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TELECOM FACTORY CORE

Advances in Machine Tools and Manufacturing

Technology

WELCOME TO TRAINING UNDER THE TIME BOUND/POST BASED

EXECUTIVE PROMOTION POLICY FOR TELECOM FACTORY EXECUTIVES

1. Machine Tools are defined as the Power Driven

Equipment designed to drill, bore, grind or cut

metal or other materials.

2. In other words it is safe to say all machine tools

are “Machines that helps people to make

things”.

D E F I N I T I O N O F M A C H I N E T O O L

Machines that a modern perspective might call machine tools have existed for millennia

However, modern machine tools began to develop only after the development of the steam engine , which led to the Industrial Revolution. Today, most machine tools are powered by electricity

Soon after the World War II , the numerical control ( NC) machine was developed. NC and CNC machines could precisely repeat sequences over and over, and could produce much more complex pieces than even the most skilled tool operators.

Some examples of machine tools are Broaching Machine, Drill Press, Gear Shaper, Hobbling Machine ,Lathe, Milling Machine, Planer, Grinding Machines etc.

H I S T O R Y

For fabrication or shaping parts, several techniques are used to

remove unwanted metal. Among these are :-

• Electrical Discharge Machining

• Grinding ( abrasive cutting )

• Multiple edge cutting tools

• Single edge cutting tools

• Other techniques are used to add desired material.

Devices that fabricate components by selective addition

of material are called rapid prototyping machines.

1. Machine Tool Builder Support

2. CNC Control and Components

3. Accessories for machine tools like rotary tables ,

integrated spindles and machining heads etc.

4. Retrofitting CNC Machines

5. CNC Lathes, millturn tables, machining centers, multi-

tarring machining centres, laser processing machines.

6. Semi Conductor Manufacturing related machines

M A C H I N E T O O L AU T O M AT I O N

ADVANCES IN MACHINE TOOLS

Usage of CNC Machines to have increased productivity

Use of laser cutting tools to cut a wide range of materials from metals, Plastics, ceramics and wood.

Machine tools industry has evolved significantly over the years, with development in both hardware technologies and related software applications.

The adoption of CAD-CAM integration technologies has enabled increased accuracy and brought in automation in the machining process.

With the use of software applications enable advanced features in machining systems live higher precision machining to handle growing miniaturization, ability to handle different materials that include glass and ceramics and also medical devices.

Automation of the manufacturing engineering process

Development of total manufacturing solution rather than simply supplying equipment alone.

Never wear jewellery while working around machine tools . Rings,

watches or bracelets may be caught in a revolving part which could

result in the hand being pulled into the machine.

Never use compressed air without safety nozzle to clean machines

or clothing. It will blow sharp , dangerous metal chips a long

distance.

Always use a rag when handling sharp cutters such as milling

cutters and end mills.

Do not expose power tools to rain or use in damp or wet

locations.

Always secure the workpiece. Use clamps or a Visa. It is safer

than using your hands, and it frees both hands to operate the tool

SAFETY RULES FOR MACHINE TOOLS

Do not operate any machine tool without proper lighting.

Gloves should never be worn when operating machinery

except when absolutely necessary.

Always stop the machine before cleaning it or taking

measurements of the work piece.

Do not lubricate a machine while it is in motion. Injury to the

operator and damage to the machine may result from this

practice.

Know where fire extinguishers are located in the shop area and

how to use them.

SAFETY RULES FOR MACHINE TOOLS

MANUFACTURING PROCESS

AND ITS TECHNOLOGY

Manufacturing Process :-

Manufacturing is a field of engineering that generally deals with different

Practices of manufacturing and researches and development of processes,

Machines and equipments. It also deals with the integration of different

Facilities and the systems of producing quality products ( with optimal

Expenditure) by applying the principles of physics and the study of manufac-

turing systems such as mass production, computer integrated manufactu-

ring, computer aided technologies in manufacturing, just in time manufac-

turing , mass customization, flexible manufacturing etc.

Some of the manufacturing processes are casting, Molding,Forming,

Machining, joining etc.

NON- TRADITIONAL MANUFACUTIRING

TECHNIQUES AND ITS APPLICATIONS

Non-Traditional Manufacturing Techniques

Applications

• Electrical Discharge Machining ( EDM)

Its chief applications are in the manufacture and reconditioning of fresh tool and forging as well as moulds for injecting moulding.

• Electrochemical Machining ( ECM)

One of the main appliactions of ECM is in the aerospace industry to machine difficult –to- Machine materials and complex shaped parts.

• Chemical Machining(CHM) Chemical Milling is primarily used to machine performed aerospace parts to obtain a maximum strength-to-weight ratio. Chemical etching is used for engraving highly intricate details on nearly any metal and to produce printed circuit boards.

Non-Traditional Manufacturing Techniques

Applications

d. Ultrasonic Machining(USM) USM is particularly suited to: 1. Round holes and holes of any shape for which a

tool can be made. The range of obtainable shapes can be increased by moving the workpiece during cutting.

2. Coining operation for materials such as glass, ceramics etc.

3. Threading by appropriately rotating and translating the workpiece/tool.

4. USM is particularly useful in micro-drilling holes upto 0.1mm.

Other promising areas of application of ultrasonics are the welding and sealing of plastics,staking or inserting metal to plastics etc.

NON- TRADITIONAL MANUFACUTIRING

TECHNIQUES AND ITS APPLICATIONS

Non-Traditional Manufacturing Techniques

Applications

e. Abrasive Jet machining (AJM ) e)The major field of application of the AJM process is in the machining of essentially brittle and heat-sensitive materials like glass,quartz,sapphire,semiconductor materials,mica and ceramics.The AJM process is used in drilling holes,cutting slots,cleaning hard surfaces,cutting fine lines,deburring, scribing,grooving,polishing and radiusing. Delicate cleaning,such as removal of smudges from antique documents is also possible with AJM.

f) Laser Beam Machining (LBM) LBM at present is found to be suitable only in exceptional cases like machining very small holes and cutting complex profiles in thin,hard materials like ceramics. It is also used in partial cutting or engraving.Other applications include sheet metal trimming,blanking and resistor riming.

NON- TRADITIONAL MANUFACUTIRING

TECHNIQUES AND ITS APPLICATIONS

Non-Traditional Manufacturing Techniques

Applications

g. Electron Beam Machining ( EBM)

While electron beams are beginning to be extensively used for welding, their machining application are still rate. EBM is generally limited to drilling extremely small holes and cutting narrow solts or contours in thin materials to close tolerances.

NON- TRADITIONAL MANUFACUTIRING

TECHNIQUES AND ITS APPLICATIONS

MODERN DEVELOPMENT

ROBOTICS

Robotics is the application of mechatronics and automation to create robots,which are often used in manufacturing to perform tasks that are dangerous,unpleasant, or repetitive. These robots may be of any shape and size, but all are preprogrammed and interact physically with the world. To create a robot, an engineer typically employs kinematics ( to determine the robot’s range of motion) and mechanics ( to determine the stresses within the robot). Robots are used extensively in manufacturing engineering.

• Robots allow businesses to save money on labour, performs tasks that are either too dangerous or too precise for humans to perform economically,

and to insure better quality .Many companies employ assembly lines of robots, and some factories are so robotized that they can run by them-

selves. Outside the factory, robots have been employed in bomb disposal, space exploration , and many other fields, Robots are also sold for various residential applications.

ROBOTICS

• Robotics is the application of mechatronics and automation to create

robots, which are often used in manufacturing to perform tasks that

are dangerous, unpleasant, or repetitive. These robots may be of any

shape and size, but all are preprogrammed and interact physically

with the world. To create a robot, an engineer typically employs

kinematics ( to determine the robot’s range of motion) and

mechanics ( to determine the stresses within the robot). Robots are

used extensively in manufacturing engineering.

• Robots allow businesses to save money on labour, performs tasks

that are either too dangerous or too precise for humans to perform

economically, and to insure better quality .Many companies employ

assembly lines of robots, and some factories are so robotized that

they can run by them-selves. Outside the factory, robots have been

employed in bomb disposal, space exploration , and many other

fields, Robots are also sold for various residential applications.

ADVANCE MANUFACTURING

“The Advanced Manufacturing entity makes extensive use of

computer, high precision, and information technologies integrated

with a high performance workforce in a production system capable

of furnishing a heterogeneous mix of products in small or large

volumes with both the efficiency of mass production and the

flexibility of custom manufacturing in order to respond quickly

to customers demands.

USE OF TECHNOLOGY TO IMPROVE

PRODUCTS AND PROCESESS

“Advanced manufacturing centers upon improving the performance

of industry through the innovative application of technologies ,

processes and methods to product design and production”. “A

concise definition of advanced manufacturing offered by some is

manufacturing that entails rapid transfer of science and

technology ( S&T) into manufacturing products and processes.”

PRODUCTS

Any organization characterizes advanced manufacturing products as follows:

• Products with high levels of design

• Technologically complex products

• Innovative products

• Reliable, affordable and available products

• Newer, better, more exciting products

• Products that solve a variety of society’s problems.

PROCESS TECHNOLOGIES

The manufacturing process technologies described in definitions of advanced

Manufacturing include :

• Computer technologies ( eg CAD,CAE,CAM)

• High Performance Computing ( HPC) for modeling,simulation and analysis

• High Precision technologies

• Information technologies

• Advanced robotics and other intelligent production systems

• Automation

• Control systems to monitor processes

• Sustainable and green processes and technologies

• New Industrial platform technologies ( eg composite materials )

• Ability to custom manufacture

• Ability to manufacture high or low volume ( scalability)

USE OF BUSINESS/MANAGEMENT

METHODOLOGIES

The following business or management methodologies were listed as

being a part of advanced manufacturing :

• Quality Control

• Lean Production Technologies

• Supply chain integration

• Advanced Planning and Scheduling

ROLE OF TECHNOLOGY

• Technology plays a key role in creating and maintaining

competitiveness in the global arena. Technology may be defined as all

the knowledge, products, processes ,tools, methods and systems

employed in the creation of goods or in providing services. It consists

of three important interdependent, co- determining and dynamic

components.

• Hardware : the physical and logical equipment that is used to carry out

the required tasks.

• Software : the knowledge of how to use the hardware in order to carry

out the required tasks.

• Brain ware : the reasons for using the technology in a particular way.

BENEFITS OF ADVANCE

MANUFACTURING TECHNOLOGY ( AMT)

• The tangible benefits, which are easily quantifiable,include: inventory

savings,less floor space, improved return on equity (ROE) and

reduced unit cost of production.

• The intangible benefits, which are difficult to quantify, include

enhanced competitive advantages,increased flexibility,improved

product quality and quick response to customer demand.

• The potential benefits which can accrue from investments in

advanced manufacturing technologies have become increasingly

evident with growing global competition.

• Technology plays a major role in quality and flexibility improvement

in process sector companies.

CLASSIFICATION OF ADVANCE

MANUFACTURING TECHNOLOGY ( AMT)

These advanced manufacturing technologies are classified into

Direct AMT, Indirect AMT, and Administrative AMT. These terms

correspond to the hardware ( Direct AMT), Software (Indirect AMT)

and brainware ( Administrative (AMT).

Direct AMT : Technology used on the factory floor to cut,join,

reshape, transport, store or modify materials e.g. CNC,

DNC,robotics, FMS,AS/RS AMHS,AGV, RP etc.

Indirect AMT : Technology used to desing products and schedule

production e.g. CAD,MRP,SPC,BC,MRP II etc.

Administrative AMT : Technology used to give administrative

support to the factory and integrate its operations with the rest of the

organisation e.g. ERP, ABC, OA etc.

Manufacturing objectives have been referred as measures of

competitiveness.

Manufacturing objectives capture how capabilities based

competition will evolve. “Manufacturing objectives represent a

holistic set of tasks, which should be performed by the

manufacturing function in order to support the business

strategy.

MANUFACTURING OBJECTIVES

THANK YOU