
One of the biggest downsides is the waterjet cutting speed is slower than other cutting alternatives. This slower
speed is especially evident around the curved cuts and corners.

(viii) EDM (Electric Discharge Machine)

The EDM uses an electrical arc to remove materials from a workpiece. It functions similarly to the plasma cutter.
Besides, this machine produces parts through a non-contact process, and machines parts regardless of hardness.
Nevertheless, this machine works only on conductive materials like plasma cutting. In other words, you cannot
use this machine to fabricate ceramics, wood, plastics, and other materials that do not conduct electricity.

(ix) CNC Router Machine

CNC routers can cut a variety of forms and patterns on flat surfaces of any material. The CNC router machine is
used to fabricate musical instruments, signage, door carvings, moldings, and interior and exterior decorations.
However, the overall operation of the CNC router machine can be quite noisy due to its different components.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 (x) Multi-Axis CNC Machine

This CNC machine can move in four or more directions or axes. Compared to a two or three-axis machine, multi-
axis machining is more complex and produces more accurate parts. It also offers machinists greater machining
flexibility. Besides, machines in this category range from 4-axis machines up to 12-axis machines.
Machines in this category are quite different from 2 and 3-axis machines and often require the expertise of a
professional to function optimally.

(xi) 3D Printer

A 3D printer uses a digital file to create 3D solid objects. Unlike other processes discussed in this article, 3D
printing is an additive manufacturing process. It is a process that successively creates products by adding materials
to each other.
However, the cost of procuring this CNC equipment and manufacturing components using this process are quite
high. Also, 3D printing speed is slow, especially when used for mass production processes.

(xii) CNC Automatic Tool Changer

Also known as ATC is a variation of different types of CNC machines. However, what this machine does is
automatically change the machine cutting tool. This increases the production speed and reduces lead time.
The ATC carries out this switch for two major reasons: replacing a broken or worn-out tool and swapping out a
wrong tool for the right one.

5.3 Types of CNC Machines by Number of Coordinate Axes

(i) 2-Axis CNC Machines

The most fundamental CNC systems available are 2-axis CNC machines. Machines in this category move in the
X-axis (horizontal) and Y-axis (Vertical).
Typically, these machines produce precise straight cuts, drill holes in boards, or process just one workpiece surface
without moving it.

(ii) 3-Axis CNC Machines

The most prevalent kind of CNC machine is the 3-axis machine. Like the 2-axis machines, machines in this
category also work on immobile workpieces. These machines can work on the fundamental pieces in 2.5
dimensions. 3-axis CNC machines move in the conventional X and Y axis, with an additional Z axis for depth.

(iii) 4-Axis CNC Machines

This machine has an A-axis, known as the axis of rotation, and the X, Y, and Z axes. This axis enables the rotation
of the cutting tool along the X-axis. Cutouts and arc cutting are also excellent uses for these machines.

(iv) 5-Axis CNC Machines

5-axis CNC provides the cutting tool with a pivoting motion along an axis called the C-axis. The C-axis is the
axis on which turning and pivoting occur.
These machines can machine five surfaces of material concurrently with the work surface remaining stationary,
which allows them to produce intricate and precise parts. These machines are extremely helpful in making
equipment used in the medical industry because of their excellent accuracy.

(v) 7-Axis CNC Machines

On CNC machines in this category, there are seven axes: three conventional axes for the workpiece’s rotation,
three for the cutting tool’s movement, and one for the arm’s rotation, known as the E-axis, this axis.
Due to the complexity of the parts they can make, these machines frequently produce aeronautical, medical, and
military equipment.

(vi) 9-Axis CNC Machines

A combined CNC system with a 5-axis milling machine and a 4-axis lathe machine is a 9-axis CNC machine. The
lathe completes the workpiece’s internal features, while the milling machine works on the surface to achieve the
necessary surface finish.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 For this reason, it is easier to produce interior and external parts’ features using a 9-axis machine. Dental implants,
medical instruments, and sophisticated aircraft equipment can all be produced using these devices.

(vii) 12-Axis CNC Machines

The 12-axis machines have two cutting heads that can move in X, Y, Z, A, B, and C axes. These machines increase
production speed while also increasing precision by orders of magnitude.

5.4 Types of CNC Machines According to Moving Trail

(i) Point Control

In a point control system, the moving components of CNC machines are only controlled precisely from one point
to another without being machined in the process. If simultaneous positioning is not required, this positioning is
the most cost-effective system that you can use for reverting, tapping, spot welding, and drilling.

(ii) Linear Control

Together with precisely arranging the moving components of CNC machines from one location to another, linear
control systems also regulate the pace and trajectory of movement between two connected sites.
With a parallel coordinate axis, this control ensures linear cutting movement. This is why they often finds
application in simple CNC milling and grinding machines.

(iii) Contouring Control

The workpiece moves following the programmed trajectory and speed relative to the cutter under the control of
the contouring control system, which also coordinates the motion of multiple feed shafts simultaneously. This
allows for continuous cutting to occur while the movement is being made.
Contour control makes processing plane curves or spatial surface contours easier. It finds application in CNC
grinders, milling, and turning machines.

5.5 Types of CNC Machines Divided by Servo System

(i) Open Loop Control System

A detection and feedback device is not present in an open-loop control system. The driving circuit amplifies the
power before the CNC device’s instruction signal, which is transmitted in a single direction, drives the stepping
motor that moves the machine table.One benefit of the open-loop control system is its low pricing, which makes
it affordable. On the downside, it has poor accuracy and stability, reducing the work quality.

(ii) Semi-Closed Loop Control System

The worktable’s actual displacement is calculated using a semi-closed loop control system’s angular displacement
detection device installed directly at the end of the servo motor shaft or ball screw.
This device compares the calculated value with the worktable’s original instruction displacement value and then
controls using the difference. This system’s pricing is moderate, but precision and stability are high.

(iii) Closed-Loop Control System

A closed-loop control system uses a linear displacement-detecting device mounted on the machine tool’s moving
parts or tabletop. The CNC device’s comparator receives the actual displacement discovered and compares it to
the value of the program instruction.
Controlling the stability of a closed-loop control CNC machine is quite difficult. However, this machine
guarantees high precision.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 6. Machining centres
A machining center (MC) is an advanced computer-controlled machine tool that can be used for performing a
variety of machining operations and processes. Unlike traditional machines that feature turrets or other
mechanisms of manual tool change, an MC consists of an automatic tool-changing mechanism (ATC), allowing
for multiple cutting tools to be utilized during the machining process.
This enables quick changes of the cutting tool, thus improving production efficiency and reducing cycle time. The
core of an MC lies in its versatility, accuracy, and ability to handle complex operations like milling, turning,
boring, drilling, and more.

6.1 Main elements of machining centre

(i) Main Spindle Area

The main spindle area is responsible for holding the cutting tools and providing the necessary rotation for
machining operations. It houses the motor drives and spindle head, contributing to the accuracy and efficiency of
the process. The spindle area plays a pivotal role in achieving desired surface finishes and precision in workpieces.

(ii) Taper Feed Mechanism

The taper feed mechanism is an essential part of the machining center that allows for the precise positioning and
movement of the cutting tools. It controls the depth and orientation of the tools, ensuring smooth and accurate
cuts. This mechanism works in coordination with the servo motor, making it a crucial component in determining
the quality of the finished product.

(iii) Automatic Tool Changer (ATC) System

The automatic tool changer (ATC) system is a groundbreaking feature in machining centers. It provides quick and
efficient tool changes, reducing manual intervention and cycle time. The ATC system includes a tool magazine
where different cutting tools are stored, enabling the machine to switch between tools seamlessly. This enhances
production efficiency and offers versatility in machining operations.

(iv) Tool Magazine

The tool magazine is an integral part of the ATC system. It stores various cutting tools such as end mills, drills,
and more, providing a central repository for the tools needed in the machining process. The tool magazine ensures
that the correct tool is selected and placed in the spindle, facilitating quick changes and continuous operations.

(v) Automatic Pallet Changer (APC) System

Designed to increase throughput and minimize downtime, the automatic pallet changer (APC) system automates
the loading and unloading of workpieces. The APC system consists of multiple pallets that can be preloaded with
raw material, allowing for uninterrupted machining. This automation significantly enhances production
efficiency, reducing manual handling and errors.

(vi) Chip and Coolant Handling System

Machining processes generate chips and require cooling to maintain tool life and part quality. The chip and coolant
handling system manages these aspects, collecting chips through chip conveyors and providing the necessary

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 coolant to the cutting area. This system ensures a clean and efficient working environment, contributing to the
machine’s longevity and performance.

(vii) Overload and Wear Detectors

Machining centers are equipped with overload protection devices and wear detectors to monitor tool wear and
machine performance. These sensors detect abnormal conditions, such as tool breakage or excessive load, and
provide alerts to prevent potential damage. These features add a layer of safety and reliability, ensuring consistent
quality and minimizing unplanned downtime.

(viii) Automatic Door Operation Mechanism

Modern machining centers often include an automatic door operation mechanism that provides easy access to the
work area. This feature adds convenience and safety, allowing operators to load and unload workpieces
effortlessly, without the need to manually open and close heavy doors.

6.2 Main axes of a machining center

Machining centers function on various axes to control the movement of the cutting tool and the workpiece. The
coordination of these axes ensures precise cuts and intricate designs. Here’s a breakdown of the main axes and
their purposes:
 X-Axis: Controls the left and right movement of the tool or worktable.
 Y-Axis: Governs the forward and backward movement of the tool or worktable.
 Z-Axis: Manages the up and down movement of the tool or worktable.
 A-Axis: Controls the rotation around the X-axis.
 B-Axis: Handles the rotation around the Y-axis.
 C-Axis: Responsible for the rotation around the Z-axis.
Together, these axes provide complete control over the position, orientation, and movement of the cutting tool,
allowing for complex and precise machining processes.

6.3 Different types of machining centres

(i) Horizontal Machining Center (HMC)

A horizontal machining center (HMC) is defined by its horizontal orientation of the spindle. With powerful rigidity
and robust construction, these machines are tailored for handling hefty workpieces.
An HMC typically comprises an automatic pallet changer (APC) system with six to eight pallets, which allows
continuous work on different pieces without manual intervention. Designed for large-scale production, HMCs are
known for high material removal rates (MRR). Their horizontal setup allows for efficient machining of up to 4
surfaces without reorienting the workpiece. The metal chips fall away from the workpiece, preventing
accumulation and enhancing the suitability for operations like boring. Some HMC models even feature a spindle
that can rotate to a vertical position, falling under the universal machining center category.
Commonly used in the manufacturing of components like automotive parts and gears, brands like Mazak produce
HMCs known for their reliability and performance.

(ii) Vertical Machining Center (VMC)

A vertical machining center (VMC) is characterized by a vertically aligned spindle, offering accessibility and
adaptability. These centers typically include ATC and APC systems but with a more compact design, making
them suitable for smaller spaces or individual users.
The vertical alignment of the spindle means that metal chips can accumulate on the surface of the workpiece and
need to be cleared. With options ranging from 3-axis to 4-axis models, VMCs can access workpieces from various
angles without manual adjustment.

(iii) Universal Machine Center (UMC)

A universal machining center (UMC) stands out for its capability to orient the spindle both horizontally and
vertically. Often encompassing 5-axis systems or higher, UMCs can access a workpiece from multiple sides in
one setup, allowing intricate machining processes. A 5-axis UMC, for example, moves the cutting tool along X,
Y, and Z linear axes while rotating on the A and B axes. This results in exceptional precision when crafting
components like aerospace parts or complex molds. Using shorter cutting tools with extensive speed ranges,
UMCs minimize vibration and boost production efficiency, all while reducing cycle times.
A fusion of the features of HMCs and VMCs, UMCs represent an adaptable solution for many industries. Brands
like DMG MORI are renowned for their state-of-the-art UMC models. 3E Rapid Prototyping (3ERP),
an ISO9001-2015 certified provider of CNC machining services, has 18 machining centers, ranging from 3-axis

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik
 to 5-axis models, which ensure each project is of high quality and capable of overcoming the challenges of tight
tolerances and complex geometries.

6.4 Typical operations performed on a machining center

 Milling: Milling involves removing material to shape the workpiece using rotary cutters. It can be used to
produce a wide variety of complex shapes and features, such as slots, pockets, and even complex surface
contours, making it one of the most versatile machining operations.
 Drilling: Drilling is the process of creating holes in the workpiece. It is performed using a rotating cutting
tool, usually a drill bit, that moves along the axis of the hole. Drill bits come in various sizes and types,
allowing for a range of hole diameters and depths.
 Boring: Boring is used to enlarge existing holes with high precision. Unlike drilling, which creates a hole,
boring fine-tunes the diameter to precise tolerances. Boring can also be used to correct any misalignment in
the hole, ensuring that it is perfectly cylindrical.
 Tapping: Tapping involves cutting threads inside a hole, providing a path for screws or other threaded
objects. The process uses a specialized tool known as a tap that’s threaded in a manner corresponding to the
desired thread pattern. It’s essential for applications requiring the secure fastening of components.
 Grinding: Grinding achieves fine surface finishes through the use of an abrasive wheel. Unlike milling or
turning, grinding removes material very slowly in small amounts, allowing for extremely precise control of
the surface’s shape and finish. It’s often used to finish parts that require smooth surfaces or tight tolerances.
 Reaming: Reaming fine-tunes the size of drilled holes, offering a higher degree of accuracy than drilling
alone. A reamer, which is a specialized tool with cutting edges, is used to slightly enlarge the hole and
improve its finish and alignment. Reaming ensures that the holes are of the exact size and perfectly round.

Sub: Automation in Manufacturing Sub code: MEC701 Prepared by: Dr. Lokeswar Patnaik