AUTOMATION

IPE 4101 MACHINE TOOLS AND MACHINING

 WHAT IS AUTOMATION?

 Automation enables processes to occur automatically — i.e.,

immediately and without human labor.
 In many cases, monitoring of processes can be automated, as
well. Monitoring will often include summary statistics for key
measurements, and can even be integrated with automated
recommendation systems.
 Automation will transform a wide variety of vital job functions
across industries such as robotics, cyber security, wireless
applications and banking.
 Automation experts are already helping various industries
navigate complicated problems in their workflow processes;
the revolution is here.
 Automation provides benefits across all industries.
While the following list is by no means exhaustive,
it provides a sense the benefits.
• Improved quality
• Consistency
• Time savings
• Metric visibility
• Enhanced operational efficiency
• Better governance
• Reliability
• Reduced turnaround times
• Reduced costs of operations
 In the technology sector, the impact of
automation is soaring and evolving at a rapid
pace, covering both hardware and software
segments.
 Similarly, in the healthcare industry,

automation is making huge waves improving

treatment, patient experience and provider
well-being.
MAIN CATEGORIES OF AUTOMATION
 FIXED AUTOMATION

 If the automation repeats the same tasks with

identical units, it is Fixed Automation.
 Also known as Hard Automation, Fixed Automation
involves the employment of specific-purpose
equipment to automate a repetitive sequence of tasks,
processing or assembly operations.
 Generally, the operational sequence is not complex,
involves fundamental functionalities like rotational or
plain linear motion, or an amalgamation of both.
 ADVANTAGES AND DISADVANTAGES OF FIXED
AUTOMATION

 The advantages of fixed automation are

 improved rate of production,
 low cost of the unit, and
 the automation of the material handling
process.
 The most notable limitation, here,
 Is that Hard Automation units must be
replaced when new tasks need to be
completed.
 PROGRAMMABLE AUTOMATION

 Programmable Automation allows for fresh programs to

be designed and deployed to the system to implement
new processes. Both traditional thermostats and
traditional cruise control are examples of
programmable automation — you set a speed or
temperature and the mechanisms consistently produce
the programmed outcome.
 Whereas with fixed automation, automation is designed
with only one set of operation sequences,
 Programmable Automation allows for reprogramming
for different tasks after a batch of one type is complete.
 ADVANTAGES AND DISADVANTAGES OF
PROGRAMMABLE AUTOMATION

 The main advantage of the programmable

automation is greater flexibility to deal with
the variation of designs.
 While it is the best-fit for batch production
of a variety of designs, it produces fewer
units than both Fixed and Flexible
Automation because of the changeover-time
between functions.
 FLEXIBLE AUTOMATION

 This automation type is an extension of programmable

automation that has the capacity to produce a spectrum of
products with next-to-zero downtime and no complicated
change-over manual procedure, which means greater
production rate.
 Because there is no need for complex reprogramming,
Flexible Automation can switch between tasks.
 Think to our thermostat and cruise control examples.
Modern adaptive cruise control and self-learning thermostats
are examples of Flexible Automation — users don’t need to
reprogram the mechanisms to change their outcomes.
 In manufacturing, because there is no need for
batch production, tasks can be completed on
demand.
 Flexible Automation enables automatic and
rapid changes to programmed sequences, such
as production of design variations, with
virtually no down-time.
 In short, Flexible Automation allows for a
variety of procedure outcomes and high output.
CONSTRUCTION OF CAPSTAN LATHE
CAPSTAN LATHE
 In the bar feeding mechanism, the bar is pushed after the
chuck is released without stopping the Lathe Machine.
 We use this mechanism for minimizing the setting time.
The bar is passed through the pedestal bushing, bar
holding chuck, headstock spindle, and the collet chuck.
 The collet chuck is screwed on the headstock spindle and
holding the feed bar and also helps the bar to rotates as
per spindle speed. Bar holding chuck rotates within the
sliding block with the rotation of the feeding bar. Also,
you can see a rope and a deadweight in this mechanism.
 One side of the rope is attached with the sliding block with
the help of pin and another side of rope passes through 2
different pulleys and then connecting with a deadweight at
its end.
 So now when the collet chuck released by the lever the dead
weight tends to move in the downward direction, due to this
it exerts thrust on the bar holding chuck and feed the bar
until it touches the workshop. As we already have seen that
Capstan Lathe is best for bar types jobs that’s why we are
generally seeing Bar Feeding Mechanism on Capstan Lathe.
RACHET MECHANISM FOR TURRET INDEXING
 AUTOMATIC LATHE

 These are machine tools in which components are

machined automatically.
 The working cycle is fully automatic that is
repeated to produce duplicate parts with out
participation of operator.
 All movements of cutting tools, their sequence of
operations, applications, feeding of raw material,
parting off, un loading of finished parts all are done
on machine.
 All working & idle operations are performed in
definite sequence by control system adopted in
automatic which is set up to suit a given work.
 Only operation reqd to be performed manually is
loading of bar stock/ individual casting/ forged
blanks.
 These machines are used when production
requirements are too high for turret lathes to
produce economicall
 ADVANTAGES

 Greater production over a given period.

 More economy in floor space.

 More consistently accurate work than turrets.

 More constant flow of production.

 Scrap loss is reduced by reducing operator error.

 During machine operation operator is free to

operate another machine/ can inspect completed
parts.
 SEMI AUTOMATICS

 These are turning machines used for chucking

work.
 In this type of lathes although all movements of
w/p (or) tools are automatically controlled, but
w/p has to be loaded into & removed from chuck
at beginning & end of each cycle of operation.
 Machine cycle is automated, but direct
participation of operator is required to start
subsequent cycle, i.e., to machine each w/p.
 Operator work is to load w/p or blank into
machine, start the ma/c, checks the work, &
removes the completed part by hand.
 AUTOMATICS & SEMI AUTOMATICS are
designed to perform following operations:
 • Centering, cylindrical turning, tapered, formed
surfaces, drilling, boring, reaming, facing, knurling,
thread cutting, facing, milling, grinding, cut off.
 • With help of special attachments additional
operations like slotting can be done on this m/c.
.
 SELECTION OF LATHE :

 Same job can be machined on engine, capstan,

turret, automatic lathes .
 Main considerations are:

• Quantity of production reqd.

• Number of machining operations to be done on job,
number of tools reqd. to employed.
• Over all dimensions of that portion of job which is to
be machined
 CLASSIFICATION OF AUTOMATIC
LATHES
 • Depending up on type of work machined these
machines are classified as:
 1. Magazine loaded Automatics:

1. • Machines used for producing components from

separate blanks.
2. • Also called as automatic checking machines.
 2. Automatic Bar Machines:
1. • designed for machining components from bar/ pipe
stock.
2. • M/c’s are used for manufacture of high quality fasteners
(screws, nuts), bushings, shafts, rings, rollers, handles
which are usually made of bar / pipe stock.
 Depending upon number of work spindles,
automatic lathes are classified as:
1. Single Spindle Automatics.
2. Multi Spindle Automatics.
 • Depending upon purpose & arrangement of
spindle also automatics are classified as:
1. Purpose- General & single purpose m/c.
2. Arrangement of spindle- Horizontal & vertical
 I) TYPE OF SINGLE SPINDLE AUTOMATICS

 a) Automatic Cutting Off Machine:

 These machines produce short w/p’s of simple
form by means of cross sliding tools.
 Machines are simple in design.
 • Head stock with spindle is mounted on bed.

 • 2 cross slides are located on bed at front end of

spindle.
 • CAMS on cam shaft actuate movements of
cross slide through system of levers.
 OPERATION:

 •The reqd. length of work(stock) is fed out with a

cam mechanism, up to stock stop which is
automatically advanced in line with spindle axis at
each end of cycle.
 • Stock is held in collet chuck of rotating spindle.

 • Machining is done by tools that are held in slides

operating only in cross wise direction.
 • Typical simple parts (3 to 20 mm dia) machined
on such a machine is shown in fig.
B) SINGLE SPINDLE AUTOMATIC SCREW M/C
 B) SINGLE SPINDLE AUTOMATIC SCREW M/C

 • Used for producing small screws(12.7 to 60 mm dia)

generally, but also in production of all sorts of small turned
parts.
 • These are completely automatic bar type turret lathes,
designed for machining complex internal & external
surfaces on parts made of bar stock/separate blanks.
 • Up to 10 different cutting tools can be employed at one
time in tooling of this kind of screw machine.
 • 2 cross slides(front & rear) are employed for cross
feeding tools.
 B) SINGLE SPINDLE AUTOMATIC SCREW M/C

 • Vertical tool slides for parting off operation may

also be provided .
 • Head stock is stationary & houses the spindle.
 • Bar stock is held in collet chuck & advanced
after each piece is finished & cut off.
 • All movements of machine units are actuated by
cams mounted on cam shaft.
 B) SINGLE SPINDLE AUTOMATIC SCREW M/C

 • Bar stock is pushed through stock tube in a bracket & its

leading end is clamped in rotating spindle by means of
collet chuck.
 • By stock feeding mechanism bar is fed out for next part.

 • Machining of central hole is done by tools that are

mounted on turret slide.
 • Parting off/ Cutting off, form tools are mounted on cross
slide.
 • At end of each cut turret slide is with drawn automatically
& indexed to bring next tool to position.
 SWISS TYPE AUTOMATIC LATHE

 The headstock travels enabling axial feed of the bar stock

against the cutting tools as indicated in figure.
 There is no tailstock or turret

 High spindle speed (2000 – 10,000 rpm) for small job diameter

 The cutting tools (up-to five in number including two on the

rocker arm) are fed radially.
 Drilling and threading tools, if required, are moved axially using
swivelling device(s)
 The cylindrical blanks are prefinished by grinding and are
moved through a carbide guide bush as shown.
SWISS TYPE AUTOMATIC LATHE
KINEMATIC SYSTEM OF SWISS TYPE AUTOMATIC
LATHE