automated machine tools
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B E H 2 0 3 0 2
I N D U S T R I A L A U T O M A T I O N S Y S T E M
AUTOMATED MACHINE
TOOLS
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DEFINITION
What is automated machine tools?
Automated machine tools are more commonly known asnumerically controlled (NC) machine tools.
Refers to the automation of machine tools that areoperated by abstractly programmed commands encodedon a storage medium, as opposed to manually controlled
via handwheels or levers
Guides, tracks and other devices built into machinery toraise its precision level are a kind of automatic control.
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Initially, machine tools were created to reduce theamount of human skill required in manufacture.
These automatic aids to proficiency, adhering to thedouble principle of accuracy for inter-changeability andspeed for economy.
Applications: laser cutting, welding, flame and plasmacutting, bending, spinning, pinning, gluing, fabriccutting, sewing, routing, picking and placing (PnP)
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GENERAL CHARACTERISTICS OFPRODUCTION JOB
Automated machine tools are most appropriate if:
Parts are processed frequently and in small lot sizes
The part geometry is complex
Many operations must be performed in the part in itsprocessing
Much metal needs to be removed
Engineering design changes are likely
Close tolerance must be held on the workpart
It is an expensive part where mistakes in processing would becostly
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Advantages Disadvantages
Greater accuracy andrepeatability
Lower scrap rates More complex part
geometries are possible Inspection requirements
are reduced Shorter manufacturing lead
times Operator skill-level
requirements are reduced
Inflexibility
Higher maintenanceeffort
Part programming
Higher utilization ofNC equipment
ADVANTAGES & DISADVANTAGES
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EXAMPLES & FUNCTIONS
Automated Lathe Machine
Laser Cutting Machine
Drilling MachineAutomated Welding Machine
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AUTOMATED LATHE MACHINE
is a machine tool which turns cylindrical material,touches a cutting tool to it, and cuts the material
is used for producing cylindrical work. The workpiece is rotated while the cutting tool movement iscontrolled by the machine.
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LATHE FUNDAMENTAL
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Principle parts Descriptions
Headshock In where spindle locked. Can either operate in belt driven mode orself driven mode.
Tailshock adjusted laterally (front to back) to cut a material by loosening theclamping screws at the bottom of the tailstock.
Ways Base foundation part of lathe. Keep the tailshock and carriage,which slide on them, in alignment with headshock.
Spindle Place for working pieces mounted on.
Apron attached to the front of the carriage and controls the movement ofthe carriage and the crossslide
Carriage is the movable support for the crossfeed slide and the compoundrest.
Belt drive Connected to motor, drives spindle in belt driven mode.
Lead screw Used for thread cutting.
Crosslide mounted to the top of the carriage in a dovetail and moves on thecarriage at a right angle to the axis of the lathe.
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AUTOMATIC LATHE VS MANUAL LATHE
Automatic Lathe
Contain single or multiple spindles
Programmable machine memorymakes spindle works simultaneously
Station contain multiple tools that cutsmaterial in sequence
The tools are usually arranged inseveral axes, such as turret (rotary
indexing), horizontal slide (linearindexing), and vertical slide (linearindexing)
The linear groups are called "gangs"
Manual Lathe
Mostly contain only singlespindle
Each station worksindependently
Manually insert working piecesinto spindle and tune cutting
tools position
Outdated machine due toinefficiency and time consume
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Important Elements in Lathe
A beginner of a
lathe must operatewith low rotatingspeed, small cuttingdepth and lowsending speed.
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Cutting tools selection inlathe
Easy and hard processingin lathe
TOOLS & PROCESS
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LASER CUTTING MACHINE
Technology that uses a laser to cut materials.
Made by the Western Electric Engineering Research Centeron 1965.
The first production laser
cutting machine was used todrill holes in diamond dies.
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Typically used for industrial manufacturing applications,but is also starting to be used by schools, small businessesand hobbyists.
Works by directing the output of a high-power laser, bycomputer (computer numerical control), at the material tobe cut.
Industrial laser cutters are mostly used to cut flat-sheetmaterial as well as structural and piping materials.
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TYPES OF LASER CUTTING
Lasing Materials Applications
CO2 (Carbon dioxide) Cutting, Boring & Scribing Engraving
Nd (Neodymium) Boring high energy pulses, and low
repetition speed (1khz)
Nd-TAG (Neodymium yttriumaluminum garnet)
Very high energy pulses and for boring,engraving, trimming
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MACHINE CONFIGURATIONS
Generally three different configurations of industrial laser
cutting machines:-
- Moving material,
- Hybrid,
- Flying Optics systems.
These refer to the way that the laser beam is moved over
the material to be cut or processed.
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Moving material lasers
Moving
material lasershave astationarycutting head andmove the
material underit.
Provides aconstant
distance fromthe lasergenerator to thework piece.
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Hybrid Lasers
Provide a tablewhich moves in one
axis (usually the X-axis) and move thehead along theshorter (Y) axis.
More constant beam
delivery path lengththan a flying opticmachine and maypermit a simplerbeam delivery system.
Reduced power lossin the delivery systemand more capacity perwatt than flying opticsmachines.
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Flying optics lasers
Feature a stationary
table and a cutting head
(with laser beam) that
moves over the work
piece in both of the
horizontal dimensions.
Cutters, keep the work
piece stationary during
processing and do not
require material
clamping.
Fastest type, which is
advantageous when
cutting thinner work
pieces.
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Advantages Disadvantages
Easier work-holding and
reduced contaminationof work-piece compare tomechanical cutting tools.
More precise and using
less energy when cuttingsheet metal compare toplasma cutting.
Main disadvantage is
the high powerconsumption.
Cannot cut through the
greater metal thicknessthat plasma can.
ADVANTAGE & DISADVANTAGE
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DRILLING MACHINE(PCB CNC Circuit Board Drilling Machine)
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INTRODUCTION
Used for drilling holes in various materials orfastening various materials together with the use offasteners.
Used in woodworking, metalworking, construction. Specially designed drills are also used in medicine,
space missions and other applications.
Drills are available with a wide variety of
performance characteristics, such as power andcapacity.
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OPERATION
Holes by way of a PCB are frequently drilled withlittle drill bits developed of sound tungsten carbide.
The drilling is accomplished by automated drilling
gadgets with placement managed by a drill tape ordrill file.
These computer system-produced files are alsoregarded as numerically managed drill (NCD) files or
Excellon files. The drill file describes the place and dimensions of
just about every drilled hole.
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These holes are generally stuffed with annular rings(hollow rivets) to produce vias.
Vias permit the electrical and thermal connection ofconductors on opposite sides with the PCB.
High drill speed important for selling price effectivedrilling of many holes per board will cause reallysignificant temperatures at the drill bit suggestion, andsubstantial temperatures (400-700 degrees) soften steeland decompose (oxidize) laminate filler.
Drilling devices could be manually operated,mechanically automated, or digitally automated by wayof pc numerical command (cnc)
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AUTOMATED WELDING MACHINE
Designed for welding PVC, Polyolefine, and linoleum floorcoverings in dry rooms
Automated welding can
provide large gains in
quality, productivity and
profitability
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Semi-automatic Fully automatic
uses a pre-programmedautomatic welding
machine, but the partsare actually loaded ontothe welding bench (or itsequivalent) by anoperator, who arranges
them and then switcheson the welding machineuntil the weld has beencompleted.
a custom machine
loads the workpiece,indexes the part ortorch into position,accomplishes the weld,
monitors the quality ofthe joint and unloadsthe finished product.
CATEGORIES OF WELDING AUTOMATION
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much faster than skillfulhuman welders
produce decentworkmanship despitetheir greater speed
provide a high quality
weld, since they aretotally uniform in theirapplication of the electricarc or other welding tool
cost of setting up is veryhigh
take an extremely longtime to set up
carry out the task in arepetitive manner and
must be completelyreconfigured if adifferent weld needs to
be made
ADVANTAGE & DISADVANTAGE
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CONCLUSION