COMPUTER AIDED MANUFACTURING

PROF. N. RAMESH BABU

MANUFACTURING ENGINEERING SECTION

DEPARTMENT OF MECHANICAL ENGINEERING
INDIAN INSTITUTE OF TECHNOLOGY MADRAS
CHENNAI – 600 036
Email: nrbabu@iitm.ac.in
 TOPICS OF COVERAGE

 HISTORICAL PERSPECTIVE

 AUTOMATION IN MANUFACTURING
 COMPUTER AIDED MANUFACTURING

 NUMERICAL CONTROL
 DEVELOPMENTS IN NUMERICAL CONTROL

 SEQUENTIAL CONTROLLERS
 TECHNOLOGICAL BACKGROUND

 PROGRAMMING OF NC/CNC MACHINE TOOLS

 TRENDS IN CNC MACHINING
HISTORICAL PERSPECTIVE
HISTORICAL PERSPECTIVE

WOOD CUTTERS LATHE

ENGINE LATHE
HISTORICAL PERSPECTIVE

TURRET LATHE
CAPSTAN LATHE
COPYING LATHE
(TEMPLATE CONTROL)

AUTOMATIC LATHES
(SINGLE / MULTISPINDLE)
 Goals of Manufacturing
• Production of a large variety of products
• Flexibility in production volumes
• Consistency in Product quality
• Lower cost of production
• Lower cost of Inventory
• Lower operating and maintenance costs
• Lower cost of labour etc.

The above goals are achievable with automation

 FACTORS RESPONSIBLE FOR AUTOMATION IN
PRODUCTION

 Inconsistency in skills of operators

 Reduced lead times

 Inconsistency in quality

 Incapability to handle part variety

 Incapability to meet due dates

 etc..
 AUTOMATION - GOALS

1. PRODUCTIVITY ENHANCEMENT

2. QUALITY ASURANCE

3. COST REDUCTION
 Degrees of Automation

Includes the application of hand tools (knife,

hammer, pliers etc) to increase workman
Zero order
efficiency but replaces human energy (or)
control.
Includes portable or stationary machines or
tools (pneumatic drills, portable electric tools,
First order wood lathes, etc.) which are mechanically
actuated but must be fed and controlled by the
operator.
Includes 100% mechanically powered machines
(radial drills, bench lathes etc.) but the operator
Second order
must do complete setup and provide on-off
control.
 Degrees of Automation
Includes completely self-acting machines (turret
Third order lathes, screw machines, grinders, transfer
machines, etc.) with open loop performance.
Includes machines having monitored
performance (turning engines, honing machines
Fourth order 5-axis milling, etc). Machine motions are
corrected as necessary (closed loop feedback
control)
Includes machines that use small special
Fifth order purpose computers, the control being based on
the automatic solution of control equations.
Includes machines or devices wherein control is
Sixth order based on the automatic solution of complex
formal logic equations.
Degrees of Automation
Includes machines that learn from mistakes
Seventh order and attempt different modes of operation as
necessary.
Machines that can extrapolate from experience
(inductive reasoning) and form modes of
operation beyond actual experience (could be
Eighth order
an automatic operations research machine
that sets up much of its own local
programming).
Machines having the creativity or originality to
Ninth order devise new concepts and can work beyond
their programming.
Machines having all the above potentials, plus
Tenth order the characteristics of dominance (able to give
orders to designers and operators).
 PRODUCTION
• PROCESSING
– PRIMARY / SECONDARY PROCESSING
– HEAT TREATMENT
– INSPECTION
– ASSEMBLY

• HANDLING
– WORK MATERIAL, TOOLS, FIXTURES
– SEMI FINISHED PARTS
– FINISHED PARTS
 AUTOMATION IN PRODUCTION
TYPES OF AUTOMATION

– RIGID AUTOMATION

• AUTOMATIC MACHINE TOOLS

• UNIT BUILT MACHINE TOOLS
• AUTOMATIC TRANSFER LINES

– FLEXIBLE AUTOMATION

• NC/CNC MACHINE TOOLS

• FLEXIBLE MANUFACTURING SYSTEMS
• RECONFIGURABLE MACHINE TOOLS
• RECONFIGURABLE MANUFACTURING SYSTEMS
 AUTOMATION IN PRODUCTION
RIGID AUTOMATION FLEXIBLE AUTOMATION

• SINGLE VARIETY • LARGE VARIETY

• MASS PRODUCTION • BATCH PRODUCTION

• LARGE SET UP TIME • SHORT SET UP TIME

• COMPLEX MECHANISMS • SIMPLE MECHANISMS

• DESIGN & MANUFACTURE OF • PROGRAMMABLE AND

TEMPLATES OR CAMS REPROGRAMMABLE
Technologies Responsible For Automation in
Production
PROCESSING HANDLING

Automats Conveyors, RGVs

…

NC/CNC Robots, AGVs ...

Computers, networking technologies etc.

FIGURE 1 OVERALL KINEMATIC SCHEME OF AN AUTOMATIC SCREW MACHINE
FIGURE 2 INDEXING MECHANISM
FIGURE 3
FEED DRIVE FOR WORK TABLE
RECIRCULATING BALL SCREW DRIVE
INFORMATION FLOW TO GENERATE NC PROGRAM FOR A COMPONENT
COMPONENT (PART) DRAWING
COMPONENT (PART) COORDINATE SYSTEM

X Coordinate = Diameter
Function blocks of a machine control unit
STRUCTURE OF DATA INPUT UNIT IN NC MACHINE
FUNCTION BLOCKS OF A MACHINE CONTROL UNIT
SCHEMATIC OF FUNCTIONAL CONTROL OF NC MACHINE TOOL
An Approach for Realisation of
Industrie 4.0

Prof. N. Ramesh Babu

V Balaraman Institute Chair

Manufacturing Engineering Section

Department of Mechanical Engineering
Indian Institute of Technology Madras Chennai –
600 036
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Outline
• What is Industrie 4.0?
• Why do we talk about Industrie 4.0?
• Requirements for realisation of Industrie 4.0
– System thinking
– Transformational skills
– Innovations
• Approach for realisation of Industrie 4.0
– Case studies and illustrations

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33
34
Lee, Jay, Hung-An Kao, and Shanhu Yang. "Service innovation and smart analytics for industry 4.0
35
and big data environment." Procedia CIRP 16 (2014): 3-8.
 Wireless technology in Smart Factory

Ref: Zuehlke, Detlef, "Smart Factory—Towards a factory-of-things." Annual Reviews

in Control 34.1 (2010): 129-138.(Prof. Dr.-Ing. Detlef Zuehlke – RWTH Aachen,
Germany) 36
 Flow of Data and Information in a CPS enabled Factory

Ref: Lee, Jay, Behrad Bagheri, and Hung-An Kao. "A cyber-physical systems architecture for
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industry 4.0-based manufacturing systems." Manufacturing Letters 3 (2015): 18-23.
 Comparison of IoT and today’s factory

Ref: Lee, Jay, Behrad Bagheri, and Hung-An Kao. "A cyber-physical systems architecture for
industry 4.0-based manufacturing systems." Manufacturing Letters 3 (2015): 18-23.
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Cyber-Physical Systems (CPS) is defined as transformative technologies for managing
interconnected systems between its physical assets and computational capabilities.

5C architecture for
CPS in Industry 4.0

Ref: Lee, Jay, Behrad Bagheri, and Hung-An Kao. "A cyber-physical systems architecture for
39
industry 4.0-based manufacturing systems." Manufacturing Letters 3 (2015): 18-23.
 5C in CPS: Application and Technique

Ref: Lee, Jay, Behrad Bagheri, and Hung-An Kao. "A cyber-physical systems architecture for
40
industry 4.0-based manufacturing systems." Manufacturing Letters 3 (2015): 18-23.
 Attributes of a Smarter Manufacturing Sector
Old Traditional Factory
• More jobs: labor-intensive
• Lower output and productivity
• Lower quality products
• Lower paying unskilled jobs
• Higher risk working conditions
• Higher environmental impact
• Higher production costs
• Rigid, high-volume production
• Longer time-to-market
• Socially optimized (Six Sigma)
New Smart Manufacturing Plant
• Less jobs: automation-intensive
• Higher output and productivity
• Higher quality products
• Higher paying skilled jobs
• Safer working environment
• Less waste, resource use
• Lower production costs
• More flexible customization
• Faster time-to-market
• IT-optimized (models, simulation)
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Evolution from Embedded Systems to Cyber – Physical Systems

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 Global Process Solutions (GPS)
Where

Data Science meets Process Science

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What is Manufacturing?

A collection of PROCESSES

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Manufacturing: A collection of Processes

Physical Processes
e.g. Casting, forging, grinding,
machining, etc.
where energy is applied foe
physical change of work material

Information Processes
- e.g. Engineering, order entry,
customer service, inventory,
production planning, etc.

Pick and place /

Transfer Processes

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 Production Unit, viewed as a System
Value or Benefits
Sales, Profits, Business Performance
Capital,
Equipment / Customer
Fixed Assets need Transformation
Process
• Physical Proc.
INPUT OUTPUT

USE
• Info. Processes Product
• Pick and Place /
Transfer Proc.

$$$$$$
Expenses /
Resources/ Diagnostic
V. Cost
Constraints Process Science:
Tools and
Techniques In-process data
and its use

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 Progressive Impact of “Process Science”
backed up by Diagnostic Tools
—Diagnostics
—Problem Solving Equipment Component
Technical System
—Process Improvement Transformation
Output Output
-—Process Maintenance Tooling Operational
Parameters
—New Solution or Step Change
In-Process
Process Measurement
Output
Monitoring
160%
Diagnostic
New Solution Tools
Process Improvement
Process Science
120%
Base Line
100%
Problem resolution
80%
Why ???
Diagnostics

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 Measurement of In-process Signals and their Analysis

• Collect and compare base line Analysis

information (Remote)
Feature recognition
Data Base Digital Data
• Resolve Process problems. (Local or Remote) and Signal
• Estimation of Equipment Capability Analytics Processing
(Stiffness, Accuracy, Data Science
Process capability,…)
• Analysis / Performance comparison Analysis
– Over time (Local)
– Across machines or across systems.
– Across plants or locations Feature
– Analytics
Input
Recognition
– Data Science
• Development of New Products (R&D)
• Implementing “New “ Products In – Process
and Processes Transformation Signals
• Complaint Investigations
– Avoid Credits
– Reduce warranty costs
– Reduce machine set up and
debugging efforts. Output
State of the art:
• Thousands of Manufacturing Engineers work at the shop floor level to solve the process
problems using Intuition and experience
• Number of such qualified engineers is decreasing rapidly
• STIMS Institute has developed tools and skills for in-process signal acquisition, analysis
and problem solving (together with IIT – Chennai and MGTL).
• STIMS Institute is developing automation solution to integrate such process signals with
automation for signal analysis and decision making.
• NEXT STEP: Integrate the above with Big Data tools and business models.

Better use of Machine tool capacity

Cycle time reduction

Cycle time reduction in bottle neck operation resulted

in 40% increase in production line through put.
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