ADDITIVE MANUFACTURING (15ME82)

MODULE – 5
MANUFACTURING CONTROL AND AUTOMATION

CONTENTS
1. MODULE DETAILS
2. INTRODUCTION TO NC/CNC/DNC MACHINE
3. CNC PROGRAMMING
4. AUTOMATION IN PRODUCTION SYSTEM
5. SOLVED PROBLEMS - 4
6. IMPORTANT QUESTIONS - 7
7. TEXT & ADDITIONAL REFERENCE BOOKS - 4
8. WEB REFERENCE - 4
9. ASSIGNMENT QUESTIONS - 4
10. PREVIOUS VTU QUESTION PAPER - 1

MODULE DETAILS:

MANUFACTURING CONTROL AND AUTOMATION

CNC technology – An overview: Introduction to NC/CNC/DNC machine tools,
Classification of NC/CNC machine tools, Advantage, disadvantages of NC/CNC machine
tools, Application of NC/CNC Part programming: CNC programming and introduction,
Manual part programming: Basic (Drilling, milling, turning etc.), Special part
programming, Advanced part programming, Computer aided part programming (APT)
Introduction: Automation in production system principles and strategies of
automation,basic Elements of an automated system. Advanced Automation
functions.Levels of Automations, introduction to automation productivity
Control Technologies in Automation: Industrial control system. Process industry vs
discrete manufacturing industries. Continuous vs discrete control. Continuous process and
its forms. Other control system components. 10 hours

1
 ADDITIVE MANUFACTURING (15ME82)

CNC technology - An overview

Introduction to NC/CNC/DNC machine tools

AN OVERVIEW OF CNC MACHINES

Historical Perspective
The word NC which stands for numerical control refer to control of a machine or a process using
symbolic codes consisting of characters and numerals. The word CNC came into existence in
seventies when microprocessors and microcomputers replaced integrated circuit IC based controls
used for NC machines. The development of numerical control owes much to the United States air
force. The concept of NC was proposed in the late 1940s by John Parsons who recommended a
method of automatic machine control that would guide a milling cutter to produce a curvilinear
motion in order to generate smooth profiles on the work-pieces. In 1949, the U.S Air Force
awarded Parsons a contract to develop new type of machine tool that would be able to speed up
production methods.
Parsons sub-contracted the Massachusetts Institute of Technology (MIT) to develop a practical
implementation of his concept. Scientists and engineers at M.I.T built a control system for a two
axis milling machine that used a perforated paper tape as the input media. This prototype was
produced by retrofitting a conventional tracer mill with numerical control servomechanisms for
the three axes of the machine. By 1955, these machines were available to industries with some
small modifications.
The machine tool builders gradually began developing their own projects to introduce commercial
NC units. Also, certain industry users, especially airframe builders, worked to devise numerical
control machines to satisfy their own particular production needs. The Air force continued its
encouragement of NC development by sponsoring additional research at MIT to design a part
programming language that could be used in controlling N.C. machines. In a short period of time,
all the major machine tool manufacturers were producing some machines with NC, but it was not
until late 1970s that computer-based NC became widely used. NC matured as an automation
technology when electronics industry developed new products. At first, miniature electronic tubes
were developed, but the controls were big, bulky, and not very reliable. Then solid-state circuitry
and eventually modular or integrated circuits were developed. The control unit became smaller,
more reliable, and less expensive.

Computer Numerical Control

Computer numerical control (CNC) is the numerical control system in which a dedicated computer
is built into the control to perform basic and advanced NC functions. CNC controls are also
referred to as soft-wired NC systems because most of their control functions are implemented by
the control software programs. CNC is a computer assisted process to control general purpose
machines from instructions generated by a processor and stored in a memory system. It is a
specific form of control system where position is the principal controlled variable. All numerical

2
 ADDITIVE MANUFACTURING (15ME82)
control machines manufactured since the seventies are of CNC type. The computer allows for the
following: storage of additional programs, program editing, running of program from memory,
machine and control diagnostics, special routines, inch/metric, incremental/absolute switch
ability.
CNC machines can be used as standalone units or in a network of machines such as flexible
machine centers. The controller uses a permanent resident program called an executive program
to process the codes into the electrical pulses that control the machine. In any CNC machine,
executive program resides in ROM and all the NC codes in RAM. The information in ROM is
written into the electronic chips and cannot be erased and they become active the machine is on.
The contents in RAM are lost when the controller is turned off Some use special type of RAM
called CMOS memory, which retains its contents.

Figure: CNC LATHE

Direct Numerical Control

The main tasks performed by the computer are to program and edit part programs as well as
download part programs to NC machines. Machine tool controllers have limited memory and a
part program may contain few thousands of blocks. So the program is stored in a separate the
power is turned off. computer and sent directly to the machine, one
block at a time. First DNC system developed was Molins System 24 in 1967 by Cincinnati
Milacron and General Electric. They are now referred to as flexible manufacturing systems (FMS).
The computers that were used at those times were quite expensive.

3
ADDITIVE MANUFACTURING (15ME82)

DNC system

Figure: DNC system

Manually operated milling Machine

4
 ADDITIVE MANUFACTURING (15ME82)
Advantages & Disadvantages of CNC machine tools
Computer controlled machine milling machine Some of the dominant
advantages of the CNC machines are:
• CNC machines can be used continuously and only need to be switched off for occasional
maintenance.
• These machines require less skilled people to operate unlike manual lathes / milling
machines etc.
• CNC machines can be updated by improving the software used to drive the machines.
• Training for the use of CNC machines can be done through the use of 'virtual software'.
• The manufacturing process can be simulated virtually and no need to make a prototype or
a model. This saves time and money.
• Once programmed, these machines can be left and do not require any human intervention,
except for work loading and unloading.
• These machines can manufacture several components to the required accuracy without any
fatigue as in the case of manually operated machines.
• Savings in time that could be achieved with the CNC machines are quite significant.

Some of the disadvantages of the CNC machines are:

 CNC machines are generally more expensive than manually operated machines.
 The CNC machine operator only needs basic training and skills, enough to supervise
several machines.
 Increase in electrical maintenance, high initial investment and high per hour operating
costs than the traditional systems.
 Fewer workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.

Applications of NC/CNC machine tools:

CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch
presses etc. and now expanded to robotics, grinders, welding machinery, EDM's, flame cutters and
also for inspection equipment etc. The machines controlled by CNC can be classified into the
following categories:
 CNC mills and machining centers CNC lathes and turning centers.
 CNC EDM
 CNC grinding machines
 CNC cutting machines (laser, plasma, electron, or flame)
 CNC fabrication machines (sheet metal punch press, bending machine, or press brake)
 CNC welding machines
 CNC coordinate measuring machines

CNC Coordinate Measuring Machines:

A coordinate measuring machine is a dimensional measuring device, designed to move the

measuring probe to determine the coordinates along the surface of the work piece. Apart from

5
 ADDITIVE MANUFACTURING (15ME82)
dimensional measurement, these machines are also used for profile measurement, angularity,
digitizing or imaging.
A CMM consists of four main components:
1. The machine, measuring probe, control system and
2. Motorized CMMs with automatic probing systems
3. Direct computer controlled (DCC) CMMs
4. CMMs linked with CAD, CAM and FMS etc.

CNC welding machines:

The control system in a CMM performs the function of a live interaction between various machine
drives, displacement transducers, probing systems and the peripheral devices. Control systems can
be classified according to the following groups of
CMMs.
1. Manually driven CMMs

Figure: 4 axis CNC TIG welding machine

The salient features of CNC welding machines are:

• Superior quality and weld precision.

• These machines are also equipped with rotary tables.
• Weld moves, welding feed rate, wire feed, torch heights & welding current can be
programmed.
• CNC welding machines are used for laser welding, welding of plastics, submerged arc
welding, wire welding machines, butt welding, flash butt welding etc.

6
 ADDITIVE MANUFACTURING (15ME82)
• These machines are generally used in automobile workshops cost of these machines will
be twice than the conventional welding machines.

CNC EDM & WEDM Machines:

EDM is a nontraditional machining method primarily used to machine hard metals that could not
be machined by traditional machining methods. Material removal will be taking place by a series
of electric arcs discharging across the gap between the electrode and the work piece. There are
two main types- ram EDM & wire cut EDM. In wire-cut EDM, a thin wire is fed through the work
piece and is constantly fed from a spool and is held between upper and lower guides. These guides
move in the x-y plane and are precisely controlled by the CNC.
Wire feed rate is also controlled by the CNC.

CLASSIFICATION OF CNC MACHINE TOOLS

(1) Based on the motion type ' Point-to-point & Contouring systems
There are two main types of machine tools and the control systems required for use with them
differ because of the basic differences in the functions of the machines to be controlled. They are
known as point-to-point and contouring controls.

(1.1) Point-to-point systems

Some machine tools for example drilling, boring and tapping machines etc, require the cutter and
the work piece to be placed at a certain fixed relative positions at which they must remain while
the cutter does its work. These machines are known as point-to-point machines as shown in figure
22.1 (a) and the control equipment for use with them are known as point-to point control
equipment. Feed rates need not to be programmed. In these machine tools, each axis is driven
separately. In a point-to-point control system, the dimensional information that must be given to
the machine tool will be a series of required position of the two slides. Servo systems can be used
to move the slides and no attempt is made to move the slide until the cutter has been retracted
back.

(1.2) Contouring systems (Continuous path systems)

Other type of machine tools involves motion of work piece with respect to the cutter while cutting
operation is taking place. These machine tools include milling, routing machines etc. and are
known as contouring machines as shown in figure 22.1 (b) and the controls required for their
control are known as contouring control.
Contouring machines can also be used as point-to-point machines, but it will be uneconomical to
use them unless the work piece also requires having a contouring operation to be performed on it.
These machines require simultaneous control of axes. In contouring machines, relative positions
of the work piece and the tool should be continuously controlled.
The control system must be able to accept information regarding velocities and positions of the
machines slides. Feed rates should be programmed.

7
 ADDITIVE MANUFACTURING (15ME82)

CNC CONTROL – Closed and Open Loop

CNC systems require motor drives to control both the position and the velocity of the
machine axes. Each axis must be driven separately and follow the command signal generated by
the NC control. There are two ways to activate the servo drives: the open-loop system and the
closed-loop system

Open Loop - Programmed instructions are fed into the controller through an input device. These
instructions are then converted to electrical pulses (signals) by the controller and sent to the servo
amplifier to energize the servo motors. The cumulative number of electrical pulses determines the
distance each servo drive will move, and the pulse frequency determines the velocity.

The primary drawback of the open-loop system is that there is no feedback system to check
whether the program position and velocity has been achieved. If the system performance is affected
by load, temperature, humidity, or lubrication then the actual output could deviate from the desired
output.For these reasons, the open-loop system is generally used in point-to-point systems where
the accuracy requirements are not critical. Very few, if any, continuous-path systems utilize open-
loop control.

Closed Loop - The closed-loop system has a feedback subsystem to monitor the actual output and
correct any discrepancy from the programmed input. The feedback system could be either analog
or digital. The analog systems measure the variation of physical variables such as position and
velocity in terms of voltage levels. Digital systems monitor output variations by means of electrical
pulses Closed-loop systems are very powerful and accurate because they are capable of monitoring
operating conditions through feedback subsystems and automatically compensating for any
variations in real-time. Most modern closed-loop CNC systems are able to provide very close
resolution of 0.0001 of an inch. Closed-looped systems would, naturally, require more control
devices and circuitry in order for them to implement both position and velocity control. This,
obviously, makes them more complex and more expensive than the open-loop
system. A closed/open comparison is shown below in fig 22.2.

8
ADDITIVE MANUFACTURING (15ME82)

9
 ADDITIVE MANUFACTURING (15ME82)
Based on the number of axes ' 2, 3, 4 & 5 axes CNC machines.
(3.1) 2& 3 axes CNC machines
CNC lathes will be coming under 2 axes machines. There will be two axes along which motion
takes place. The saddle will be moving longitudinally on the bed (Z-axis) and the cross slide moves
transversely on the saddle (along X axes machines, there will be one more axis, perpendicular to
the above two axes. By the simultaneous control of all the 3 axes, complex surfaces can be
machined.
(3.2) 4 & 5 axes CNC machines
4 and 5 axes CNC machines provide multi axis machining capabilities beyond the standard 3 axis
CNC tool path movements. A 5 axis milling Centre includes the three X, Y, Z axes, the A axis
which is rotary tilting of the spindle and the B axis, which can be a rotary index table.

Five axes CNC machine

Importance of higher axes machining:

Reduced cycle time by machining complex components using a single setup. In addition to time
savings, improved accuracy can also be achieved as positioning errors between setups are
eliminated.
• Improved surface finish and tool life by tilting the tool to maintain optimum tool to part
contact all the times.
• Improved access to under cuts and deep pockets. By tilting the tool, the tool can be made
normal to the work surface and the errors may be reduced as the major component of
cutting force will be along the tool axis.
Higher axes machining has been widely used for machining sculptures surfaces in aerospace and
automobile industry.

10
 ADDITIVE MANUFACTURING (15ME82)
Turning centre:

Traditional centre lathes have horizontal beds. The saddle moves longitudinally and the cross slide
moves transversely. Although the tools can be clearly seen, the operator must lean over the tool
post to position them accurately. Concentration of chips may be creating a heat source and there
may be temperature gradients in the machine tool. Keeping the above points in view, developments
in the structure of the turning centers lead to the positioning the saddle and the cross slide behind
the spindle on a slant bed as shown in the figure. Chips fall freely because of slant bed
configuration which is more ergonomically acceptable from operator's point of view.

Based on the power supply ' Electric, Hydraulic & Pneumatic systems
Mechanical power unit refers to a device which transforms some form of energy to mechanical
power which may be used for driving slides, saddles or gantries forming a part of machine tool.
The input power may be of electrical, hydraulic or pneumatic.
Electric systems:
Electric motors may be used for controlling both positioning and contouring machines. They may
be either a.c. or d.c. motor and the torque and direction of rotation need to be controlled. The speed
of a d.c. motor can be controlled by varying either the field or the armature supply. The clutch-
controlled motor can either be an a.c. or d.c. motor. They are generally used for small machine
tools because of heat losses in the clutches. Split field motors are the simplest form of motors and
can be controlled in a manner according to the machine tool. These are small and generally run at
high maximum speeds and so require reduction gears of high ratio. Separately excited motors are
used with control systems for driving the slides of large machine tools.
Hydraulic systems:
These hydraulic systems may be used with positioning and contouring machine tools of all sizes.
These systems may be either in the form of rams or motors. Hydraulic motors are smaller than
electric motors of equivalent power. There are several types of hydraulic motors. The advantage
of using hydraulic motors is that they can be very small and have considerable torque. This means
that they may be incorporated in servo systems which require having a rapid response.

11
 ADDITIVE MANUFACTURING (15ME82)
Different components related to CNC machine tools
Any CNC machine tool essentially consists of the following parts:

(1.1) Part program:

A part program is a series of coded instructions required to produce a part. It controls the
movement of the machine tool and on/off control of auxiliary functions such as spindle rotation
and coolant. The coded instructions are composed of letters, numbers and symbols.

(1.2) Program input device

The program input device is the means for part program to be entered into the CNC control. Three
commonly used program input devices are punch tape reader, magnetic tape reader, and computer
via RS-232-C communication.

(1.3) Machine Control Unit:

The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following
functions:
• To read the coded instructions.
• To decode the coded instructions.
• To implement interpolations (linear, circular, and helical) to generate axis motion
commands.
• To feed the axis motion commands to the amplifier circuits for driving the axis
mechanisms.
• To receive the feedback signals of position and speed for each drive axis.
• To implement auxiliary control functions such as coolant or spindle on/off and tool change.
(1.4 ) Drive System
A drive system consists of amplifier circuits, drive motors, and ball lead-screws. The MCU feeds
the control signals (position and speed) of each axis to the amplifier circuits. The control signals
are augmented to actuate drive motors which in turn rotate the ball leadscrews to position the
machine table.
( 1.5 ) Machine Tool:

CNC controls are used to control various types of machine tools. Regardless of which type of
machine tool is controlled, it always has a slide table and a spindle to control of position and speed.
The machine table is controlled in the X and Y axes, while the spindle runs along the Z axis.

( 1.6 ) Feed Back System:

The feedback system is also referred to as the measuring system. It uses position and speed
transducers to continuously monitor the position at which the cutting tool is located at any
particular instant. The MCU uses the difference between reference signals and feedback signals
to generate the control signals for correcting position and speed errors.

12
 ADDITIVE MANUFACTURING (15ME82)

ADVANTAGES
 CNC machines can be used continuously 24 hours a day, 365 days a year and only need
to be switched off for occasional maintenance.
 CNC machines are programmed with a design which can then be manufactured hundreds
or even thousands of times. Each manufactured product will be exactly the same.
 Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc.
which need skilled engineers.
 CNC machines can be updated by improving the software used to drive the machines
 Training in the use of CNCs is available through the use of ‘virtual software’. This is
software that allows the operator to practice using the CNC machine on the screen of a
computer. The software is similar to a computer game.
 CNC machines can be programmed by advanced design software such as Pro/DESKTOP,
enabling the manufacture of products that cannot be made by manual machines, even those
used by skilled designers / engineers.
 Modern design software allows the designer to simulate the manufacture of his/her idea.
There is no need to make a prototype or a model. This saves time and money.
 One person can supervise many CNC machines as once they are programmed they can
usually be left to work by themselves. Sometimes only the cutting tools need replacing
occasionally.
 A skilled engineer can make the same component many times. However, if each
component is carefully studied, each one will vary slightly. A CNC machine will
manufacture each component as an exact match.

DISADVANTAGES
o CNC machines are more expensive than manually operated machines, although costs are
slowly coming down.
o The CNC machine operator only needs basic training and skills, enough to supervise
several machines. In years gone by, engineers needed years of training to operate centre
lathes, milling machines and other manually operated machines. This means many of the
old skills are been lost.
o Less workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.
o Many countries no longer teach pupils / students how to use manually operated lathes /
milling machines etc... Pupils / students no longer develop the detailed skills required by
engineers of the past. These include mathematical and engineering skills.
APPLICATION
CNC machine is used
In the metal removal industry
In the metal fabrication industry
In the electrical discharge machining industry
In the woodworking industry
Laser welding in automobile industry

13
 ADDITIVE MANUFACTURING (15ME82)
CNC Programming and Introduction
The part program is a collection of all data required to produce the part. It is arranged in the form
of blocks of information. Each block contains the numerical data required for processing a
segment of the work piece.
Part program is of two type:

CNC Programming
Programming consists of a series of instructions in form of letter codes

14
 ADDITIVE MANUFACTURING (15ME82)

Preparatory Codes:
G codes- Initial machining setup and establishing operating conditions
N codes- specify program line number to executed by the MCU
Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y, Z direction
Feed and Speed Codes: F and S- Specify feed and spindle speed
Tool codes: T – specify tool number

Miscellaneous codes – M codes for coolant control and other activities

Programming Key Letters

O - Program number (Used for program identification)
N - Sequence number (Used for line identification)
G - Preparatory function
X - X axis designation
Y - Y axis designation
Z - Z axis designation
R - Radius designation
F – Feed rate designation
S - Spindle speed designation
H - Tool length offset designation
D - Tool radius offset designation
T - Tool Designation
M - Miscellaneous function
Table of Important G Codes
G00 Rapid Transverse
G01 Linear Interpolation
G02 Circular Interpolation, CW
G03 Circular Interpolation, CCW
G17 XY Plane, G18 XZ Plane, G19 YZ Plane
G20/G70 Inch units
G21/G71 Metric Units
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation (plus)
G44 Tool length compensation (minus)
G49 Tool length compensation cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning

15
 ADDITIVE MANUFACTURING (15ME82)
CNC MILL

In CNC Mill we have 3 axes – X axis (along length), Y axis (along breadth) & Z axis (along
thickness). The position of the Z axis is along the spindle axis and it is +ve in a direction away
from the workpiece. The position of the X & Y axis is parallel to and on the worktable. X axis is
along the length and Y axis is along the breadth of the table. X and Y axes are +ve in directions
moving away from the workpiece.

Z
Spindle
Home Position

Y
Work
Table

Machine Zero X
Point

Max. Y
Max. X

1. Automatic Tool Changer (ATC): It is a facility or device provided on the CNC

Mill for automatically indexing the tool magazine and making the required tool
change as indicated in the CNC program.

2. Automatic Pallet Changer (APC): It is a time saving facility provided on the CNC
Mill/Machining Center for automatically loading and unloading the pallets. Pallets are
portable work holding devices. While a loaded pallet is being used, a machined-
component may be unloaded from the previous pallet and a to-be-machined workpiece
may be loaded on to the next pallet.

3. Dimensional Notations used in CNC Mill are:

X Coordinate value along the length of the table

Y Coordinate value along the breadth of the table
Z Coordinate value along the vertical to the table

16
 ADDITIVE MANUFACTURING (15ME82)
4. Dimensioning Method - Absolute & Incremental Dimensioning:

In absolute dimensioning, coordinate values are measured from the program zero point. In
incremental dimensioning, the coordinate values are measured from the previous programmed
point.

Note: Incremental program is easy to program but tedious to change values in between. Error
committed in any block is carried over to the consecutive blocks. Whereas, absolute programming
is a bit inconvenient as all coordinates are measured from a fixed point. Error committed in any
block will affect only that block. Consecutive blocks are not affected.

17
 ADDITIVE MANUFACTURING (15ME82)
a. Commonly used G-codes on the Machining Center:

G Code Meaning G Code Meaning

Rapid Traverse (Tool
Tool Length Compensation
G00 moves at a predetermined G43
(+ve direction)
rapid speed)
Tool Length Compensation
G01 Linear interpolation G44
(-ve direction)
Tool Length Compensation
G02 Circular Interpolation CW G49
CANCEL
Circular Interpolation G54 to Work piece coordinate
G03
CCW G59 system selection
G17 XY Plane Selection G73 Peck Drilling Cycle
G18 XZ Plane Selection G74 Counter Tapping Cycle
G19 YZ Plane Selection G80 Canned Cycle Cancel
G81 to
G20 Inches programming Canned Cycles
G89
G21 Metric programming G90 Absolute Programming
Return to reference point OR
G28 G91 Incremental Programming
home position
Cutter Radius Compensation Feed programmed in
G40 G94
CANCEL mm/min
Cutter Radius Compensation
G41 G95 Feed programmed in mm/rev
(Left)
Cutter Radius Compensation Return to initial point in
G42 G98
(Right) Canned Cycle
Return to reference point in
G99
Canned Cycle

b. Commonly used M-codes on the Machining Center:

M Code Meaning M Code Meaning

M01 Optional stop M09 Coolant OFF
M02 Program end M70 X Mirror ON
M03 Spindle ON CW M80 X Mirror OFF
M04 Spindle ON M71 Y Mirror ON
CCW
M05 Spindle OFF M81 Y Mirror OFF

18
 ADDITIVE MANUFACTURING (15ME82)
M06 Tool change M98 Sub program Call
M08 Coolant ON M99 Sub program End
Program stop &
M30
rewind

c. Structure of the program for CNC Mill (FANUC): The CNC program
can be divided into 3 parts - Start-Up, Body & End of the program

5. Start – Up: The commands in this portion of the program are used to initialize the
controller and the machine tool for further operation.
O1000
G21/G20 G94/G95
G91 G28 Z0
G28 X0 Y0
G90
G50 S3500
M06 T01
M03/M04 S1000
G00 X-10 Y-10 Z20

Commands Explanation
While writing a program on FANUC controller first line has to be
O1000 started with letter ‘O’ followed by a 4-digit number which specifies the
program name.
G21 specifies that programming must be done in metric units (mm) OR
G20 specifies that programming is done in imperial (inch) units.
G21/G20 G94/G95
G94 specifies that the feed is programmed in mm/min OR G95
specifies that the feed is programmed in mm/rev.
G28 specifies “Go to Home Position”. Homing operation is always
carried out in incremental mode (i.e., G91).
G91 G28 Z0
G28 Z0 sends the Z axis slide to home position.
G28 X0 Y0
G28 X0 Y0 sends the X & Y axis slides to home position.
G90
G90 cancels the incremental mode sets the default absolute
programming mode.
G50 S3500 This sets the maximum speed of the spindle at 3500 rpm.
M06 T01 Make tool change to T01.

19
 ADDITIVE MANUFACTURING (15ME82)
M03 – makes the spindle to rotate in CW direction
M03/M04 S1000 M04 - makes the spindle to rotate in CCW
direction S1000 – Spindle rotates at 1000 rpm
G00 X-10 Y-10 Z20 G00 – rapidly moves the tool to the point X-10, Y-10, Z20

6. Body of the program: This portion of the program consists of the commands that
represent the actual machining part. It changes from job to job.

7. End of program:

G91 G28 Z0
G28 X0 Y0
M05
M30

EXPLANATION:

G91 G28 Z0 Tool returns to home position.

G28 X0 Y0
M05 Stops the spindle rotation.
M30 Program stop & rewind.

8. Slotting: This is an operation where the vertical milling cutter is used to produce a continuous
slot. The slot produced may be linear or a contour (curvi-linear).

An example to demonstrate writing a simple Program:

Write a part program to perform the linear slotting operation on the component as shown in the
figure.
O0001 1 8 1
0 0
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01 (10 mm end mill)
M03 S1000
G00 X10 Y10 Z2

20
 ADDITIVE MANUFACTURING (15ME82)
G01 Z-1 F50
X10 Y90
X90 Y90
X90 Y10
X10 Y10
G00 Z5 Billet Size : 100 x
G91 G28 Z0 100 x 10 mm
G28 X0 Y0
M05 M30 Cutter Dia: 6 mm

AUTOMATION IN PRODUCTION SYSTEM:

Automation can be defined as a technology concerned with the application of mechanical,
electronic, and computer-based systems to operate and control production.

Two categories of automation in the production system are:

Computerized manufacturing support systems.

Automated manufacturing systems.

In modern production systems, the two categories overlap to some extent because the automated
manufacturing systems operating on the factory floor are themselves often implemented by
computer systems.
The term computer-integrated rnanufacturing is used to indicate this extensive use of computers
in production systems.

REASONS FOR AUTOMATION

1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating

21
 ADDITIVE MANUFACTURING (15ME82)
Automated Manufacturing Systems
Automated manufacturing systems can be classified into three basic types.
1. Fixed automation
2. Programmable automation
3. Flexible automation
1. Fixed automation – In this type, the sequence of processing or assembly operations is
fixed by the equipment configuration. Here the movement is restricted to one or two types only.
Ex: Rotational feeding of bottles. This type is most suitable for custom made engineering
equipment when high level of production with less product variety is required.
The typical features of fixed automation are:
 High initial investment for custom-engineered equipment
 High production rates
 Relatively inflexible in accommodating product changes

2. Programmable automation – Here the production equipment is designed with the

capability to change the sequence of operations to accommodate the product variety. The
operation is controlled by a program. These are characterized by high investment in general
purpose equipment, lower production rate than the fixed type, flexibility to accommodate
product variety, batch type of production. This type of automation can be achieved through NC
machines, industrial robots and programmable logical controllers.
Some of the features that characterize programmable
automation include:
 High investment in general-purpose equipment
 Low production rates relative to fixed automation
 Flexibility to deal with changes in product configuration Most suitable for batch
production

3. Flexible automation- It is an extension of the previous type. This can produce more
variety of products with virtually no change over time. This system is featured by high
investment, continuous production of variable product mix, medium production rates, flexible
to deal with variety. This can be achieved through flexible manufacturing system like a CNC
machine.
The features of flexible automation can be summarized as
follows:
 High investment for a custom-engineered system
 Continuous production of variable mixtures of products
 Medium production rates

22
 ADDITIVE MANUFACTURING (15ME82)

Levels of Automation
1. Device level. This is the lowest level in the automation hierarchy. It includes the actuators,
sensors, and other hardware components that comprise the machine level. The devices are
combined into the individual control loops of the machine, for example, the feedback
control loop for one axis of a CNC machine or one joint of an industrial robot.
2. Machine level. Hardware at the device level is assembled into individual machines.
Examples include CNC machine tools and similar production equipment, industrial robots,
powered conveyors, and automated guided vehicles. Control functions at this level include
performing the sequence of steps in the program of instructions in the correct order and
making sure that each step is properly executed.
3. Cell or system level. This is the manufacturing cell or system level, which operates under
instructions from the plant level. A manufacturing cell or system is a group of machines or
workstations connected and supported by a material handling system, computer, and other
equipment appropriate to the manufacturing process. Production lines are included in this
level. Functions include part dispatching and machine loading, coordination among
machines and material handling system, and collecting and evaluating inspection data.
4. Plant level. This is the factory or production systems level. It receives instructions from
the corporate information system and translates them into operational plans for production.
Likely functions include order processing, process planning, inventory control, purchasing,
material requirements planning, shop floor control, and quality control.
5. Enterprise level. This is the highest level, consisting of the corporate information system.
It is concerned with all of the functions necessary to manage the company: marketing and
sales, accounting, design, research, aggregate planning, and master production scheduling.
The corporate information system is usually managed using Enterprise Resource Planning.

23
 ADDITIVE MANUFACTURING (15ME82)

PROBLEMS
Program 1:
Write a part program to perform the circle slotting operation on the component
as shown in the figure without making use of a subprogram. Maximum depth
of cut that can be given in a single pass is 1 mm. Take cutter dia = 8 mm.

O0004

G21 G94
R 30
G91 G28 Z0

G28 X0 Y0

G90
P1 P2
M06 T01 (8 mm end mill)

M03 S1000

G00 X-30 Y0 Z2

100
G01 Z-1 F50

G02 X30 Y0 R30

X-30 Y0 R30

G01 Z-2 F50

G02 X30 Y0 R30

X-30 Y0 R30
Billet Size : 100 x 100 x 10 mm
G01 Z-3 F50 Cutter Dia: 8 mm
G02 X30 Y0 R30

X-30 Y0 R30

G01 Z-4 F50

G02 X30 Y0 R30

24
 ADDITIVE MANUFACTURING (15ME82)
X-30 Y0 R30

G01 Z-5 F50

G02 X30 Y0 R30

X-30 Y0 R30

G01 Z5

G91 G28 Z0

G28 X0 Y0

M05

M30

Program 2:
Write a part program to perform the circle slotting operation on the
component as shown in the figure. Use a subprogram, taking a depth of
cut of 1 mm in each pass. Take cutter dia = 8 mm.

O0005

G21 G94

G91 G28 Z0

G28 X0 Y0 R 30

G90

M06 T01 (8 mm end mill)

M03 S1000 P1 P2

G00 X-30 Y0 Z5

G01 Z0 F30

M98 P0053937
100
G00 Z5
Billet Size : 100 x 100 x 10 mm
G91 G28 Z0 Cutter Dia: 8 mm
G28 X0 Y0

M05

25
 ADDITIVE MANUFACTURING (15ME82)
M30

O3937 (Sub program)

G91 G01 Z-1 F50

G90 G02 X30 Y0 R30

X-30 Y0 R30

M99

Program 3:
Write a part program to perform the contour slotting operation on the
component as shown in the figure.

O0003

G21 G94

G91 G28 Z0 10 60
R 10
G28 X0 Y0

G90 P4 P5 X Y
P6 P1 20 10
P3
M06 T01 (6 mm end mill)
P2 10 20
M03 S1000 P3 10 80
P4 20 90
G00 X20 Y10 Z2 R 10 P5 80 90
P2
P6 90 80
G01 Z-1 F50 P1 P7 P7 90 10
G03 X10 Y20 R10 P1 20 10

G01 X10 Y80 X20 Y90 20 70 10

X80 Y90 Billet Size : 100 x 100 x 10 mm

G02 X90 Y80 R10

G01 X90 Y10 Cutter Dia: 8 mm

X20 Y10

G00 Z5

G91 G28 Z0

G28 X0 Y0

M05

M30

26
 ADDITIVE MANUFACTURING (15ME82)

IMPORTANT QUESTIONS:

1. Identify the five levels of automation in a production plant.

2. Name three of the four conditions under which automated production

lines are appropriate. What is an automated production line?

3. Name some of the industrial applications of automated production lines.

4. Explain the various levels of automation with suitable examples.

5. Explain the various reason for automation.

6. List advantages of NC machine over CNC machines.

7. Explain the application of CNC machines taking industrial examples.

References
1. Boucher, T. O., Computer Automation in Manufacturing, Chapman & Hall, London,
UK, 1996.
2. Groover, M. P., “Automation,” Encyclopaedia Britannica, Macropaedia, 15th ed.,
Chicago, IL, 1992. Vol. 14, pp. 548–557. [3] Groover, M. P., “Automation,” Handbook
of Design, Manufacturing, and Automation, R. C. Dorf and A. Kusiak (eds.), John Wiley
& Sons, Inc., New York, 1994, pp. 3–21.
3. Text Book on Automation, Production Systems, and Computer-Integrated
Manufacturing. by Mikell P. Groover.
4. Computer Aided Manufacturing - P.N. Rao, N.K. Tewari and T.K. Kundra Tata McGraw
Hill 1999

Web References
1. https://www.engr.uvic.ca/~mech410/CAM_references/CNC_Computer_Numerical_Co
ntrol_Programmig_Basics.pdf
2. https://www.brainkart.com/article/Process-Industries-Versus-Discrete-Manufacturing-
Industries_6387/
3. https://www.youtube.com/watch?v=9Xvkk_QtNSk
4. http://www.vtuboss.in/2018/07/vtu-mechanical-engineerng-8th-sem-cbcs.html

27
 ADDITIVE MANUFACTURING (15ME82)

ASSIGNMENT QUESTIONS
1. Write a part program to perform the circle slotting operation on the component
as shown in the figure wit out making use of a subprogram. Maximum depth of
cut that can be given in a single pass is 1 mm. Take cutter Dia = 8 mm.

R 30

P1 P2

100
Billet Size : 100 x 100 x 10 mm
Cutter Dia: 8 mm

2. Write a part program to perform the square slab milling operation on a workpiece
of dimensions 100mm×100mm×10 mm. The slab’s dimension is 64mm×64mm×6mm
and is located at the centre of the workpiece. Use a cutter diameter of 10 mm.
Take program zero at the left bottom end of the workpiece.

3. Write a part program to perform the Circular Pocket Milling operation on a

workpiece of dimensions 100mm×100mm×10 mm. The pocket’s dimension is
R37×6mm depth and is located at the centre of the workpiece. Use a cutter
diameter of 10 mm. Take program zero at the top face center of the workpiece.

4. Write a part program to perform the Square Pocket Milling operation on a

workpiece of dimensions 100mm×100mm×10 mm. The pocket’s dimension is
57mm×57mm×8mm and is located at the centre of the workpiece. Use a cutter
diameter of 10 mm. Take program zero at the top face center of the workpiece.

28
ADDITIVE MANUFACTURING (15ME82)

29
ADDITIVE MANUFACTURING (15ME82)

30