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Module-5
Fundamentals of Machine Tools and Operations:
Fundamentals of Machining and machine tools, Construction and Working Principle of
Lathe, Various Lathe Operations: Turning, Facing, Taper Turning and Knurling.
Construction and Working of Milling Machines and applications.
Construction and working of simple Drilling Machines and applications.
(Sketches of layout need not be dealt with for all machine tools)
Introduction to Modern Manufacturing Tools and Techniques:
CNC: Introduction, components of CNC, advantages and applications of CNC, CNC
Machining centres and Turning Centers. Concepts of Smart Manufacturing and Industrial
IoT.
Introduction to Mechatronics: Concept of open-loop and closed-loop systems,
Examples of Mechatronic systems and their working principle.

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Introduction:
Manufacturing process may be defined as a process of converting, the raw material into your
finished product of required size and shape depending upon the various processes and methods.

Manufacturing process is broadly classified into two groups.

Manufacturing
Process

Secondary Tertiary Manufacturing

Primary Manufacturing
manufacturing Process:
Process:
Process: Metal Fabrication &
Metal Forming process
Metal Cutting Process Finishing Process

Joining Process,
Rolling, Forging & Machining Fabrication Process,
Casting Process Grinding & Surface
Finishing Operations

Figure: Block diagram of Classification of manufacturing Process

In metal cutting process, extra amount of material is removed from the workpiece in the form
of chips. The material removed due to the relative motion between the cutting tool and the
work-piece.
In metal forming process, no material is removed, but it is forced to change its size and shape
by applying external pressure.

Machine Tools:

When machines perform the metal cutting operations by the cutting tools mounted on them,
they are called “Machine tools”. A machine tool may be defined as a power-driven machine
which accomplishes the cutting or machining operations on it. The machine tools used for most
of the machining processes are Lathe, Drilling, Planing, Milling and Grinding machines

Lathe Machine Tool:

The Lathe is one of the oldest machine tools used to produce cylindrical objects. The modern
engine late are first developed in the year 1797 by an Englishman Henry Maudslay. The main
function of the lathe is to removal of metal from a work piece of work to give it a required
shape and size. This is accomplished by holding the work securely and rigidly on the machine
and then turning it against a cutting tool which will remove the material from the work in the
form of a chip. To cut the material properly, the tool should be harder than that of the material
of the workpiece.

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Principle working of a Lathe Machine Tool:

Lathe machine is one of the most important machine tools which is used in the metalworking
industry. It operates on the principle of a rotating work piece and a fixed cutting tool. The
cutting tool is feed into the work piece which rotates about its own axis causing the workpiece
to form the desired shape.

Figure: Principle of turning operation on Lathe

Classification of Lathe Machine Tools:

Lathes are classified based on their design, construction and application. Following are some
of the important lathes used in industries.
1. Speed Lathe
2. Engine Lathe
3. Bench Lathe
4. Tool Room Lathe
5. Capstan & Turret Lathe
6. Special Purpose Lathe
7. Automatic Lathe
8. CNC Lathe (Turning Centres)

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Construction & Working Principle of Centre Lathe/ Engine Lathe:

The schematic arrangement of the Centre or Engine Lathe is as shown in the following figure.
The major parts of a centre lathes are:
1. Bed & Guideways
2. Headstock
3. Tailstock
4. Lathe bed
5. Carriage Assembly
6. Driving mechanism & Feeding mechanism

Figure: Schematic arrangement of Centre Lathe.

Bed: The bed forms, the base of the machine. The headstock and the tail stocks are located at
either end of the bed and the carriage rest over the lathe bed and slides on it. The guide ways
of the lathe bed may be flat and inverted V type having an include angle of 90 degree.

Headstock: The headstock is secured permanently on the inner waves, at the left end of the
lathe bed and it provides mechanical means of rotating the work at multiple speeds, It contains
a hallow spindle and mechanism for driving and altering this spindle speed. All the parts are
housed within the headstock casting.

Tailstock: The tail stock is located on the inner waves at the right end and top of the bed ways.
This has two main uses.
1. It supports the other end of the workpiece. When it is being machine between the centres.

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2. It holds the tool for performing operations, such as drilling. Riming tapping etc., to
accommodate different length of work.
The body of the Tailstock can be adjusted along the length of the bed-ways by sliding it to the
desired position, and can be locked on a lathe bed-way.
4. Carriage: The carriage of a lathe has several parts that serves to support, move and control
the cutting tool. It consists of the following parts saddle cross, slide, Compound slide, tool post
and apron.
Saddle: The saddle is an H- shape casting that fits over the bed and slides along the
base. It carries the cross slide and tool post.
Cross slide: It is mounted on the saddle and enables the movement of the cutting tool
laterally, across the lathe bed by means of a cross feed handle. It also serves as the support for
the compound rest.
Compound rest: The compound rest is mounted on top of the cross slide and has a
circular base graduated in degrees. It is used for obtaining angular cuts and short tapers. As
well as convenient positioning of the tool at the work.
The tool post: This is located on top of the compound slide to hold the tool and enable
it to be adjusted to convenient Working position,

Feed mechanism: The movement of the tool related to the work is called as a feed. The feed
can be given either by the hand, or by automatic or powered feed. To get the automatic feed,
carriage is engaged to feed rod. while for cutting threads, carriage is engaged to screw rod.

Lathe Operations:

Some of the operations carried out on a lathe machine are as listed below;
1. Facing
2. Turning
3. Step turning
4. Taper turning
5. Knurling
6. Thread cutting
7. Drilling
8. Counter sinking
9. Contour forming
10. Boring etc.,

1. Facing: Is the operation of machining the ends of a piece of the work to produce a flat
surface perpendicular with the axis. This is also used to cut the work to the required
length. The operation involves feeding the tool perpendicular to the axis of rotation of
the work piece. A regular cutting tool may be used for facing a large work piece. The
cutting edge should be set at the same height as the centre of the work piece. A properly
ground facing tool is mounted in a tool holder in the tool post to accomplish facing
operation.

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Figure: Facing operation

2. Turning Operation:

Figure: Turning Operation

The process of metal removal from the cylindrical jobs is called straight or plain
turning. Cross-slide and the carriage are used to perform turning operation and make
the operation faster and economical. Plain turning operations are generally performed
in two steps-rough and finish turning.
Rough turning is usually done for rolled, cast or forged parts to remove the uneven or
sandy or rough surface on the jobs. A roughing tool does roughing and used for excess
stock removal. For finishing a tool with slightly round cutting edge is used. The depth
of cut rate is at the range of 0.2 to 1 mm and the feed rate between 0.1 to 0.3 mm.

3. Knurling:

Figure: Knurling operations

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Knurling is an operation performed on the lathe to generate serrated surface on the work
piece. This is used to produce a rough surface for griping like the barrel of the
micrometre or screw gauge. This is done by a special tool called knurling tool which
has a set of hardened rollers with the desired serrations.
During knurling operation, the hardened rollers of the tool are pressed against the
slowly rotating work pieces such that the impression of tool serrations are formed on
the work pieces surface.

4. Taper turning:
Taper turning is an operation to produce conical surface on the work piece. This can be
machined by either work piece inclined to the axis of the lathe or tool moving inclined
to the axis of the lathe.
There are many methods for taper turning
a) By swivelling the compound rest.
b) By offsetting the tail stock.
c) By taper turning attachment.
d) By using form tool/ Broad nose tool
e) Combination of Longitudinal and Transverse feed movement.

a) Taper Turning by Swiveling the compound Tool Rest

Figure: Taper turning by Swiveling the compound rest method

The work pieces which require steep taper for short lengths the taper turning was done
by swiveling the compound rest method. In this method the compound tool rest is swiveled to
the required taper angle and then locked in the angular position. The carriage is also locked at
that position. For taper turning the compound rest is moved linearly at an angle so that the
cutting tool produces the tapered surface on the work piece. This method is limited to short
taper lengths due to the limited movement of the compound tool rest.
The taper angle is calculated by,

Where,
D= bigger diameter of the taper (mm)
d= smaller diameter of the taper (mm)
L= Length of the taper (mm)

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b) Taper Turning by Offsetting the Tailstock (or Tailstock set over method)
In this method the work piece is inclined with respect to the lathe axis and tool
movement is in line with the lathe axis to produce the required taper. Here the tail stock body
is shifted by small distance (offset) laterally. This makes the work piece is shifted at one end
and hence there will be an inclination with respect to the lathe axis. The tool is moved parallel
to the lathe axis and fed against the revolving work piece which produces the required taper.

Figure: Taper turning by Setover method

The offset is
calculated by,

Specification of Lathe Machine tool:

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Milling Machine Tool

Milling is a metal cutting operation in which the cutting tool is a slow revolving cutter
having cutting teeth formed on its periphery. The milling cutter is a multipoint cutting tool.
The work piece is mounted on a movable worktable, which will be fed against the revolving
milling cutter to perform the cutting operation.

Principle of Milling

(a) (b)
Figure: (a) Up milling and (b) Down milling operation

Figure shown above is the principle of cutting action of a milling cutter. The milling
cutter is mounted on a rotating shaft known as arbor. The work piece which is mounted on the
table can be fed either in the direction opposite to that of the rotating cutter as shown in above
fig (a) or in the same direction to that of the cutter as shown in above fig (b). When the work
piece is fed in the opposite direction to the cutter tooth at the point of contact, the process is
called as conventional or up-milling.

Milling Machine Tool: A Milling Machine is a machine tool in which a stationary work piece
is fed against a rotating multi point cutter.

Various types of milling machines are

1) Plain or horizontal type of milling machine.
2) Vertical Milling Machine
3) Universal Milling machine
4) Planer type milling machine
5) Profile cutting milling machine.

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Horizontal Milling Machine

The schematic arrangement of horizontal milling machine/ column and knee typr milling
machine is as shown in the figure.

Figure: Horizontal / Column & Nee type milling machine

Milling machine has some principal parts. Their understanding would help us in understanding
how the machine operates. The various parts are
1. Base
2. Column
3. Arbor
4. Knee
5. Saddle
6. Table
7. Overhanging arm
8. Driving and feeding Mechanism

Base: Base forms the foundation of the machine tool. It’s a rectangular casting made up of Cast
Iron. The one end of the base houses the Column and other end of the base contains a space for
table elevating screw or knee supporting screw.
Column: The column is another rectangular casting mounted on one end of the base. The
column is ribbed heavily in order to support the knee. The front vertical face of the column is
provided with a vertical slide, which may be of square or dovetail type. The knee moves up
and down on this slide. At the top of the column, an internal dovetail slide accommodates a
cast overarm. The overarm supports the arbor. It also houses the driving mechanism to drive
the spindle and feeding mechanism to feed the table.
Arbor: The arbor is a horizontal shaft provided with a straight body and tapered shank. On the
straight portion of arbor, rotary cutters are mounted. The tapered end of the arbor fits into the
tapered hole of the spindle. The other end of the arbor is mounted in a bearing housed in the

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projecting overarm. The knee of the casting mounted on the front vertical slide of the column
and is moved up or down by an elevating screw. The upper face of the knee is provided with
guide ways so as to mount the saddle.
Knee: The Knee is a casting mounted on the front vertical slide of the column and is moved
up or down by an elevating screw. The upper face of the knee is provided with guide ways so
as to mount the saddle.
Saddle: The saddle is casting provided with two slides one at the top and the other at the
bottom, which are exactly right angles to each other. The lower slide fits within the guideways
on the top of the knee and the upper slide receives the dovetail guides provided on the bottom
of the table.
Table: The table is mounted on the top of the saddle. The bottom of the table has a dovetail
slide which fits in the slide way on the top of the saddle. The top the table is machined with
full length T-slots for mounting vices or other work holding fixtures.
Overhanging Arm: The overhanging arm extends from the column in order to support the
arbor. The front brace attached to the overhanging arm supports the free end of the arbor and
thus provides rigidity to the rotating cutter.

Milling machine Operations/ Applications:

A variety of milling operations are performed on a milling machine to produce a horizontal,
vertical, inclined surfaces, keyways, slots, gear teeth etc., A few of the most commonly used
milling operations are described here.
1. Slab Milling
This method is also called as plain milling. The plain milling is the most common types of
milling machine operations.
 Slab milling is performed to produce a plain, flat, horizontal surface parallel to the axis of
rotation of a plain milling cutter.
 The operation is also known as slab milling.
 To perform the operation, the work and the cutter are secured properly on the machine.
 The depth of cut is set by rotating the vertical feed screw of the table. And the machine is
started after selecting the right speed and feed.

Figure: Slab/ Plain Milling Operation

2. Slot Milling
The slot milling, also called as groove or keyway cutting is done on a horizontal milling cutter or
using an end milling cutter.
 The operation of producing of keyways, grooves and slots of varying shapes and sizes can
be performed in a milling machine.
 It is done by using a plain milling cutter, a metal slitting saw, an end mill or by a side
milling cutter.

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 The open slots can be cut by a plain milling cutter, a metal slitting saw, or by a side
milling cutter. The closed slots are produced by using endmills.

Figure: Slot Milling/ Grooving operation

3. Face Milling

Figure: Face Milling operation

In this method, the flat surfaces are milled by the cutters, which are mounted with their axes
perpendicular to the milled surfaces.
 The face milling is the simplest milling machine operations.
 This operation is performed by a face milling cutter rotated about an axis perpendicular to
the work surface.
 The operation is carried in plain milling, and the cutter is mounted on a stub arbor to
design a flat surface.
 The depth of cut is adjusted by rotating the cross-feed screw of the table.

4. Angular Milling
In this method, inclined surfaces are produces by milling cutters having their teeth inclined to their
axes. Dovetail grooves and V-guides are machined by this method.
 The angular milling is the operation of producing an angular surface on a workpiece other
than at right angles of the axis of the milling machine spindle.
 The angular groove may be single or double angle and may be of varying included angle
according to the type and contour of the angular cutter used.
 One simple example of angular milling is the production of V-blocks.

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Figure: Angular Milling

5. Form Milling

Figure: Form Milling

In this method, surfaces having irregular profile are milled by suitable cutters.
 The form milling is the operation of producing the irregular contour by using form
cutters.
 The irregular shape may be convex, concave, or of any other shape. After machining,
the formed surface is inspected by a template gauge.
 Cutting rate for form milling is 20% to 30% less than that of the plain milling.

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Drilling Machine Tool

Introduction

Drilling machine is one of the most important machine tools in a workshop. It was
designed to produce a cylindrical hole of required diameter and depth on metal workpieces.
Though holes can be made by different machine tools in a shop, drilling machine is designed
specifically to perform the operation of drilling and similar operations. Drilling can be done
easily at a low cost in a shorter period of time in a drilling machine.

Drilling can be called as the operation of producing a cylindrical hole of required

diameter and depth by removing metal by the rotating edges of a drill. The cutting tool known
as drill is fitted into the spindle of the drilling machine. A mark of indentation is made at the
required location with a centre punch. The rotating drill is pressed at the location and is fed
into the work. The hole can be made up to a required depth.

Types of drilling machines

Drilling machines are manufactured in different types and sizes according to the type
of operation, amount of feed, depth of cut, spindle speeds, method of spindle movement and
the required accuracy.
The different types of drilling machines are:
1. Portable drilling machine (or) Hand drilling machine
2. Sensitive drilling machine (or) Bench drilling machine
3. Upright drilling machine
4. Radial drilling machine
5. Gang drilling machine
6. Multiple spindle drilling machine
7. Deep hole drilling machine

Upright drilling machine

The upright drilling machine is designed for handling medium sized workpieces.
Though it looks like a sensitive drilling machine, it is larger and heavier than a sensitive drilling
machine. Holes of diameter up to 50mm can be made with this type of machine. Besides, it is
supplied with power feed arrangement. For drilling different types of work, the machine is
provided with a number of spindle speeds and feed.

Base
The base is a rectangular casting made of cast iron and so can withstand vibrations. It is
mounted on a on the floor. It supports all the other parts of the machine on it.

Column
The column stands vertically on the base at one end. It supports the work table and the drill
head. The drill head has drill spindle and the driving motor on either side of the column.

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Figure: Upright Drilling Machine

Table
The table is mounted on the vertical column and can be adjusted up and down on it. The table
has ‘T’-slots on it for holding the workpieces or to hold any other work holding device. The
table can be adjusted vertically to accommodate workpieces of different heights and can be
clamped at the required position.

Drill head
Drill head is mounted on the top side of the column. The drill spindle and the driving motor
are connected by means of a V-belt and cone pulleys. The motion is transmitted to the spindle
from the motor by the belt. The pinion attached to the handle meshes with the rack on the sleeve
of the spindle for providing the drill the required down feed.

Radial drilling machine

The radial drilling machine is intended for drilling on medium to large and heavy workpieces.
It has a heavy round column mounted on a large base. The column supports a radial arm, hich
can be raised or lowered to enable the table to accommodate workpieces of different heights.
The arm, which has the drill head on it, can be swung around to any position. The drill head
can be made to slide on the radial arm. The machine is named so because of this reason. It
consists of parts like base, column, radial arm, drill head and driving mechanism. A radial
drilling machine is illustrated in Figure.

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Figure: Radial drilling Machine

Drilling machine operations

Though drilling is the primary operation performed in a drilling machine, a number of similar
operations are also performed on holes using different tools. The different operations that can
be performed in a drilling machine are:
1. Drilling
2. Reaming
3. Boring
4. Counter boring
5. Countersinking
6. Spot facing
7. Tapping
8. Trepanning

1. Drilling:
Drilling can be called as the operation of producing a
cylindrical hole of required diameter and depth by removing metal
by the rotating edges of a drill. The cutting tool known as drill is
fitted into the spindle of the drilling machine. A mark of
indentation is made at the required location with a centre punch.
The rotating drill is pressed at the location and is fed into the work.
The hole can be made up to a required depth.

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2. Reaming:
Reaming shown in Figure, is an accurate way of sizing
and finishing a hole which has been previously drilled.
In order to finish a hole and to bring it to the accurate
size, the hole is drilled slightly undersize. The speed of
the spindle is made half that of drilling and automatic
feed may be employed.
The tool used for reaming is known as the reamer which
has multiple cutting edges. Reamer cannot be used to
drill a hole. It simply. follows the path which has been
previously drilled and removes a very small amount of
metal.

3. Boring
Boring is the operation of enlarging the size of the previously drilled hole. For this purpose
a special purpose cutting tool is used. Boring operation is also carried out to finish a hole
accurately and to bring it to the required size.

Figure: Boring operation

4. Tapping:
Tapping shown in Figure is the operation of cutting
internal threads by means of a cutting tool called a tap. A
tap may be considered as a bolt with accurate threads cut
on it. The threads act as cutting edges which are hardened
and ground. When the tap is screwed into the hole it
removes metal and cuts internal threads which will fit
into external threads of the same size.

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Introduction to Modern Manufacturing Tools and Techniques

Computer Numeric Control [CNC] Machine:

Introduction: Computer Numeric Control (CNC) is the automation of machine tools that are
operated by precisely programmed commands encoded on a storage medium (computer
command module, usually located on the device. Most NC today is computer (or computerized)
numerical control (CNC), in which computers play an integral part of the control.

Definition
Computer Numerical Control (CNC) is one in which the functions and motions of a machine
tool are controlled by means of a prepared program containing coded alphanumeric data. CNC
can control the motions of the work piece or tool, the input parameters such as feed, depth of
cut, speed, and the functions such as turning spindle on/off, turning coolant on/off etc,.

Components of CNC:
A CNC machine tool following units in its construction,
1) Input device
2) MCU or machine control unit
3) Machine tool
4) Driving System
5) Feedback devices
6) Display Unit

Figure: lock diagram shoing Components of CNC machine tool

1. Input Devices: In put devises are the devises used to enter the part program into the
machine tool. Universal Serial Bus (USB), ethernet communication, Tapes and
recording devices can be used as input devices.
2. Machine Control Unit: The machine control unit (MCU) is a microcomputer that
stores the program and executes the commands into actions by the machine tool. The
MCU consists of two main units: the data processing unit (DPU) and the control loops

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unit (CLU). The DPU processes the data from the part program and provides it to the
CLU which operates the drives attached to the machine leadscrews and receives
feedback signals on the actual position and velocity of each one of the axes. A driver
(dc motor) and a feedback device are attached to the leadscrew. The CLU consists of
the circuits for position and velocity control loops, deceleration and backlash take up,
function controls such as spindle on/off.
3. Machine Tool: The machine tool could be one of the following: lathe, milling machine,
laser, plasma, Coordinate measuring machine etc. Machine tool actuated as per the
program through various mechanical driving and feeding mechanisms. Machine tool
perform the intended task over the work piece.
4. Driving system: A drive system essentially is made up of amplifier circuits, drive
motors and ball lead screws. Commonly used types of electrical motors include DC
Servo motors, AC servo motors, Stepping motors and Linear motors
5. Feed back devices: For accurate operation of a CNC machine, the positional values
and speed of the axes need to continuously updated. Inorder to perform this task
Positional feed back devices and velocity feed back devices are used.
The positional feedback systems gives the position of the tool/ workpice with respect
to the reference point. Velocity feed back system gives the state of the velocity of the
sped of the spindle, cutting tool and the movement of the table etc.,
6. Display Unit: Device that ensures interaction between the machine operator and the
machine is called as a display unit. It displays the current status of the operation such
as the spindle RPM, running part program, feed rate, position of the machine slide etc.
it also shows the graphic simulation of the path taken by the tool and that the operator
can verify the part program before actual machining and any malfunction of the CNC
system is also displayed as warnings.

Advantages of the CNC Machine Tool:

 Accuracy and repeatability obtained is high. Most aircraft parts are produced today on
CNC machines
 Complex shaped contours can be machined. Turbine blades, impellers etc.
 Can be easily programmed to handle variety of product styles
 High volume of production compared to conventional machines
 Lesser skilled or trained people can operate CNC machines unlike conventional ones
where high skilled people are required
 CNC machines can be used uninterruptedly without turning them off provided regular
maintenance is done
 Avoids errors that were otherwise committed by humans operating conventional
machines
 Since CNC machines can be programmed, one person may well take care of a number
of CNC machines. Reduces employees and hence costs are reduced
 Using CNC machines results in a safer work environment

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 Can be upgraded to a newer technologies by replacing the existing CNC controller with
advanced one

Disadvantages of the CNC Machine:

 Thorough programming knowledge is required by the operators or programmers.
Skilled programmers required, cost of the labour can be high
 Cost of the CNC machine is high compared to the conventional machine tools
 Spares of CNC machines are relatively costlier than conventional machines
 CNC machines require air conditioned environment and /or a chiller unit. Thus extra
costs are involved.

CNC Machining Centres:

 The term “machining centers” describes almost any CNC milling and drilling machine
that includes an automatic tool changer and a table that clamps the workpiece in place.
 CNC machine center is a advance manufacturing machine tool which performs wide
range of machining operation with accuracy and good quality surface finish.
 The orientation of the spindle is the most fundamental defining characteristic of a CNC
machining centers.
 CNC machining centers can further be classified based on the rotation of either the work
piece Or the rotation of the tool as:
1. CNC turning machines
2. CNC Milling machines

CNC Turing Centres:

 The primary function of a CNC Turning Center is that it rotates (or “turns”) your
workpiece.
 CNC Turning Machines are one of the oldest and simplest forms of machining parts,
called “lathes,” .
 Can be either horizontal or vertical depending on the weight and tolerance of the
workpiece.
 Work-peices for this process are usually round, but can be other shapes — like squares
or hexagons.
 The work-piece is held in place by an instrument known as the “chuck.” The chuck then
spins at various RPMs (depending on the capability of your machine).
 When this occurs, the machine’s tool moves into the rotating workpiece and begins to
shave away material to create the desired shape.

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Figure: CNC Turning centre and machining centre

CNC Milling Centres/ Machining Centres:

 The primary function of a CNC Milling Machine is that your tool will be doing the
rotating and moving while your workpiece stays in one spot (generally).
 Milling is a more specific process that is similar to drilling and cutting.
 These machines can also be either horizontal or vertical, again depending on the
tolerance and weight of your workpiece.
 This process has many axes that allow for a variety of shapes, holes, and slots to be cut
into the workpiece at many angles.
 These axes provide many different maneuvers, either by the spindle or the bed, to cut
the part desired to the exact specifications.

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Smart Manufacturing & Industrial IoT

Industry 4.0 is the next step in the evolution of technology in industry. In the last century,
manufacturing technology progressed from Henry Ford’s assembly line to computerization
taking physical data and digitizing it.

Then automation was introduced, and now, with Industry 4.0, value is being added through
artificial intelligence (AI), autonomous systems and analytics. Smart manufacturing employs
these technologies to drive greater efficiency and productivity in manufacturing across
industries. The backbone of this digital transformation consists of Industrial Internet of Things
(IIoT) systems that instruct, manage and monitor machines, equipment, processes and supply
chains.

Today, sensors, machine-to-machine communications, AI, machine learning, augmented

reality and sophisticated analytics drive improvements across the industrial value chain through
real-time operational data and insights in a smart manufacturing environment..

The level and quality of this orchestration within the industrial IoT (IIoT) ecosystem is a critical
component in a manufacturer’s ability to improve operational processes, boost production,
drive greater efficiency and take advantage of new service opportunities.

IoT Applications for Smart Factory

1. IT and OT Integration: Boost productivity with automation, robotics, and augmented

and virtual reality, all enabled by data orientation and networking. IIoT platforms
integrate traditional IT functions with those of operational technology (OT) to
transform factory floor operations. 5G accelerates this transformation by eliminating
cabling and enabling ultra-reliable, mission-critical wireless communications for IIoT
use cases and applications that require minimal latency and real-time communication.
2. Process Optimization: Improve factory operations to get the greatest return on
investment. Smart factories create efficiencies and new capabilities that help
manufacturers improve productivity, reduce costs and identify new revenue
opportunities. With real-time overall equipment effectiveness (OEE) visualization tools
that offer data collection and transformation, you can have full visibility into your
factory’s efficiency.
3. Predictive Maintenance and Condition Monitoring: Monitor the condition and
performance of connected machines and assets to improve asset availability and
performance. Sensors on factory equipment transmit critical data regarding equipment
health and utilization. This feedback helps manufacturers maximize equipment uptime,
avoid operational disruptions, improve maintenance efficiency, reduce costs and boost
productivity.
4. Supply Chain and Warehouse Management: Optimize production and avoid costly
disruptions with real-time visibility throughout the value chain. Supply chain
management requires end-to-end visibility of raw materials and finished goods at all
production and delivery stages to be effective. IIoT solutions for supply chain

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management enable production managers and suppliers to adapt quickly to changes that
affect availability, fine-tune warehousing, better manage assets and inventory to meet
demand, and monitor the status of raw materials and goods in transit.
5. Improved Quality Control: When it comes to the smart factory, manufacturers large
and small need solutions that provide vertical and horizontal integration, making it
easier to connect the factory to inbound and outbound supply chains. Telit IIoT data
orchestration, device management and enterprise system integration solutions are
perfectly suited to all manufacturing verticals, including automotive, pharmaceuticals,
machinery, oil and gas, electrical power generation, water, and more.

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Introduction to Mechatronics

Introduction:
Mechatronics basically refers to mechanical electronic systems and normally described as a
synergistic combination of mechanics, electrical, electronics, computer and control which,
when combined, make possible the generation of simple, more economic, and reliable systems.
The term "mechatronics" was first assigned by Mr. Tetsuro Mori, a senior engineer of the
Japanese company Yaskawa, in 1969.

• “The word, mechatronics is composed of mecha from mechanics and tronics from
electronics. In other words, technologies and developed products will be incorporating
electronics more and more into mechanisms, intimately and organically, and making it
impossible to tell where one ends and the other begins.”
• According to F. Harshama, M. Tomizuka “Synergistic integration of mechanical
engineering with electronics and intelligent computer control in the design and
manufacturing of industrial products and processes.”

Definition: Mechatronics is the synergistic integration of sensors, actuators, signal

conditioning, power electronics, decision and control algorithms, and computer hardware and
software to manage complexity, uncertainty, and communication in engineered systems.”

Figure: key elements of Mechatronic System

Classification of control systems

Control systems may be classified into two types depending upon whether the
controlled variable (i.e., the output) affects the actuating signal or not. The two types of control
systems are the open-loop control system and the closed-loop control systems.

Open loop control systems

In an open-loop control system, an input known as reference input is applied, most often
through an amplifier and an output called the Controlled output is obtained. In this system, the
input to the controller is in no way affected by the value of controlled output. The input is
applied or fixed by human judgement and estimate. The block diagrammatic representation of
an open loop control system is shown in Figure. This type of control system is simple and
inexpensive, but it is inaccurate.

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Reference Input Amplifier Controller Controlled output

Figure: An open loop control system

A typical example of an open-loop control system is an electric heating device without a

thermostat. The heating device will be switched 'ON' by a timing device while the duration of
heating time will be estimated by a human operator. After a set time, the heating device will
get switched OFF. In this system it is quite likely that the room gets overheated or remains
under heated. Further, the heating time, once set, remains independent of the outside
temperature and other conditions.

The disadvantage of the open-loop control system is that the system does not adapt itself to the
environmental conditions and other related functions. For example, in addition to the external
temperature, if the doors and windows are opened and closed frequently, the heating time
allowed may not be sufficient to bring the room temperature to the desired level. Improvement
in this trol system can be made if the human operator or an appropriate control system can be
made if the human operator or an appropriate control element continuously measures the room
temperature. In such a system, the output, i.e., the room temperature, is measured continuously
and the input, i.e., the time of heating, is varied accordingly. This is achieved through the use
of a feedback systems. Such control systems are therefore known as feedback control systems
or closed-loop control systems.

The open-loop control systems are not intelligent enough to compare the input signal (reference
signal) with the output continually for providing the desired output. Any system which operates
only on the basis of time, falls under the category of an open loop control system.

Electric Heating Out-put

Input (On/Off) Switch Desired
Device
Temperature

Figure: Room heating System

Closed Loop System

In closed - loop control systems the output signal has a direct effect upon the control
action. A corrective signal which drives the controller is derived from some kind of comparison
between the input variable and the control variable. The actuating signal, also called the ‘error
signal’ is the difference between the input reference signal and the feed back signal. The feed
back signal is a function of the output signal. It is fed to the controller so as to reduce the error,
i.e., to bring the output of the system to the desired value.
A closed-loop feed back control system is shown in a block diagram form in Figure.
The system uses feedback action to reduce the system error. The feed back used is called
'negative feed back' as the feedback action aims at reducing the system error.

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Comparator
Input Controlled output
Amplifier Controller Process
Signal

Feedback Signal

Figure: A closed loop Control System

Examples of closed-loop control system:

1. Room heating system with feed back control.
2. Autopiloting system for aircraft cruise control.
3. Machine tool positioning system etc.,

Room heating system with feed back control:

In a feed back room heating system, there is a thermostat which adjusts the burner in
accordance to the room temperature. The fuel oil input to the furnace depends on a comparison
of the actual room temperature with the desired temperature. This comparison produces an
error signal. The controller increases the fuel oil valve aperture if the error signal indicates that
the room temperature is lower than the desired value. Thus maintaining the desired level of
temperature in the room.

Comparator
Input Controlled output
Fuel Valve Furnace
Signal Desired Temperature

Thermostat

Figure: A Closed loop room heating system

Example of Mechatronic system:

A Automatic Washing Machine:
Consider an automatic washing machine as the building blocks of the automatic machine is as
shown in the figure. Most of the washing machines are operated as follows. After the cloths to
be washed have been put into the machine, the soap, water and bleach are entered in the proper
amounts. The washing machine is energised. When the cycle is completed, the machine shuts
itself off. If the proper amounts of soap, bleach and water and the appropriate temperature of
the water are predetermined by the manufaturer of the machine, or automatically entered by
the machine itself, then the input is the time for the wash and wring cycle.

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Figure: Automatic Washing Machine

The timer is usually set by a human operator. The output of the machine is more difficult
to identify. Defining "Clean" as the absence of all foreign substances from the items to be
washed, one can identify the output as the percentage of cleanliness. In this case, the percentage
of cleanliness can be controlled by adjusting the amount of soap, bleach and water and the
temperature of the water. In such a case all of these quantities are inputs to the system.

Questions:
Machine Tools:
1. Define a machine tool
2. What is the function of a lathe ?
3. With a neat sketch highlight the specification of a lathe.
4. Explain the principle of taper turning with necessary sketches.
5. Briefly explain the following operations performed on a lathe:
a. Plain turning b. Taper turning c. Knurling
6. Explain the swiveling of tool post method of taper turning.
7. Explain briefly taper turning by tailstock set over method.
8. Name the various machining operations that can be conducted on a lathe.
9. What is drilling? Mention different types of drilling machines.
10. What is the main advantage of a radial drilling machine.
11. Name the various operations that can be performed on a drilling machine.
12. Differentiate between (a) Drilling and Reaming. (b) Boring and Counterboring.
(c) Countersinking and Spot facing.
13. Explain countersinking operation on a drilling machine with simple sketch27. Explain
how and when a thread cutting is performed on a drilling machine.

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14. What is milling ? Explain. Classify the different types of Milling Machines.
15. What is the difference between milling, drilling and turning?
16. With the help of sketches differentiate between up and down milling operations.
17. List out the various operations that can be performed on a milling machine.
18. Explain briefly the specifications of a Milling Machine.

CNC Machine Tools & Mecatronics

1. With the help of a neat block diagram, explain the basic elements of an automated
system.
2. Define Computer Numerical Control. 1
3. Discuss the elements of a CNC system with a neat block diagram.
4. List and explain the salient features of a CNC control.
5. What are the advantages of the CNC Machines?
6. Describe how CNC turning centres are different from CNC Machining Centres.
7. What is Smart Manufacturing and how Industrial IOT is easing out the manufacturing
process.
8. Define Mechtronics. With the help of a block diagram describe the key elements of
Mechatronic System
9. What is open loop control system and Closed loop control system.
10. With Suitable example, explain the working of a mechatronic system.(Closed loop
Control System)

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