Automated

Machining

Manufacturing
Processes
 Outline

Machining Centers
Equipment
Tool Changers
Centering and Clamping
Selection of Equipment
Selection of Tooling
Machine Performance
Monitoring
Manufacturing Cells
Manufacturing Economics
 Machining Centers

Machining Center
A computer-controlled machine
tool capable of many types of
cutting operations on multiple
surfaces and directions on a
workpiece
Manufacturing Centers
Z
Y

3-Axis Operation

4-Axis Operation

φ
θ

5-Axis Operation
Components of a
Machining Center
 Example of a
Machining Center
 Example of a
Machining Center
Example of a Machining
Center

Example of a 5-axis CNC machine (the tool pivots

instead of the workpiece)
Example of a Vertical
Machining Center
Example of a Horizontal
Machining Center
 Examples of
Manufactured Parts
Automated Robotic
Loading
Automated Robotic
Loading
 Equipment

Pallets
The workpiece is placed on a
pallet (module) which can be
oriented in different directions
by the machine

Automatic Pallet Changers

When the workpiece is
finished, automatic pallet
changers remove it and
replace it with another
workpiece
 Pallets

Example of a part mounted on a pallet

Courtesy Toth Industries
Pallet Changers
 Equipment

Automatic Tool Changer

Can switch between up to 200
tools stored in a magazine,
drum, or chain

Tool Exchange Arm

Picks up particular tools with
attached toolholders
 Tool Changer
Types
Automatic (Sequential) Spindle
Turns one increment in one
direction for each tool change; tools
must be placed in the spindle in the
order they are used

Indexable (Random Access) Spindle

Turns either direction to make a
specific tool accessible; tools can
be placed in any order as long as
the computer knows their positions
 Tool Changer
Types

3 1

4 6

Sequential Spindle

8 1 4

6 2

5 3
7

Random Access Spindle

Tool Changer Spindle
Tool Changer Spindle

Tool changer spindle capable of holding 60 tools

Courtesy of Toth Industries
Tool Changer Arm
Tool Changer Arm
Tool Changer Arm
Tool Changer –
Live Spindle
 Types of
Manufacturing
Cutting From Bulk Material
Starting with a readily available
shape (rods, ingots etc.) and
machining the part from this

Cutting From Near Net Shape

Starting with a pre-formed
(often cast) piece with the
general shape of the part and
removing little material
 Centering and
Clamping
Pre-cast designs should be
made so that the machines can
clamp and orient them quickly
and accurately

Parts to be lathed should have

radially symmetrical outer
surfaces and pre-cast holes to
mark the center; they should
also have a center of mass on
the center line to prevent
vibration
 Orienting and
Clamping

notches
holes

Pre-cast parts should have at

least three distinct features that
the computer can recognize
and use to orient the part
 Centering and
Clamping
Pre-cast parts should have flat
parallel surfaces for clamping
or cylindrical surfaces for
chucking

Areas to be clamped or chucked

can be ground flat after casting
to improve grip
 Selection of
Equipment
Various types of parts may require
various machining centers

Parts with numerous cylindrical

surfaces (or other radially
symmetrical surfaces) should be
mounted on a machine center
capable of turning

Specialized machine centers are

available for high-speed machining
and for ultraprecision cutting
 Selection of
Equipment
Example: Pump Cover

Starting with the rough casting,

drill and ream the center hole,
then cut the internal notch with
a milling cutter. Mount the
piece on a mandrel and use
turning operations to cut the
faces and outer edge. Mill the
external notch and drill and
ream the smaller holes in the
plate.
 Selection
of Tooling
The proper selection of tools
depends on the workpiece
material, size and shape of
holes, radii of the corners of
milling pockets, and various
other parameters

The selection of tools affects the

cost and time of the operation
Machine Performance
Monitoring
Machine Performance
Monitoring
Y
Y’
Part Orientation

X’

Cutting Performance
 Machine Performance
Monitoring
Tool/Part-Checking Station
Measures workpieces and
tools so that the computer can
compensate for variations and
tool wear

Touch Probes
Pressed against a workpiece
or tool to measure its exact
size and position
Touch Probes
 Measurement and
Adjustment
critical distances

Holes to be drilled Holes to be drilled

(initial) (adjusted)

Advanced machining software can

use data from probes to adjust its
coordinate system, ensuring that
critical distances remain within
tolerances even in deformed
workpieces
 Touch Probes

tool
holder

probe

part

Using a touch probe to measure a part

Courtesy Toth Industries
 Touch Probes

A machining center, being used to measure and determine

the orientation of a part
Courtesy of Toth Industries
 Touch Probes

tool changer arm probe part

A machining center, being used to measure and determine the

orientation of a part
Courtesy of Toth Industries
 Touch Probes

To determine the orientation of the part, the machine measures

the two large holes and calculates their centers. A line
constructed between the centers serves as a base for the
computer’s coordinate system.
Courtesy of Toth Industries
 Machine Performance
Monitoring
Tool Failure Detection:
- Time
When the total cutting time of
the tool exceeds the pre-
programmed tool life, the tool
is replaced
- Horsepower
Dull tools draw more power; if
the power exceeds pre-
programmed limits, the tool is
replaced
 Machine Performance
Monitoring
Tool Failure Detection:
- Acoustic Emissions
Cutting tools produce
ultrasonic vibrations and
weakened ones produce up to
five times the normal
amplitude; when it rapidly
increases, the tool is
immediately replaced
 Machine Performance
Monitoring
Tool Failure Detection:
- Feed Force
Records the feed force of
sharp tools; if the force
increase exceeds a
predetermined percentage, the
tool is replaced; if the force
suddenly rises, the tool has
broken and is replaced
immediately
Manufacturing
Cells
Manufacturing
Cells
Manufacturing
Cells
Manufacturing Cells –
Examples

Courtesy of Toth Industries

 Manufacturing
Economics
Cost:
If the cutting speed is too low,
the cost of cutting increases
because of increased power
consumption

If the cutting speed is too high,

the cost of tool replacement
increases because tools wear
out faster
 Manufacturing
Economics
Time:
If the cutting speed is too low,
the cutting time increases

If the cutting speed is too high,

the tool replacement time
increases
Manufacturing
Economics
 Summary

Machining Centers allow increased

automation and efficiency,
especially in large-scale production

Monitoring, by an operator or the

machine itself, is necessary to
prevent damage to the parts
produced

Cutting speed can be varied to

minimize the total cost or time of
the operation
The End