MODULE 2

CHAPTER 1-BROACHING

Broaching is a fastest machining process by using a special tool (Broach). It is best suited for mass production, and can be
produce accurate plane or formed shapes on internal or external surfaces.

PRINCIPLE OF BROACHING:-In broaching, the broach is pushed or pulled over a external flat surface of a stationary work
piece. In internal broaching. In internal broaching the broach is pushed or pulled through the hole in the stationary work
piece.

BROACHING TOOL :-is made up of a series of cutting edges which are gradually increase in size along its length

Three types teeth are provided on broach tool

1.Roughing teeth 2.Semi-finishing teeth 3.Finishing teeth

 (INTERNEL PULL TYPE BROACH)

ADVANTAGES AND DIS ADVANTAGES OF BROACHING

Advantages:-Fast process,Simple process,High accuracy,Good finishing,Good life of broach tool,Cutting fluid can be
applied easly,Economical for mass production,Low tool waer etc

Disadvantages:-Not suitable for small quantity production,Cost of tool is high,Tool grinding is expensive,Small jobs can
not be machined,Work piece must be strong

CLASSIFICATION OF BROACHING:

1. Pull broaching - The broach is pulled through stationary work

2. Push broaching - The broach is pushed through stationary work

3. Surface broaching - The broach moves across the work

4. Continuous broaching - The work is moved continuously against stationary broach

TYPES OF BROACHES

1. According to the type of operation:- a) internal b) external

2. According to the method of operation:- a) push type b) pull type

3. According to type of construction:- a) solid broach b) built-up broach c) inserted tooth broach

d) progressive cut broach

BROACHING MACHINES

1.HORIZONDAL BROACHING MACHINE:-Used for for surfface broaching or internel broaching.The work is placed in the
fixture.The tool is then pulled over the surfface.Cutting spped is 30 m/min.
2.VERTICAL BROACHING MACHINE:-Used for surfface broaching or internal broaching.It has a vertical slide in which he
tool is hold.Work is held in a fixture.

Vertical Broaching machine can be

1.Pull down type 2.Push down type 3.Push up type

CHAPTER 2:GEAR MANUFACTURING

METHODS OF MAKING GEARS: 1.Casting 2.Powder metallurgy 3.Plastic moulding 4.Stamping

5.Extruding 6.Coining 7.Rolling 8.Machining :-a) Form cutting b) Template method c) Generating method

1.FORM CUTTING:- a) Gear cutting by single point tool b) Gear cutting by form cutter
Gear cutting by single point cutting tool

Gear cutting by milling cutter

GEAR GENERATING METHODS

1.Gear cutting by rack cutter:-It is done with a rack cutter.The cutter will be reciprocating.The work piece will
be rotating.The cutting is taken place by the relationship between rake and work piece.Used fpr cutting large
double helical gears and external spur gears.

2.Gear cutting by Pininon cutter:-It is done in a vertical type shaper.Work piece is palced in a vrtiacl
arbor.Pinion cutter is placed in a spindle.The cutter will be reciprocating along the work piece.The cutting will
be occur because of the relation between work and the tool as 2 gears.
3.Gear Hobbing:-Most important gear making process using a special type cutter known as hob.It is done in a
gear hobbinng machine.
Gear Hob:- It is a special type cutter.It cuts like a milling cutter and teeth are lie on a helix like a worm.

Principle of gear hobbing:-The hob will be rorating and it is fed inti the gear blank which is also
rotating.Because of the correct relationship between hob and work piece like a worm and worm wheel,metal
will be removed from the work piece and the gear will be generated.

Appications:-For making spur,helical gears and worm wheel.also fpr making sprockets.
Advantages:-Fast process,No indexing is needed,High production rate,Good accuiracy.
Disadvantages:-Can not produce internal gears and spur gears,Hob is costly.
Gear Finishing Methods:
Different gear finishing methods are
1.Gear shaving:-Commenly used method.Here we uese a cutter in the form of a rack or gear
2.Gear Burnishing:-It is a deformation process, so that no meterial will be removed.
3.Gear grinding:-In this process,we grind the gear using grinding wheels,which will be in the form of gears
4.Gear lapping
5.Gear horning:-It is done with a tool known as horn

CHAPTER 3:PRESS TOOLS

It is the process of making products by using sheet metal with the help of punch and die
PRESS WORKING NOMENCLATURE(DIFFERENT PARTS OF A PRESS TOOL)
It incorporates two sections, upper or punch section and a lower or die section. The main components are as
follows.
1.Punch 2.Punch holder 3.Die block 4.Bolster plate 5.Guide posts and bushings 6.Bed 7.Stripper

TYPES OF DIES
The dies are broadly classified into the following types
1.Simple die 2.Progressive die 3.Compound die 4.Combination die 5.Inverted die

1.SIMPLE DIE:-In simple die only a single operation is performed for each stroke of the ram.
Simple dies may be further classified into
1.Cutting dies 2.Forming dies
2.PROGRESSIVE DIE:-Used for batch production.In this process two cutting operations are performed at
different stataions by using seperate punch and die for each process.

3.COMPOUND DIE:-I n this die, 2 or more cutting operations are performed at a single station in a single stroke
of the ram.

4.COMBINATION DIE:-In this type of die,both cutting and forming operations are performed in a single stroke
at different stations
 PRESS TOOL OPERATIONS
A large number of operations can be performed by using press tools, and all press tool operations can be
broadly classified into two types.
1.Cutting operations
a) blanking b) piercing c) lancing d) cutting off and parting e) Notching
f) shaving g) trimming
2.Shapng operation
a) forming b) drawing c) bending
1.Blanking:-Process of cutting out different shapes from sheet metal by using puch and die

2.Piercing:-Process of making holes of different types in sheet by using puch and die

3.Lancing:-Process of partually cutting holes in sheet metal by using punch and die
4.Cutting off:-Removing a strip of sheet

5.Parting:-Process of seperating a sheet in two 2 parts

6.Emposing:-It is a forming operation using punch and die to make different shapes of products

7.Coining:-Forming process,in which the metal is foced to flow the space provided in the die and punch.
8.Drawing:-Process of making hollow shapes such as cups from flat sheet

9.Bending:-Process of curving the sheet in different shapes.

CHAPTER 4:JIGS AND FIXTURS

Jigs and fixtures are production devices usually associated with mass production.

A jig :-is a work holding device which also locate or guide the cutting tool with respect to the work piece. It is
not fastened to the machine on which it is used .

A fixture:- is a work holding device but does not locates or guides the cutting tool. It is fastened to the table or
base of the machine.

ELEMENTS OF JIGS AND FIXTURES

The jigs and fixtures should possess the following components to perform their basic functions

1.Locating elements- to keep the work piece in position with respect to cutting tool
 2.Clamping elements- to hold the work piece against the cutting force during the machining operation

3.Tool guiding and setting elements

DIFFERENCE BETWEEN JIGS AND FIXTURES

 JIG:-1.Hold the work piece and guide the tool 2.Uselly moveble with the machine table 3.Used for
drilling,reaming,boring and counter boring 4.Lighter in constroction
 Fixture:-1.Hold the work piece but do not guide the tool 2.Clamped in the fixed position of the
machine table 3.Used for welding,turning etc 4.Heavy in construction
ADVANTAGES OF JIGS AND FIXTURES
 Reduces the operation time, and increases productivity
 Facilitates uniform quality and ensures interchangeability of component
 Unskilled operators can do the job, thus Saving in labour cost
 Ensures higher accuracy and surface quality
 Reduce the over all cost of product
PRINCIPLE OF LOCATION(ALSO KNOWN AS 3-2-1 PRINCIPLE)
An object in space has 6 digress of freedom.3 linear movements along x,y and z axes and 3 rotation
about this 3 axes.

Locating means preventing the degrees of freedom of the work piece when it is placed in the jig or fixture.It
can be done by providing pins at correct positions as follows

Pins 1,2,3:-prevent linear motion

along y and rotation about z and x

Pins 4,5:-Prevent linear motion

along z and rotation about y

Pin 6:-Prevent linar motion along x

TYPES OF DRILL JIGS

1.Template jig 2.Plate jig 3.Channel jig 4.Box jig 5.Leaf jig 6.Indexing jig 7.Universal jig

1.Template jig:-Simple type of jig.Used for making plain holes.It has holes to guide the toll
2.Plate jig:-It is plate jig with drill bushes

3.Channel jig:-It is in the form of a channel.The work piece is located in the channel and clamped by a
screws.Used for drilling drilling

4.Box jig:-Used for drilling in more than 1 plane.The jig will be in the form of a box.One side of the box is
provided with a latch to place the work piece.
TYPES OF FIXTURES

All fixtures used in industry can be divided into two groups

1.Universal fixtures :-Machine vise Three jaw self-centering chuck Universal dividing head

Magnetic chuck

2.Special fixtures:-Milling fixtures Boring fixtures Grinding fixtures Welding fixtures

MODULE 3
CHAPTER 1: GRINDING MACHINE AND ITS OPERATIONS
Grinding is a metal cutting operation like any other process of machining removing metal in comparatively
smaller volume. The cutting tool used is an abrasive wheel having many numbers of cutting edges. The
machine on which grinding operation is performed is called a grinding machine.

ABRASIVES:- Abrasives are used for grinding and polishing operations. It should have uniform physical properties of
hardness, toughness and resistance to fracture.
Abrasive may be classified into two principal groups.
1.Natural abrasives 2.Artificial abrasives
Natural abrasives:-
 These are obtained from earth’s crust
 It include sandstone, emery, corundum and diamond
 Sandstone is used to grind only softer materials only
 Emery is natural alumina, it contains aluminium oxide and iron oxide
 corundum is also a natural aluminium oxide, it contains more percentage of aluminium oxide than emery
 Both emery and corundum have a greater hardness and abrasive action than sandstone
 Diamond is the hardest available natural abrasive, used to grind cemented carbides
Artificial abrasives:-
Artificial abrasive are of two types
a. Silicon carbide abrasives
b. Aluminium oxide abrasives

 Silicon carbide:- Silicon carbide is manufactured from 52 parts of silica, 34 parts of powdered coke, 2
parts of salt and 12 parts of sawdust in a long rectangular electric furnace of the resistance type that is
built of loose brick work. This is manufactured under trade names of carborundum. It is denoted by
the letter ‘S’. It is used for grinding materials of low tensile strength such as cemented carbides,
ceramic materials, grey brass, bronze, copper, aluminium, vulcanized rubber etc
 Aluminium oxide abrassives:- Aluminium oxide is manufactured by heating mineral bauxite, silica, iron
oxide, titanium oxide, etc. mixed with ground coke and iron borings in arc type electric furnace.
Aluminium oxide is tough and not easily fractured, so it is better adapted to grinding materials of high
tensile strength such as most steels, carbon steels, high speed steels, and tough bronzes. This is
denoted by the letter ‘A’.
BONDING MATERIALS
A bond is an adhesive substance that is employed to hold abrasive grains together in the form of
grinding wheels. There are several types of bonds

GRIT, GRADE AND STRUCTURE OF A GRIDING WHEEL

Grit (grain size):- The grinding wheel is made up of thousands of abrasive grains.
 The grain size or grit number indicates the size of the abrasive grains used in making a wheel, or the
size of the cutting teeth. There are four different groups of grain size namely coarse, medium, fine and
very fine.
Grade:-The grade of a grinding wheel refers to the hardness with which the wheel holds the abrasive
grains in place. The grade is indicated by a letter of the English alphabet.The grade of the bond can be
classified in three categories

Structure :-The relative spacing occupied by the abrasives and the bond is referred to as structure.It
is denoted by the number and size of void spaces between grains, It may be dense or open

MARKING SYSTEM FOR GRINDING WHEELS:- The Indian standard marking system for grinding wheels
has been prepared with a view of establishing a uniform system of marking of grinding wheels to
designate their various characteristics.

EXAMPLE
 SELECTION OF GRINDING WHEELS
When selecting a grinding wheel the following factors should be considered
1. Constant factors
• Material to be removed
• Amount of material to be removed
• Wheel contact
• Type of grinding machine
2. Variable factors
• Wheel speed
• Work speed
• Condition of the machine
• Skill of operator
ADVANTAGES OF GRINDING
 The surface finish obtained is superior to that of any other machine tool
 Hardened components can be machined by grinding
 Grinding requires very little pressure permitting its use on light and delicate parts
DISADVANTAGES OF GRINDING
 Work surface get over heated
 Wheel chatter and vibration results inaccuracies
 It is not suitable as a machining process where high metal removal is required
CLASSIFICATION OF GRINDING MACHINES
Grinding machines are mainly classified into two
 1.ROUGH GRINDING MACHINES 2. PRECISION GRINDING MACHINES
 Rough grinders are used to remove the large amounts of material without considering the accuracy of
the parts
 Precision grinders are used for finishing the work pieces to a very accurate size
1.ROUGH GRINDING MACHINES
a. Hand grinding machine b. Bench grinding machine c. Floor stand grinding machine d. Flexible shaft
grinding machine e. Swing frame grinding machine f. Abrasive belt grinding machine
2. PRECISION GRINDING MACHINES
a. Cylindrical grinding machines
i. External
ii. Internal
b. Surface grinding machines
i. Vertical spindle
ii. Horizontal spindle
c. Tool and cutter grinding machines
d. Special grinding machines
1.CYLINDRICAL GRINDING MACHINE:-In cylindrical grinding machine,the work piece is placed in
between the centers and rotated against the work piece

2.CENTERLESS GRINDING MACHINE:-Centerless grinding is performed on work meterils which does not
have centers.In this process the work piece is supported by a combination of grinding wheel,rugulating
whell and rest blade.Both grinding wheel and regulating wheel will rotates in the same direction but at
different speed.
3.TOOL AND CUTTER GRINDERS:-Are used for shaping of cutting edges of tools.

FINISHING OPERATIONS
1.Lapping:-Is an abrassive process used to improve the surfface finish of the components.The process
consists rubbing of the work surfface with with lap surfface,which is provided with fine abrassive
particles.

2.Horning:-Is finishing process by using a tool known as horn.In this process, the tool rotates and
reciprocates in the stationery hole to be finished.A horning tool is an expanding mandrel on which
abrassive sticks are mounted.(Add advantages,Disadvatages).Applications:-Gun barrel,bearing
hloes,Valve guides,Bushes etc

3.SUPER FINISHING:-Is process using abrassive sticks.In this process,the tool will be reciprocating with
short stroke across the rotataing work surfface.
Some other process are Burnishing,Buffing,Polishing etc
CHAPTER 2:-SURFFACE FINISHING METHODS
Surfface finishing is the process of adding meterials(in the form of liquid,solid or gas) to the surfface of
a work to improves its finish and life.
Surfface finishing may be 1.Surfface coating:-Adding meteril in the form of liquid or gas
2.Surfface cladding:Adding meterial inthe form of solid
DIFFERENT SURFFACE FINISHING METHODS
1.ELEECTRO PLATING:-Is the process of adding a metal coating to the product surfface by the process
of Faradys law of electrolyte.

For example:-Here we are adding coper to the surfface of the work

piece.For that,the work piece is taken as the cathode and coper rod is
taken as the anode.A D.C power supply is used.Coper sulphate solution is
used as the electrolyte.Now by the process of electrolysis,the cu irons in
the solution will be coated to the surfface of the work piece and cu
atoms in the rod are dissolved in the electrolyte.

2.HOT DIPPING:-Is the process of coating a metal to the work surfface by dipping the work metal to
the molten bath of the metal to be coated.

Hot dipping may be:-1.Galvenizing(Coating of Zn) 2.Tin coating 3.Parkerising(Coating of Phosphate)

3.ANODISING:-It is the process of producing oxide filim on the aluminium products.Work piece is used
as the anode and lead or graphite is used as the cathode.Sulphuric acid is used as the electrolyte.

METAL SPRAYING:-in this process,the work piece is coated with finely divided particles of metal.There
are 2 types of metal spraying
 1.Wire method:-In this process,the coating meterial will be given in the form of a wire.Then it is
melted with a oxy acelylene flame.Then it is atomized with compressed air and passed to the work
piece.

2.Powder method:-In this method,coating metal is supplied in the form of powder.

ORGANIC COATINGS:-
Different meterials used as organic coating are:
Oil base paints,Lacquer,Varnishes,Enamels,Rubber base paints etc

CHAPTER 3:NON CONVENTIONAL MACHINING

In a conventional machining the cutting tool is in direct contact with the work piece, and removes work
piece material in the form of chips.
There are situations where these processes are not suitable for the following reasons.
 The hardness and strength is very high
 The work piece is flexible and delicate to withstand cutting force
 The shape of the part is complex
 Residual stresses in the work piece are undesirable
These requirements led to the development of modern machining processes and are generally referred
as non-conventional or non-traditional methods of machining
1.Mechanical process
a) Ultrasonic machining(USM)
b) Abrasive jet machining(AJM)
2.Thermal processes
a) Electrical-discharge machining(EDM)
b) Laser beam machining(LBM)
3.Chemical processes
a) Chemical milling(CHM)
b) Chemical blanking(CHB)
4.Electrical processes
a) Electro-chemical machining(ECM)
b) Electro-chemical grinding(ECG)

ULTRASONIC MACHINING(USM)
Principle:-In this process,metals particles are removed by using abrasive grins which are made to hits
on the work piece by a tool vibtrating at ultrasonic frequncy.

Process:-
Components used:- 1. Oscillator with output amplifier 2. Transduce 3. Tool holde 4. tool
5. Work fixture 6. Circulating system for abrasive
Power supply-50 Hz Frequncy of vibration-15 to 30 KHz Tool-Steel/braas/Cu Refrigeration
sysytem-to cool the abrasive slury Abrasive-Boron carbide/Silicon carbide
Appications:Drilling,Cutting screw threads etc
Advantages:- No heat is generated during machining,Ability to machine hard materials,It is a distortion
less process,Good surface finish ,Complex shape can be machined,Conducting as well as non-
conducting materials can be machined
Disadvantages:- Cannot remove large amount of material,Maximum metal removal rate is 3
mm³/s,Power consumption is high,Tooling cost is high,Abrasive slurry need to be replaced periodically
Difficulty to machine deep holes
ABRSSIVE JET MACHINING(AJM)
Principle:-It is based on the principle of abrasive erosion.If a high velocity abrasive particle hits on a
hard or brittle surfface,it removes some metal from the work surfface.

Process:-
Components used:-Compressor,Abrsive feeder,Abrasive,Cutting nozle,Mchining chamber,filter
Regulater
Applications:-Drilling,Mchining metrials like glass,qurtz,mica etc,manufacturing electronoc divices
Advantages:- High surface finish,It can machine heat sensitive materials,It is free from
vibration,Initialization cost is low,Thin section can be machined
Disadvantages:- Low material removal rate,Nozzle life is limited,Abrasive particle cannot be reuse in
this process,It cannot use for machine soft and ductile material
LASER BEAM MACHINING(LBM)
Principle:-Laser means light amplification by stimulated emission of radiation.When a laser meterial is
palced in the presence of some energy sorce,it absorbs energy at some extend and relise when it
reaches its absorbing limit.This laser beamcan be used for cutting meterials.

Process:-
Components used:-Laser meteril,Flash lamp,Mirrors,Lense,dicharge tube
 Applications:-Drilling,Electronics industry,Automotive industry,Aero space industry
Advantages:-Hardeness is not a problem,Can be used for all types of meterials,No tool is used,High
accuracy,Flexible
Disadvantages:-High capital cost,High maintnece cost,Safety problems
ELECTRO CHEMICAL MACHINING(ECM)

Principle:-Baesd on the principle of

Faradys law of electrolysis.High rate
of electrolyte movement in the tool
wotk gap help to remove the metal.

Process:-
Componrnts used:-Work piece(Anode),Tool(Cathode),Electrolyte(Nacl or Kcl),Pump(For circulating the
electrolyte),Tool(Al,Cu,Brass,Bronze),Power supply(D.C)
Applications:-Machining of turbine blades,Die sinkining,Grinding,Drilling,Micro machining
Advantages:- Hardness is never a limitation,High degree of surface finish,Tool and work not in contact
Thin section can be machined,Complicated shape can be machined,Compatible with CNC
Disadvantages:- Metal removal rate is low,Only suitable for electrically conducting material,High heat is
produced,Excessive tool wear,Power consumption is high
ELECTRICAL DISCHARGE MACHINING(EDM)
Principle:-Also known as spark errosion.In this process, the metal is removed by the intense heat of the
electric spark by the process of vapourization.The spark is generated because of the gap between the
tool and work

Process:-

Components:-Work table
Tool(Cu,Al) Servo motor(for
controlling tool movement)
Tank Tool holder
Dielectric fluid(Kerosine) D.C
power supply Pump

Applications:-Drilling,Machining,Makining complex shapes

Advantages:-Harness is not a problem,High surfface finish,Tool and work does not contact,Coplicated
parts can be made
 Dis advantages:-Low metal removel rate,Costly,High power consumption

MODULE 4
CHAPTER 1:NUMERICALLY CONTROLLED MACHINE TOOLS
NUMERICAL CONTROL:-Controlling a machine or process by using instructions in the form of letters and
numbers

CLASSIFICATION OF N.C MACHINES:-

1.Based on feed back sysytem
(a)Open loop system:-In open loop system,no feed back facility is provided.The input signal will be given to
the machine tool.But during the process,if there is any difference in the actual process and specified
process,no monitering will be occur.

(b)Closed loo sysytem:-A closed loo system is povided with feed back facility.So the input signal is always
moniterd.So during the process if there is any error,the feed back system will give signal to the control unit.

2.CLASSIFICATION BASED ON CONTROL SYSTEM

1.Point to point system 2.Stright line sysytem 3.Contour system
 ELEMENTS OF NC MACHINE TOOLS
The main elements of a NC machine tool are
Control unit:-The instructions will be given to the control unit
Drive unit:-Signals from control unit pasess to the drive unit.And this signals helps to control the drive
motor and control the movement like feed,travelling rate etc
Magnetic box:-Signlas from control unit also passes to the magenetic box and this signals help to do the
works like coolant supply,Spindle speed,On/Off of the motor etc
Machine tool:-The machine tool do the machining operations
Feed back sysytem:-It monitor the errors in the process and send feed back to the control unit
Manuel control unit:-Helps the operator to do some functions like motor start,cooolant supply,speed
change etc

WORKING OF A NC MACHINE TOOL

Various steps involved are
1.Preperation of product drawing 2.Process planning 3.Programming 4.Tape preperation
5.Insert the tape to the control unit 6.Now as per the information getting from the contol unit,the
machine tool will be works and make the product
(note:ADD THE ABOVE PICTURE WHEN ANSWERING FOR THIS QUESTION)
ADVANTAGES OF NC MACHINES:-Complex shapes can be produced,High accuracy,Hihg flexiblity,Tool and
work set up time will be less,Productivity increses,Mass production is possible,Uniformity in
production,Repeatablity etc
DISADVANTAGES OF NC MACHINES:-High initial cost,Need of qualified programmers,Only applicable for
mass production etc
COMPUTER NUMERICAL CONTROL(CNC)
Controlling a machine or process by using programes which are prepared and store with the help of
computer.

CAD CAM
CAD-Means computer aided designing,i.e designing of products with the help of computers.
CAM-Means computer aided ,manufacturing,i.e using of computers for the process of making products.
Main advantages of cad are-Improve the productivity,standardise the design,reduce the errors,Reduce
the time etc
CAM is confined to 4 major areas
1.Numerical control 2.Proceess planning 3.Robots Factory management-Fctory data collection to get
timely information from thr factory floor.
Main featues of CAM are-Computer is dircetly connected to the manufacturing sysytem for monotor and
control the process.
APPLICATIONS OF CAD/CAM
Programming for NC,CNC and industrila robots,Designing of products and equipments,Designing of tools
and fixturs,Quality control,Process planning,Inspcetion,Scheduling,Plant lay out etc
COMPUTER AIDED PROCESS PLANNING(CAPP)
Process planning can be defined as determining the order of indivitual operations needed to produce a
given part or product.
Computer aided process planning is used to combain the design and production data into a sysytem that
generates process plans.2 approches are used to generate the CAPP
1.Variant CAPP system 2.Generative CAPP system

CHAPTER 2:ROBOTICS
A robot is a progamable device consists of mechanical and electronics components and is used to perform
various functions like material handling.
REASONS FOR USING ROBOTS
 It replaces human operators in dangerous work places.
 It strengthens and reaches requirements which are beyond the capacity of human operator.
 It eliminates errors due to tiredness and lack of concentration.
 Ability to be reprogrammed to perform a different task.
 It achieves unmanned operations during nightshifts.
BASIC ELEMENTS OF ROBOTS
Although industrial robots may vary widely, they are all made up of the following components.

1. Manipulator
2. Controller
3. Sensors
4. End effectors
5. Power source
CLASSIFICATION OF ROBOTS
1. According to the type of control 2.According to capability

a. Point-to-point robots a. Sequence controlled robots

b. Continues robots b. Adaptive robots
c. Computed trajectory robots c. Intelligence robots
d. Servo-controlled robots
3. According to the configuration 4.Based on manipulation function
a. Cartesian robot a. Pick and place robots
b. Cylindrical robot b. Special purpose robots
c. Spherical robot c. Universal robots
d. Articulated robot
CONFIGURATION OF ROBOTS (Classification of robots according to the configuration)
1. Cartesian robot:-Links has motion in 3 linear axis’s
 2. Cylindrical robot:-Links has 2 linear motions and 1 rotary motion

3. Spherical Robot:-Links has 1 linear motion and 2 rotary motions

4. Articulated robot:-Links has motion in 3 rotary axis’s

TYPES OF JOINTS
Joints are used to connect the links in the robot. And they provide relative motion between the
links of the robot. Different types of joints are
1. Liner joint(L joint):-Permits linear sliding motion between 2 parallel links
2. Orthogonal joint (O-joint):-Permits linear sliding motion between 2 links which are
perpendicular to each other.

3. Rotational joint(R-joint):-Provide rotational relative motion between 2 parallel joints

4. Twisting joint (T-joint):-Permits rotary motion between links

5. Revolving joint (V joint):-Permits motion between links which are perpendicular to each
other

NOTATION OF ROBOT’S MANIPULATOR

Robot can be divided into two parts:

1. Body and arm assembly 2.Wrist

 Each of the above has 3 degrees of freedom obtained by combination of the 5 types of joint.
A manipulator having 5 degrees of freedom could be TLR-TR
END EFFECTORS
An end effector is attached to the robot’s wrist to perform specific tasks such as handling of
parts, tools and welding torches.
They may be classified as
1. Grippers 2. Tools
Grippers are used to hold either work piece or tool.
Tools are directly attached to the robot wrist and become the end effector.
DIFFERENT TYPES OF END EFFECTORS

SPECIFICATION OF A ROBOT
A robot is generally specified by the following factors
1. Work envelope 2.Load carrying capacity 3.Maximum speed can be achieved
5. Repeatability 5.Control resolution 6.Degress of freedom 7.Program memor
ADVANTAGES OF ROBOTS:
1. Can eliminate human errors 2.Can used in dangerous working conditions 3.Reduce wastage
4.Improve the productivity 5.Increse product quality 6.Inprove flexibility
APPLICATIONS OF ROBOTS
 Material handling
 Machine loading application
 Spray painting application , Welding application
 Machining operations ,Assembly of parts
 Inspection purpose,Automotive and air space industry