Non-Traditional Machining and

Automation
(MET 255)
B.Tech. (4th Sem) Spring 2021
Department of Mechanical Engineering
NIT Srinagar

Course Incharge
Dr. Noor Zaman Khan
Course Outcomes
At the end of the course, a student should be able to:

• CO1: Analyze and access the importance of automation and industrial automated systems.

• CO2: Identify and Analyze functions and functioning of CNC machines.

• CO3: Recognize the need of non-traditional machining processes and understand the working of high energy
beam machining.

• CO4: Illustrate underlying mechanisms in non-traditional machining processes along with their applications
Syllabus of Unit 1
• Introduction to automation

• Types of automation

• Introduction to Flexible manufacturing systems (FMS)

• Elements, types and advantages of FMS

• Cellular manufacturing

• Types of flexibilities in FMS

• Test of flexibility

• Product processing strategies

• Introduction to robotics

• Elements of Robotic Systems

 Automation
• Industry: In a general sense the term “Industry” is defined as a ‘Systematic Economic
Activity that could be related to Manufacture/Service/ Trade’.

• In this course, we shall be concerned with Manufacturing Industries only.

• Automation: Auto (self) + Matos (moving) (Greek words)

• Automation therefore is the mechanism for systems that “move by itself.

• Automation can be defined as the technology by which a process or procedure is

performed without human assistance.
Reasons for automation

• Shortage of labor

• High cost of labor

• To increase productivity

• Competition

• Safety

• Reducing manufacturing lead time

• Lower costs in the long run

Reasons against automation

• Labor resistance

• Cost of upgraded labor – new skill set

• Initial investment

• Management of process improvements

• Reengineering- redesign a machine or device and restructure a

company
Components of an Automated System

An automated system consists of three basic components:

• (1) power
• (2) a program of instructions
• (3) a control system to carry out the instructions

The relationship among these components is shown in Figure

i. Power-: So as to drive the process and operate the system as well.

ii. Program of Instructions- To govern the process.

iii. Control System- To actuate the instructions

Types of Manufacturing Automation
Fixed, Programmable, Flexible
Fixed Automation: Fixed automation is a system in which the sequence of processing (or assembly) operations
is fixed by the equipment configuration.

• It is used in high volume production with dedicated equipment, which has a fixed set of operation.

• The program of instructions is determined by the equipment design and cannot be easily changed.

• Continuous flow and Discrete Mass Production systems use this automation.

• E.g.: Conveyors, Paint Shops, Transfer lines etc.

Typical features

(1) High initial investment for specialized equipment,

(2) High production rates,

(3) Relatively inflexible to accommodate product variety.

(4) Low unit cost
Fixed automation is appropriate in the following circumstances.

A. Low variability in product type as in size, shape, part count and material

B. Predictable and stable demand for 2- to 5-year time period, so that manufacturing
capacity requirement is also stable

C. High production volume desired per unit time

D. Significant cost pressures due to competitive market conditions. So automation

systems should be tuned to perform optimally for the particular product.
Programmable Automation:
• In programmable automation the production equipment is designed with the capability to change the sequence
of operations to accommodate different product configuration.

• New programs can be prepared for new parts, and the equipment can read each program and execute the
• encoded instructions.
• It is typically used in Batch process where job variety is low and product volume is medium to high, and
sometimes in mass production also. e.g. in Steel Rolling Mills, Paper Mills etc.

• Examples of programmable automation include computer numerical control and industrial robotics

Features

• High investment in general purpose equipment that can be reprogrammed

• Lower production rates than fixed automation

• Ability to cope with product variety by reprogramming the equipment.

• Suitability for batch production of various part or product styles.
Flexible Automation
• Extension of programmable automation
• There is virtually no lost production time for setup changes and/or reprogramming.
• Any required changes in the program of instructions and/or setup can be accomplished quickly.
• A flexible system is therefore capable of producing a mixture of different parts or products one right after the
other instead of in batches.
• Examples of flexible automation include manufacturing cell, Flexible manufacturing systems, computer
integrated manufacturing.

Features

• High investment for a custom-engineered system

• Continuous production of different part or product styles

• Medium production rates.

• Flexibility to deal with product design variations.

Flexible Automation
• It is typically used in job shops where product varieties are high and job volumes are medium to
low. Such systems typically use Multi purpose CNC machines, Automated Guided Vehicles (AGV)
etc.

Flexible automation, is used in the following situations.

• Significant variability in product type. Product mix requires a combination of different parts and
products to be manufactured from the same production system

• Product life cycles are short. Frequent upgradation and design modifications alter production
requirements

• Production volumes are moderate, and demand is not as predictable

Types of Manufacturing Automation
What kind of automation would you recommend for manufacturing

•B
•C
•T
•T