This document discusses automation in machining operations. It describes how flexible manufacturing systems (FMS) use computer numerical control (CNC) machine tools linked by material handling systems to process multiple product styles simultaneously. FMS can be controlled through either program sequence control using relays and switches or numerical control (NC) using coded instructions. The document also discusses how robots are used for repetitive or hazardous tasks and how various transfer systems like rotary indexing machines, trunnion machines, and transfer lines automate material flow between machining stations.

1. AUTOMATION IN MACHINING
OPERATIONS
Kiran Vinu
1MS19MSE01-T

2. CONTENTS
 Automation
 Elements of automated system
 Automation in Machining
o Flexible Manufacturing System
 Program Sequence Control
 Numerical Control
o Robots
o Transfer System
 Rotary Indexing Machine
 Trunnion Machine
 Centre Column Machine
 Transfer Line
 Part Feeding Devices

3. AUTOMATION
 The technology by which a process or procedure is
accomplished without human assistance.
 It is implemented using a program of instructions
combined with a control system that executes the
instructions.
 3 types:
 Fixed automation
 Programmable automation
 Flexible automation

4. ELEMENTS OF AN AUTOMATED SYSTEM
 Power to accomplish the process and operate the
system
(electric power, fossil fuel, atomic power, water, air)
 A program of instructions to direct the process
 A control system to actuate the instructions
 Closed Loop System
 Open Loop System

5. WHY SHOULD WE AUTOMATE ?
 Higher production rates
 Better product quality
 Improved safety
 Reduction in production time
 Increase in accuracy and repeatability
 Less human error
 Less employee costs
 More efficient use of materials

6. AUTOMATION IN MACHINING
Flexible Manufacturing System (FMS)
 A flexible manufacturing system (FMS) is a form of
flexible automation in which several machine tools
are linked together by a material-handling system,
and all aspects of the system are controlled by a
central computer.
 An FMS is distinguished from an
automated production line by its ability to process
more than one product style simultaneously.
 Ideal when demand for the products is low to
medium and there are likely to be changes in
demand.

7.  The components of FMS:
 Processing machines, which are usually CNC
machine tools that perform machining operations
 A material-handling system, such as a conveyor
system, which is capable of delivering work parts to
any machine in the FMS.
 A central computer system that is responsible for
communicating NC part programs to each machine
and for coordinating the activities of the machines
and the material-handling system.
 Two basic forms
 Program sequence control
 Numerical control

8. PROGRAM SEQUENCE CONTROL
 The sequence of motions and switching is
controlled by relays, timers, switches, perforated
tape, plug boards and other controllers.
 Each line presents a different movement or switch.
It has to be printed correctly.
 There is no error control.

10. NUMERICAL CONTROL (NC)
 Numerical control is a form of programmable
automation in which a machine is controlled by
numbers (and other symbols) that have been coded
on an alternative storage medium.
 A position feedback control system is used in most
NC machines to verify that the coded instructions
have been correctly performed.
 Computer Numerical Control, or CNC.
 Direct Numerical Control, or DNC.

11. ROBOTS
 Humans are replaced by robots in many operations.
 Functions ranges from simple tasks like ‘pick and
place’ to more complex tasks like spot welding and
spray painting.
 Main advantage is the reduction of human labour
and human error.
 Design of product is an important aspect of robotic
assembly.

12. WHEN ARE ROBOTS USED ?
 The operation is repetitive, involving the same basic
work motions every cycle.
 The operation is hazardous or uncomfortable for
the human worker (e.g., spray painting, spot
welding, arc welding, and certain machine loading
and unloading tasks)
 The task requires a work part or tool that is heavy
and awkward to handle.

13. TRANSFER SYSTEMS
Rotary Indexing Machine
 To achieve higher rates of production, the rotary
indexing machine performs a sequence of
machining operations on several workparts
simultaneously.
 Parts are fixed on a horizontal circular table or dial,
and indexed between successive stations.

14. TRUNNION MACHINE
 This machine uses a vertical drum mounted on a
horizontal axis. The vertical drum is called a
trunnion.
 Several fixtures are mounted on it which hold the
workparts during processing.

15. CENTRE COLUMN MACHINE
 Another version of the dial indexing arrangement.
 In addition to the radial machining heads located
around the periphery of the horizontal table, vertical
units are mounted on the center column of the
machine.
 The center column machine is considered to be a
high-production machine which makes efficient use
of floor space.

16. TRANSFER LINE
 The workstations are arranged in a straight-line flow
pattern and parts are transferred automatically from
station to station.
 The transfer system can be synchronous or
asynchronous, workparts can be transported with or
without pallet fixtures, buffer storage can be
incorporated into the line operation if desired, and a
variety of different monitoring and control features
can be used to manage the line.
 The transfer machine offers the greatest flexibility.

17. PART FEEDING DEVICES
 Hopper
 Part Feeder
 Selector and Orientor
 Feed Track (gravity or powered)
 Escapement and Placement device
 Vertical Placement device
 Pick and Place mechanism

18. THANK YOU