Advanced Production Process 1 Module I

Turret and Capstan Lathe: Construction and parts (a) Head stock, (b) work holding devices (c) tool holding devices –
straight and circular holder, flanged tool holders, Tool layout and sequence of operation. Turret indexing
mechanism and work feeding mechanism Machine specifications.
Automatic and Copying Machines Automation - definition, automatic control principles, types - single spindle lathe,
multi-spindle lathe, tool layouts, Copying machines, Copying principles – types, Mechanical (pantograph copying
systems)
Machining and tuning centers requirements, types, characteristics and capabilities of machine centers
reconfigurable machines and systems. hexapod machines.

1.1.0 Understand the working of turret and capstan lathe

1.1.1 Indicate the parts by drawing sketches of turret and capstan lathe
1.1.2 Explain the working of head stock of turret and capstan lathe
1.1.3 Explain with line sketch capstan and turret lathe mechanism -indexing, bar feeding
1.1.4 List the work holding devices
1.1.5 List the tool holding devices
1.1.6 Sketches the tool layout in sequence for a given set of operations of a work-hexagonal bolt
1.1.7 Indicate the mode of specifying a machine for the purpose of procurement
1.2.0 Comprehend the working of automatic and copying lathe
1.2.1 Define the automation
1.2.2 Define the principle of automatic control
1.2.3 List the areas of uses of automatic machines
1.2.4 Explain the diagram the working of single spindle automatic lathe
1.2.5 Classify the multi spindle automatics
1.2.6 List the advantages of single spindle Vs multi spindle automatics
1.2.7 List the various purposes of the automatic machines
1.2.8 Define the tool layout of an automatic
1.2.9 State the copying principles
1.2.10 Classify the copying machines
1.2.11 Explain, with sketch, the pantograph copying system
1.3.0 Understand the working of machining and tuning centers
1.3.1 Describe requirements of machine centers
1.3.2 List types of machining centers
1.3.3 Explain characteristics and capabilities of machining centers.
1.3.4 Explain reconfigurable machines and systems.
1.3.5Explain hexapod machines
Advanced Production Process 2 Module I

Questions from previous board examinations

1. State four applications of automation.

2. Explain turret head indexing mechanism with the help of suitable figure.
3. Explain automatic cutting of machine with the help of simple sketch.
4. Illustrate the construction and working of a turret lathe with the help of simple figure.
5. Explain pantograph copying system with the help of necessary sketch.
6. Illustrate the tool layout sequence to manufacture a hexagonal bolt.
7. List out the work holding devices on Capstan and Turret lathe. (MARCH, 2014)
8. Compare the semiautomatic and automatic lathes. (MARCH, 2014)
9. Explain the hydraulic servo copying system for lathe with the help of sketch (MARCH, 2014)
10. Give the classification of semi-automatic sand automatic lathes. (MARCH, 2014)
11. Describe the following tool holding devices with sketch:
(i) Multiple cutter holders
(ii) Straight form tool holder
(iii) Knurling tool holders (MARCH, 2014)

12. Explain the electric copying system with sketch. (MARCH, 2014)
13. Define the tool layout of an automatic
14. List types of machining centers
15. Draw the tool layout in sequence for a given set of operations of work- hexagonal bolt
16. List the advantages of single spindle Vs multi spindle automatics
17. Sketch a pantograph copying system
18. Explain the turret lathe indexing mechanism with a neat sketch
19. Describe requirements of machine centers
20. Explain hexapod machines
21. List any four tool holding devices used in turret/capstan
22. Define spring back in bending.
23. Show the layout of Swiss type automatic screw machine and explain the working.
24. Explain the bar feeding mechanism in a turret/capstan lathe.
25. Illustrate the construction and working of a capstan lathe.
26. Identify the size and specification of a turret lathe.
27. Compare capstan lathe with engine lathe
28. Write short notes on knee tool holder
29. Draw a Capstan lathe and name the parts.
30. Explain the principle of a pantograph machine.
31. Explain with a neat sketch operation of automatic screw cutting machine.
32. List the important advantages and limitations of hydraulic controls in machine tool.
Advanced Production Process 3 Module I

Turret and capstan lathes

Turret and capstan lathes are the natural development of the engine lathe, where the tailstock is
replaced by an indexable multi station tool head, called the capstan or the turret. This head carries a
selection of standard tool holders and special attachments. A square turret is mounted on the cross
slide in place of the usual compound rest in engine lathe. Sometimes a fixed tool holder is also
mounted on the back end of the cross slide. Dimensional control is affected by means of longitudinal
(for lengths) and traversal (for diameters) adjustable stops.
Difference between center lathe and turret lathe
1. There is only one tool post 1. There are two tool posts – four way
2. Tailstock is located at the right side tool post and rear tool post
of the bed 2. Tailstock is replaced by an hexagonal
3. Only one cutting tool can be held in tool head called turret
the tailstock 3. A minimum of six tools can be held in
4. No provision to control the tool movement the turret
(feed) automatically 4. Turret movement can be controlled
5. Only one tool can be put into machining at a automatically
time. Tools have to be set every time according 5. More tools can be set on the turret and each of
to the operation to be performed them can be set at the work one by one automatically
6. Setting of tools will take more time 6. Setting of cutting tool is easy
7. A skilled operator is necessary to work on 7. After the initial settings are made, a semi-skilled
the machine operator can operate the machine
8. The machine has to be stopped to change the 8. Tools can be indexed even when the machine is on
tool 9. Production cost is reduced as the rate of production
9. The production cost is high is more
10. Motors with 3 to 5 HP are used 10. Motors with 15 HP are used
Capstan lathe and turret lathe
Capstan lathe is a ram type turret lathe in which hexagonal turret is mounted on ram slide.
The saddle, which supports the ram is clamped to the bed at a desired position. This lathe is of light
construction and has a short turret stroke and an automatic index on the turret. The turret stroke
depends on the length of the ram that varies from 100mm to 375mm. capstan lathes are used for
mass production of small to medium size components from bar and rod stock

The main parts of capstan lathe are;

Advanced Production Process 4 Module I

1. Bed- the bed is a long casting fitted with guide ways. It supports headstock, turret saddle and
cross-slide.
2. Headstock- the function of headstock is to control the spindle speeds. All geared headstock is
most common and it provides a wide range of speeds and allows heavier cuts. It is located on
the left end of the bed. Pilot bar provided at the top of headstock gives rigidity and piloting for
the tool for accurate working. It engages the hole provided in knee type tool holder.
3. Turret- it is a tool holding device shaped in the form of hexagon and is mounted on a ram.
The specially designed tools are attached to six faces of hexagonal turret and are brought into
position for different operations.
4. Turret saddle- turret saddle supports ram on which hexagonal turret is mounted. The turret
saddle can be moved over the bed and clamped in any desired positions.
5. Cross-slide- the cross-slide is mounted on the carriage. It is equipped with four station type
tool post st the front, and one rear tool post at the back of the cross-slide. It is used for facing,
forming and cutting off barstock.

Turret lathe
The turret lathe is a saddle type lathe in which hexagonal turret is mounted on a saddle
which slides directly on the guide ways of the bed. It is of heavier construction with rigid design. It
evolved from earlier lathes with the addition of the turret, which is an indexable tool holder that
allows multiple cutting operations to be performed, each with a different cutting tool, in easy, rapid
succession, with no need for the operator to perform setup tasks in between, such as installing or
uninstalling tools, nor to control the tool path. The latter is due to the tool path’s being controlled by
the machine, either in jig-like fashion, via the mechanical limits placed on it by the turret's slide and
stops, or via electronically-directed servomechanisms for computer numerical control lathes.
Advanced Production Process 5 Module I
Difference between capstan lathe and turret lathe:
S.No Capstan lathe
1 It is a light duty machine
The turret head is mounted on the ram and
2
the ram is mounted on the saddle.
The saddle will not be moved during
3
machining
4 The lengthwise movement of turret is less
5 Short work pieces only can be machined.
It is easy to move the turret head as it slides
6
over the ram
7 The turret head cannot be moved crosswise
As the construction of lathe is not rigid,
8
heavy cut cannot be given
Turret lathe
1. Turret tool head is directly fitted on the saddle
and both of them appear like one unit.
2. Saddle is moved to provide feed to the tool
3. It is difficult to move the saddle for feed
4. As the saddle can be moved along the entire
length of the bed, it is suitable for longer work
pieces
5. To index the turret tool head, a clamping lever is
released and the turret is rotated manually
6. Limit dogs are used to control the distance of
tool movement
7. Some turret lathes have the facility of moving the
turret at right angles to the lathe axis
8. Heavy and sturdy
9. Suitable for machining heavy and large work
pieces
10. Machining can be done by providing more
depth of cut and feed
Turret lathe
It is a heavy duty machine
The turret head is directly mounted on the
saddle and the saddle slides over the bed ways
The saddle is moved along with the turret head
during machining
The lengthwise movement of turret is more
Long work pieces can be machined
It is difficult to move the turret head along with
saddle
The turret head can bbe moved crosswise in
some turret lathes
As the construction of lathe is rigid, heavy cut
can be given
Capstan lathe
1. Turret head is mounted on a slide called ram
which is mounted on the saddle
2. To provide feed to the tool, saddle is locked at a
particular point and the ram is moved
3. It is easy to move the ram for feed
4. As the movement of the ram is limited, it is
suitable for machining shorter work pieces only
5. When the hand wheel for the ram is reversed,
the turret tool head is indexed automatically
6. To control the distance of tool movement, feed
stop screws are provided at the rear side of the
turret
7. No such facility
8. Lighter in construction
9. Only small and light work pieces are machined
10. Only limited amount of feed and depth of cut
are provided for machining
Advanced Production Process 6 Module I

It is used for machining work pieces up to It is used for machining work pieces up to
9
60mm diameter 200mm diameter

10 Collet is used to hold the work piece Jaw chuck is used to hold the work piece
Bar feeding mechanism of capstan lathe
The figure typically shows the kinematic arrangement of feeding and clamping of bar stock in
capstan lathes. The bar stock is held and tightly clamped in the push type spring collet which is
pushed by a push tube with the help of a pair of bell-crank levers actuated by a taper ring as shown
in figure. Bar feeding is accomplished by four elementary operations;

 unclamping of the job – by opening the collet

 bar feed by pushing it forward
 clamping of the bar by closing the collet
 Free return of the bar-pushing element.
Typical bar feeding mechanism in capstan lathe

After a job is complete and part off, the collet is opened by moving the lever manually rightward to
withdraw the push force on the collet. The bar is passed through the bar chuck spindle of the
machine and then through the collet chuck. The bar chuck rotates in the sliding bracket and the other
end supports a weight the chain running over two fixed pulleys and mounted on the slide bar. The
weight constantly exerts end thrust on the bar chuck while it revolves on the sliding bracket and
forces the bar through the spindle, the movement the collet chuck is released. Thus the bar feeding
may be accomplished without stopping the machine.

Turret indexing mechanism

The turret can indexed long with its to and fro motion. The plunger locks the index plate by
spring pressure and prevents rotary movement when the turret is moving forward. During this
advancement the tool held in the turret performs its operation. Indexing of turret is done during
backward position of turret; the actuating cam lifts the plunger out of of the groove and unlocks
indexing plate. This due to riding of the pin on the bevel surface of the cam. By this time, the spring
loaded pawl engages with a groove of the ratchet plate causes the ratchet to rotate as the turret
moves backward.
 Advanced Production Process 7 Module I

As the turret rotates through one sixth of revolution, the bevel gear causes the plate to rotate.
The ratio of the teeth between the pinion and the turret is indexed to bring it to the cutting position,
the particular stop rods for limiting the feed of each operation may be adjusted by unscrewing the
lock nuts and rotating the stop rods on the plate. Thus six stop rods may be adjusted for controlling
the longitudinal travel of tools mounted on six faces of the turret.

Work Holding Devices

Work Holding Devices of Turret Lathes - Turret is a mass production machine. In order to keep set
up time to minimum, the work holding devices should be accurate, easy and quick to operate, and
should ensure rigidity against heavy cuts. Commonly used work holding devices are:

 Collet chucks,
 Jaw chucks,
 Arbors, and
 Fixtures.

Collets: Collets are used to grip the bars passing through the head stock spindle. They are more
suitable for mass production because of their quick action and accurate setting. Collects grip the
work by the spring action of its split jaws.

Chucks: Chucks are used for the gripping of large sized work which cannot be introduced through head
stock spindle and gripped by collets. Both four jaw and three jaw chucks are used on capstan and turret
lathes.

Fixtures: It is used as a holding device when the shape of a workpiece is irregular and difficulty to hold
in a spring collect or a chuck. It is specially designed to locate and grip a work piece. It alsopermit raid
loading and un loading of work pieces.
 Advanced Production Process 8 Module I

Tool Holding Devices: A variety of tool holding devices are used in turret and capstan lathes. These
devices enable to hold different types of tools on the hexagonal turret faces and on the front and rear
tool posts. The following are some of the most commonly used tool holding devices.

1. Straight cutter holder

2. Plain or adjustable angle cutter holder
3. Multiple cutter holder
4. Multiple turning head or combination tool holder
5. Flange tool holder (extension arm)
6. Slide tool holder
7. Knee tool holder
8. Roller steady box tool holder
9. Recessing tool holder
10. Bar ending tool holder
11. Work stop
12. Self-opening die holder
13. Collapsible tap
14. Combination bar stop and centering tool
15. Combination centering and facing tool

Straight cutter holder: It is a simple tool holder in which the tool is held perpendicular to the holder
shank axis by three sets of screws. The shank can be mounted directly into the hole of the turret face, it
is used for turning, facing, chamfering etc.

Multiple cutter holders: The tool holder facilitates taking multiple cuts, taking the cuts simultaneously
with more than one tool from the same tool station is known as multiple cuts. The term combined cuts
indicates taking the cuts simultaneously by tools mounted on cross slide and those mounted on turret.
Its shank is mounted directly in a holder on turret face.

Knee tool holder: It is bolted directly to the turret face. Additional support is given by the overhead
pilot which is located in the bush.

Flange tool holder: Flange tool holder or extension holder bolted to the hexagonal turret. It is widely
used for holding boring bars, centers and shank type tools.

Knurling tool holders: It is fitted to the turret face. The knurls can be adjusted to knurl on different
diameters work.

Form tools: Tool is mounted on a dovetail slide and its height is adjusted by moving within the idle.
Circular form tool is held in similar way and its height is adjusted by rotation. Form tool holder is
usually held on cross slide.

Roller study tool holder: Roller and tool are contained within a box like structure. Both rollers are
independently mounted on slides, and can be adjusted for wide range of diameters.
 Advanced Production Process 9 Module I

Die holder: Self-opening die head s used for cutting an external threads by using a capstan lathe. The
advantages offered by the use of self-opening dies are;

 Accurate threads produced by adjustment of the cutting dies,

 Reduction in the machining time.
Advanced Production Process 10 Module I

AUTOMATIC AND COPYING LATHE

Automatic machine is one in which certain movements, commonly made by hand are made by
machine itself.

Advantages of automatic machines.

 Reduce human involvement.
 Reduce work piece damage caused by manual handling of parts.
 Raise the level of safety, particularly under hazardous working conditions.
 Increase in productivity.
 Decrease in unit cost.
 Improved accuracy.
 Less wastage through automatic controls.
 More resource utilization with better safety.

Disadvantages of automatic machines.

 Initial cost is higher
 Maintenance cost is higher
 Economical for mass production only

Comparison between semi-automatic lathe and automatic lathe

Semi-automatic lathe lathes are production lathes in which, once the machine is setup, all
the machining operations (all the movements relating to manufacturing cycle) are
performed automatically but loading of work pieces and unloading of finished components
are accomplished by the operator.

In automatic lathes all the movements related to the manufacturing cycle and also the
loading of work pieces and unloading of finished parts are performed without attention
of operator. Only it requires initial setup of the machines.

Classification of semi-automatic and automatic lathes:

Semi-automatic and automatic lathes are classified as follows:

1. According to numbers of spindles
a. Single spindle lathes
b. Multi-spindle lathes
2. According to the purpose
a. General purpose lathes
b. Single purpose lathes (cut-off machines, screw machines)
3. According to the type of blank
a. Bar type lathes
b. Chucking type lathes
4. According to the arrangement of spindle
a. Horizontal type
b. Vertical type
 Advanced Production Process 11 Module I

Single spindle automatic lathe : The general purpose single spindle automatic lathes are widely used
for quantity or mass production (by machining) of high quality fasteners; bolts, screws, studs etc.,
bushings, pins, shafts, rollers, handles and similar small metallic parts from long bars or tubes of
regular section and also often from separate small blanks. Fig shows a typical single spindle automatic
lathe.

Unlike the semiautomatic lathes, single spindle automats are:

• Preferably and essentially used for larger volume of production i.e., large lot production and mass
production
• used always for producing jobs of rod, tubular or ring type and of relatively smaller size.
• run fully automatically, including bar feeding and tool indexing, and continuously over a long
duration repeating the same machining cycle for each product
• provided with up to five radial tool slides which are moved by cams mounted on a cam shaft
• of relatively smaller size and power but have higher spindle speeds
Types of single spindle automatic machines:
The following types of single spindle are most commonly' used.

1. Automatic cutting-off machines.

2. Single-spindle automatic screw machine.
3. Swiss-type automatic screw machine.

Automatic cutting-off machines: Automatic cutting- off machines are designed to

produce small parts from bar stock in mass, production. They are primarily used for turning,
facing and cutting-off operations. Special operations such as form-turning, drilling and
threading can also be performed by using attachments.

The required length of stock is feed out with a cam mechanism up to stock stop and
is held in- collet chuck of the rotating spindle. Stock stop is automatically advanced in line
with the spindle axis at the end of each cycle. The tools on the from cross-slide perform
operations of turning or forming whereas tools on rear cross-slide perform the
facing, chamfering and cutting-off operations.
Advanced Production Process 12 Module I

Single-spindle automatic screw machine: Automatic screw machines were originally designed
formanufacturing bolts and screws from bar stock in mass production. But they are now
used for production of small ram of single-spindle automatic- screw machine. The bar is
advanced through stock tube upto stop and is clampedin the rotatingspindle by means of
collet-chuck. These machines are provided with mechanism to control the movements of
turret so that mechanism is also provided for clamping the work in the collet, releasing it at
the end of cycle and then feeding unmachined bar stock against the stop.

The tools are fixed in indexing turret and in cross-slides. The turret carries six tools
and are used for longitudinal turning and machining of the central holes. At the end of
each cut turret slide is withdrawn automatically and indexed to bring cutting tool in
position.Front and rear cross-slides are employed for cross-feeding the tools for form
turning. A tool mounted on vertical slide is used for parting off operation. All the movements
of the machine units are actuated by cams mounted on the cam shaft.

Swiss type automatic screw machine : In swiss-type automatic screw machine

headstock ismovable and the tools are fixed in t 11e slides. It is also called as sliding
head type automatic screw machine. These machines are employed for mass
production of long accurate parts of small diameter bar stock. These machines are
chiefly used In the precision industries for manufacture of watches, instruments, radio
parts etc . The swiss type automatic screw machine has the following features:

1 A sliding headstock through which bar stock fed.

2. A tool bracket which supports five tools slides and also a guide bush to support the
bar stock.
3. A camshaft at the front of the machine.
4. A special attachment (auxiliary tool mount) mounted on the right-hand side of the bed, and
5. A camshaft at the front of the machine.
Advanced Production Process 13 Module I

The swiss type automatic machine stock held by a rotating collet in the headstock
and is fed through a hard bushing in the centre of the tool head. Five single point tools ar
placed Tools on horizontal slide performs plain turning while other tools on three slides are used for
knurling, radially on the tool head (bracket) around the bushing. chamferring, recessing and
cutting-off operations. These tools are controlled by cams that brings the tools in as
required for different operations. The special operations such as centering, drilling and
reaming are performed by auxiliary slide.

Multi-Spindle lathes: Multi-spindle (semi-automatic or automatic) lathe has from two to eight work-
rotating spindles. Multi-spindle automatic lathes are widely used in mass production. More
production is possible due to the increased nurnber of operations that can be performed at
the same time on one lathe. But their machining accuracy is comparatively lower.
Each of the spindle is provided with a spring collet chuck through which bar stock is passed
and each rotates as in a single spindle machine."Suitable cutting tools such as drills, taps,
reamers etc., are located in front of the each spindle. The cross-slides are provided with
other cutting tools of turning, forming and cutting-off operations. At the finish of an
operation, each spindle rotates progressively from one position to another until the cycle is
completed.

COPYING MACHINES
Copying machines are used to reproduce the shapes. from a larger or smaller
template. Copying systems are used extensively on centre lathes, and a taper turning attachment
straight line is an copying example device of a which simple mechanical is available for
moststandard lathes.
The following types of copying machines are used to produce the most complex
forms:

-.
Advanced Production Process 14 Module I

1. Mechanical type (Pantograph copying system). .

2. Hydraulic servo copying system

3. Electric copying system

Mechanical type (Pantograph copying system): The working of mechanical type copying
machine is based upon the principle of the pantograph and is used to copy the form of
an involute gear tooth space on to the grinding wheel of a gear tooth grinding
machine. It will be noted that the follower, fulcrum and tracer must all lie on a straight line
(shown dotted). Also the type of pantograph shown produces a reverse image of the template
from on the wheel and hence template must be arranged accordingly.

Hydraulic System:

The hydraulic system for lathe tracer controlled copying unit. It has the advantage
of having very little contact pressure between the stylus and template. The hydraulic
units are basically servomechanism which magnifies a relatively small input force or signal
in order to provide a larger output force or signal for operating the mechanism. This output
signal from the servo mechanism must be continually and automatically modified to
suit variations in the input signals. The lathe saddle traverses along the bed, the stylus will
follow the template edgealways being kept in contact by spring pressure on the lefthand end
of the valve spool. If the stylus moves to the right then the spool slide will move to the right.
This will allow the oil to the left of the piston to exhaust, and will allow oil in to the right of the
piston hence moving it to the left. Therefore, the too] and tool will move to the left
reproducing the template shape upon the work piece. The responsiveness and accuracy
of the copying system depend upon the accuracy with which the spool valve is
manufactured. The spool shoulder lengths and port openings must be of a precise
length, and the resistance to oil flow must be identical at any spool position.

Electric Copying System:

Electric copying system use magnetic clutch with 'make' or "break' action to
traverse the machine slides in the direction required. Electric copying system is
illustrated in Fig. 2.8. The tracing stylus is held centrally in a universal ball joint and
is free to move in any direction. The back end of the stylus is centred in a cup which is an
integral part of the switch lever. Due to stylus movement, either contact c1 and c2
will be closed which energises the corresponding relay which in turn operates the
Advanced Production Process 15 Module I

corresponding magnetic clutch. Hence magnetic clutch moves the machine slide either left
or right corresponding to stylus movement. A stylus movement of 0.025 mm is sufficient to close
contact c1 or c2 and cause a change in the direction of the cutter travel.

MACHINING CENTERS

Machining center: A Machining center is a simply a CNC milling machine with an automatic
tool changer and an enclosure. Machining centers are very important type of CNC
machine tools and are multifunction machines equipped with automatic tool changes and
are capable of carrying out milling, drilling, reaming, tapping, boring, counter boring
and allied operations without operator intervention for change of tools. Tool
changing is carried out using an automatic tool changer and is accomplished in
4-6 seconds.

TYPES OF MACHINING CENTERS:

There are a number of different types of machining centers differentiated by the number of
programmable axes.
1. Three Axis Machining Center.
2. Horizontal Three Axis Machining Center.
3. Four Axis Machining Center.
4. Five Axis Machining Center.
5. Machining Center with pallet changer

Characteristics and capabilities of machining centers:

1. Three Axis Machining Center: machining center has programmable X and Y axes in
the plane of the table and a Z axis in the spindle's direction. This is most basic type axis
machines are of machine center.
Advanced Production Process 16 Module I

2. Horizontal Three Axis Machine: A three axis horizontal machining center. One can still only
machine one surface of a cube with the end of the cutter and four additional surfaces with
the side of the cutter.

3. Four Axis Machining Center: Four axis machining centers are generally horizontal, and the table
rotates to create the forth axis. Frequently, a fixture called a tombstone is mounted on the table and
many small parts machined at once on a large machine. One can machine four surfaces of a
cube with the end of the cutter and two additional surfaces with the side of the cutter.

4. Five Axis Machining Center : It is very similar to the four axis machine except the spindle
rotates from horizontal to vertical. These machines are used to machine complex parts and
molds in the aerospace and automotive industries.
One can machine five sides of a cube with the end of the cutter and six sides with
the side of the cutter. Besides complex geometry, we can often machine a part in one setup
on a five axis machine that would require two or more setups in a simpler machine.
This results in a more accurate part.
5. Machining Center with Pallet Changer: Most machining centers can be fitted with a pallet
changer to increase productivity. On a plain machine, it sits idle while the operator removes
the completed parts and loads the fixture with new ones. With a pallet changer, the operator
unloads and reloads one pallet while the machine works on the other. This way, the machine
continuously cuts parts.
Advanced Production Process 17 Module I

Features of Machining Centers

• Higher spindle speed 10,000-30,000 rpm.

• Higher rapid traverse 40 to 60 meters / minute.

• Quick and faster tool changing system.

• It has digital servo control system of main spindle for accuracy.

• It has very efficient thermal control system on various machine elements like main
spindle, balls and ball screws and ball bearings for accuracy

Major characteristics of CNC machining centers :

1. Machining centers are capable of handling a wide variety of part sizes and
shapes efficiently, economically, respectively, and with high dimensional accuracy
with tolerances in the order of +0.0025mm.

2. These machines are versatile and capable of quick change over from one type of
product to another.

3. The time required for loading and unloading work pieces, changing tools, gauging of the
part, and troubleshooting is reduced. Therefore productivity is improved, thus reducing labor
requirements (particularly skilled labor) and minimizing production costs.

4. These machines are equipped with tool-condition monitoring devices for the
detection of tool breakage and wear as well as probes for tool-wear compensation and for tool
positioning. In-process and post-process gauging and inspection of machines work pieces are
now features of machining centers

5. These machines are relatively compact and highly automated and have advanced control
systems, so one operator can attend to two or more machining centers at the same time,
thus reducing labor costs.

RECONFIGURABLE MANUFACTURING SYSTEM:

A reconfigurable manufacturing system (RMS) is one designed at the outset for rapid
change in its structure, as well as its hardware and software components, in order to quickly
adjust its production capacity and functionality within a part family in response to sudden
market changes or intrinsic system change.

Ideal Reconfigurable Manufacturing Systems possess six core RMS characteristics:

Modularity, Inerrability, Customized, flexibility, scalability, Convertibility and Diagnosability. RMS
facilitates a quick production launch of new products, and allows for adjustment of production
quantities that might unexpectedly vary. The ideal reconfigurable system provides exactly the
functionality and production capacity needed, and can be economically adjusted exactly
when needed. The components of RMS are CNC machines, Reconfigurable Machine
Tools, Reconfigurable Inspection Machines and material transport systems (such as gantries
Advanced Production Process 18 Module I

and conveyors) that connect the machines to form the system. Different arrangements
and configurations of these machines will have an impact on the system productivity.

RMS Principles :

Reconfigurable manufacturing systems operate according to a set of basic principles

formulated by professor Yoram Koren and eae called Koren's RMS principles. The more of
these principles applicable to a given manufacturing system, the more reconfigurable is that
system. The RMS principles are:

1. The RMS is designed for adjustable production resources to respond to imminent

needs. * The RMS capacity is rapidly scalable in small, optimal increments. * The RMS
functionality is rapidly adaptable to the production of new products.

2. To enhance the speed of responsiveness of a manufacturing system, core RMS

characteristics should be embedded in the whole system as well as in its components
(mechanical, communications and controls).

3. The RMS is designed around a part family, with just enough customized flexibility needed
to produce all parts in that family.

4. The RMS contains an economic equipment mix of flexible (e.g. CNC) and reconfigurable
machines with customized flexibility, such as Reconfigurable Machine Tools, Reconfigurable
Inspection Machines, and Reconfigurable Assembly Machines.

5. The RMS possesses hardware and software capabilities to cost-effectively respond to

unpredictable events both external (market changes) and intrinsic events (machine failure).

Comparison of RMS and FMS:

Reconfigurable Manufacturing Systems and Flexible Manufacturing Systems (FMS) have

different goals. FMS aims at increasing the variety of parts produced. RMS aims at increasing
the speed of responsiveness to markets and customers. RMS is also flexible, but only to a
limited extent its flexibility is confined to only that necessary to produce a part family. This is
the “customized flexibility" or the customization characteristic, which is not the general
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flexibility that FMS offers. The advantages of customized flexibility are faster throughput and
higher production rates. Other important advantages of RMS are rapid scalability to the
desired volume and convertibility, which are obtained within reasonable cost to
manufacturers. The best application of a FMS is found in production of small sets of products;
With RMS, however, production volume may vary from small to large.

HEXAPOD MACHINES:

A hexapod is a new design of six-legged parallel mechanism structure. Parallel mechanism

structures are those ones having parallel links (struts) joining between the base and its
platform, or the output piece. Parallel mechanism generally comprises have platform’s
which are controlled by a several prismatic joints or legs (struts) acting in parallel.

The most common configuration comprises six legs, and these legs are linear actuators
such as hydraulic cylinders, or in the case of positive mechanism they could be spring loaded.
The output piece is defined as the movable platform which has six degree of freedom relative
to the other, platform, which is the base. With six degree of freedom the movable platform is
capable of moving in three linear directions and three angular directions singularly or in any
combination.

The hexapod is .a closed chain kinematic structure. The component has to be composed of six
struts. However, there are several combinations that fall under the same name. The hexapod
consists of six struts-hydraulic ones. These struts are free to expand and contract between the
base at the bottom, and the top platform. The platform is the output element that gets the 6 DOF
of the system. The platform receives all six coordinates’ freedom in motion. Both ends of the
hydraulic struts are connected to either the platform started to be commercially available
for variety of applications that requires sub-micron accuracy.

Unique Characteristics:

• For any change in the position of the platform along one of the six axis (3 translation,
3 rotation) to be achieved, all the six struts of the hexapod change their position.

• Using software control, some models of the hexapod can attain sub-micron accuracy.

Applications of the Hexapod:

• Flight Simulators.
• Precision Machining.
• Precision Surgical Robots.

The Advantages:
• Six degree of freedom.
• High precision and accuracy.
• Computer visualization tools.
• Graphic simulation and computer animation.
• High stiffness.
• High load/weight ratio.
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• Variety in the size.

• High production rate.

Limitations and Shortcomings:

• Friction -Friction in the ball joints is a crucial problem for the hexapod. That
the friction coefficient is about 0'.8, and that is enough to exert some axial deflection on the struts
that influences the accuracy and repeatability. Using a ceramic coating and special lubricant,
the modified struts are down to 0.2 coefficient of friction.

• Length of the struts -The length of the struts affects the accuracy of the machine. When
the length increases. The accuracy decreases dramatically (possibility of bending). This
problem has been overcome by mapping each screw before installing in the machine.

• Dynamic thermal growth - This problem has appeared also in the serial linkage
mechanism. That with the increase in the speed of the spindle, there is a dramatic increase
in the dynamic thermal growth. One way to overcome that hurdle is by monitoring the
struts in real time employing one dimension finite element analysis that activates an
automatic error compensation routine built into the software and based on the known
growth rate of the struts.

• Calibration - The accuracy of the parallel- mechanism is not only dependent upon an
accurate control of the length of its links but also upon knowledge of its geometrical
characteristics. According to the fabrication tolerances many factors will play a role in
the final accuracy of the machine. Up to 132 parameters must be specified to describe the
geometrical characteristics of the mechanism which seems to be very difficult to adjust all
parameter. Therefore the calibrations of the hexapod still an open problem.