A PROJECT REPORT
ON
“SEMI-AUTOMATIC TURN MILL”
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD
OF
DIPLOMA IN
MECHATRONICS
SUBMITTED TO
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION,
MUMBAI
SUBMITTED BY
Name of Student(s) (Full Name)
1.
2.
3.
Enrollment No.
Sankalp Vijay Patil
Prathamesh Sagar More
Avadhut Aba Pukale
37035
37038
37043
GUIDED BY
Mr. Shardul Dixit (Industry Mentor)
GUIDED BY
Mr. Aniket D. Patil (Institute Mentor)
Sharad Institute of Technology Polytechnic Yadrav,
Ichalkaranji
[2022-2023]
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Sharad Institute of Technology Polytechnic Yadrav, Ichalkaranji
CERTIFICATE
This is to certify that the project report entitled “Semi-Automatic Turn Milling”
Was successfully completed by Student of sixth semester Diploma in (Mechatronics).
1.
Sankalp Vijay Patil
37035
In partial fulfillment of the requirements for the award of the Diploma in
Mechatronics and submitted to the Department of Mechatronics of Sharad Institute of
Technology Polytechnic, Yadrav work was carried out during a period for the academic
year 2022-23 as per curriculum .
Mr. Aniket D. Patil
Mr. Santosh Bodake
Guide
HOD
B. S. Tashildar
External Examiner
Principal
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ACKNOWLEDGEMENT
I would like to express my special thanks and gratitude to my project guide Mr. Aniket
D. Patil as well as our principal Mr. B. S. Tashildar who gave me the golden opportunity to do this
wonderful project on the topic Semi-Automatic Turn-Mill, which also helped me in doing a lot of
research and I came to know about so many new things I am really thankful to them.
Secondly I would also like to thank my parents and friends who helped me a lot in finalizing this
project within the limited time frame.
Date :
Sankalp Vijay Patil
Place :
37035
TY Mechatronics
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TABLE OF CONTENTS
0.0
CONTENTS
iv
0.1
ABSTRACT
v
0.2
LIST OF TABLES
vi
0.3
LIST OF FIGURES
vii
0.4
LIST OF SYMBOLS AND ABBREVIATIONS
ix
1.0
INTRODUCTION
1
1.1
Semi-Automatic turning milling project
1
1.2
Machine Setup
1
2.0
LITERATURE SURVEY
3
2.1
Introduction & Literature review
3
2.2
Previous & Current implementation
3
3.0
SCOPE OF PROJECT
6
3.1
Introduction & Application
6
3.2
Future Work
7
4.0
METHODOLOGY
8
4.1
General layout
8
4.2
Detailed description
9
5.0
DETAILS OF DESIGNS, WORKING AND PROCESSES
10
5.1
Components
10
5.2
Working of Semi Auto Lathe
16
5.3
Challenges Faced
17
6.0
RESULTS AND APPLICATIONS
21
6.1
Observations
21
7.0
CONCLUSION AND FUTURE SCOPE
23
8.0
REFERENCES
24
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ABSTRACT
Project Title: Semi-Automatic Hybrid Turning-Milling Retrofit for Late Machines
This project aims to retrofit a lathe machine with an Semi-Automated hybrid turningmilling system to increase its productivity and flexibility. Late machines, which are typically used
for turning operations, can be retrofitted with a milling head to perform both turning and milling
operations in a single setup. This hybrid approach can increase efficiency by reducing setup time,
improving accuracy, and decreasing cycle time.
The retrofit will include the installation of a milling head, motor, and drive system to
enable the machine to perform milling operations. The machine will also be equipped with an
Semi-Automated tool changer to enable rapid tool changes and reduce downtime between
operations. The retrofit will include the installation of sensors to monitor the machine's operation,
which will allow for real-time adjustments to be made to improve efficiency.
The Semi-Automated hybrid turning-milling system will be controlled by a computer
numerical control (CNC) system. The CNC system will be programmed to control the milling head,
tool changer, and other components of the system to perform complex turning and milling
operations with high precision and accuracy. The system will also be equipped with a user-friendly
interface that will allow operators to easily program and control the machine.
The project will be conducted in several stages, including the design, fabrication, and
installation of the milling head and drive system, the installation of the tool changer, and the
integration of the CNC control system.
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LIST OF TABLES
Table No.
Title
Page No.
Table: 5.1
Motor Specifications
13
Table 5.2
Servo drivers and motors combination
15
Table 6.1
Before Retrofitting
21
Table 6.2
After retrofitting
22
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LIST OF FIGURES
Figure No.
Title
Page No.
Figure 1.1
Semi Auto Machine
1
Figure 1.2
Concept Diagram
2
Figure 4.1
General layout
9
Figure 5.1
Servo motor
13
Figure 1.1
Servo motor with mounting
14
Figure 1.1
Servo Drive
15
Figure 1.1
Relay Board
16
Figure 1.1
AC3 8A contactors
17
Figure 1.1
Emergency stop
17
Figure 1.1
Cutters
18
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Chapter 1
INTRODUCTION
1.1 Semi-Automatic turning milling project
Semi-Automatic turning milling, known as Semi-Automatic turning milling, is a
machining process that combines the capabilities of turning and milling in a single setup. This
process allows for the production of complex parts with precision and accuracy, reducing the
need for multiple setups and operations. In this paper, we will provide an in-depth introduction
to Semi-Automatic turning milling, including its history, benefits, applications, and technical
aspects.
Technical Aspects of Semi-Automatic turning milling machines consist of a work
piece, cutting tools, and a tool turret that can be rotated to position different tools for various
operations. The work piece is mounted on a spindle that rotates at high speeds, while the
cutting tools are mounted on the turret and move in multiple axes to perform various
operations.
Figure: 1.1 Semi auto Machine
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1.2 Machine Setup
We connected two axis one ‘x’ and one ‘z’ to the job holder, it is built as per the
company operation required in MUKTANGAN industries. we developed the lathe machine in
the Semi-Automatic turning milling machine (as retrofit).The working of both operation turning
and milling can be done in this one system .The total system we build runs on the software
named machine Three .We purchased the domain available in the market. It runs as the CNC
machine code operation i.e. on G code and M code.
Figure: 1.2 Concept Diagram
Benefits Semi-Automatic turning milling offers numerous benefits compared to
traditional machining processes. One of the main advantages is the ability to produce complex
parts with precision and accuracy in a single setup, reducing the need for multiple operations
and setups. This saves time and reduces the risk of errors or inconsistencies that can arise from
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multiple setups. Semi-Automatic turning milling also offers improved surface finish and
dimensional accuracy compared to traditional machining processes. The use of computercontrolled machines ensures consistent and precise cuts, resulting in parts that meet tight
tolerances and specifications.
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Chapter 2
LITERATURE SURVEY
2.1 Introduction & Literature Survey

Introduction
A semi-automatic turn-mill machine is a type of machine tool that can perform both
turning and milling operations. These machines are widely used in manufacturing industries for
producing complex parts with high precision and accuracy. In this literature survey, we will
review some of the recent research papers, patents, and technical reports related to semiautomatic turn-mill machines.

Literature Review:
1.
"Design and Development of Semi-Automatic Turn-Mill Machine" by R. S.
Pawaretal. (2017)
In this research paper, the authors present the design and development of a semiautomatic turn-mill machine. The machine is equipped with a turret and a milling attachment,
and it can perform both turning and milling operations. The authors also describe the various
components of the machine and their functions.
2. "A review of turn-mill machining process" by N. K. Mehta et al. (2018)
This review paper provides an overview of the turn-mill machining process and its
various applications. The authors discuss the advantages and disadvantages of turn-mill
machines compared to other types of machine tools. They also provide a summary of the recent
developments in turn-mill machining technology.
3. "Optimization of tool path for turn-mill operations using a genetic algorithm" by
M. R. Alves et al. (2019)
In this research paper, the authors present a genetic algorithm-based approach for
optimizing the tool path for turn-mill operations. The authors demonstrate that the proposed
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method can improve the machining efficiency and reduce the machining time. They also
provide a comparison of their method with other existing approaches.
4. "Development of an automatic tool changer system for a turn-mill machine" by S.
H. Lee et al. (2020)
In this patent application, the inventors describe an automatic tool changer system for
a turn-mill machine. The system is designed to automatically change the cutting tool during the
machining process, thereby reducing the downtime and improving the machining efficiency.
5. "Process capability analysis of a turn-mill machine for precision machining of
aerospace components" by S. Kumar et al. (2021)
In this research paper, the authors present a process capability analysis of a turn-mill
machine for precision machining of aerospace components. The authors demonstrate that the
machine is capable of producing high-quality parts with high precision and accuracy. They also
provide a comparison of their results with the industry standards.
2.2 Previous & Current Implementations:

Previous Implementations:
Earlier implementations of Semi-Automatic turning-milling had some limitations.
One of the most significant was that they lacked flexibility. They were designed to work on
specific materials and designs, which made it challenging for manufacturers to use the
machines for a wide range of applications. Additionally, they were not as accurate as modern
Semi-Automatic turning-milling machines, which led to increased scrap rates and higher costs
of production.

Current Implementations:
Modern Semi-Automatic turning-milling machines have overcome many of the
limitations of previous implementations. One of the most significant advancements has been in
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the accuracy of the machines. High-precision cutting tools, real-time monitoring systems, and
advanced sensors have improved the accuracy of the process significantly. This has led to a
reduction in scrap rates, lower production costs, and improved quality of the finished product.
Another significant advancement has been the increased flexibility of modern SemiAutomatic turning-milling machines. They can now work with a wider range of materials and
designs, making them more versatile and useful in various manufacturing applications. Modern
machines are also more efficient, thanks to the use of advanced software and hardware.
Despite the significant advancements in modern Semi-Automatic turning-milling
machines, there is still a need for further improvement. One area where work is ongoing is the
development of advanced sensors and algorithms that can detect and correct errors in real-time.
This will improve the accuracy of the machines further, reduce scrap rates, and improve overall
efficiency.
Another area of ongoing work is the development of new cutting tools that can
handle a wider range of materials and designs. This will further increase the flexibility of the
machines and allow manufacturers to use them in even more applications.
In addition to these advancements, there is also significant work being done in the
area of machine learning and artificial intelligence. These technologies can help optimize the
process by analyzing large amounts of data to identify patterns and trends. This will allow for
even greater accuracy and efficiency in the manufacturing process.
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Chapter 3
SCOPE OF PROJECT
Scope of the Automatic Hybrid Turning-Milling Machine Project Report:
3.1 Introduction & Application

Introduction
The Semi-Automatic
hybrid turning-milling
machine
is an advanced
manufacturing technology that combines the capabilities of turning and milling machines. This
machine can produce complex parts more efficiently and accurately than traditional machines.
In this project report, we will provide a detailed analysis of the Semi-Automatic hybrid turningmilling machine, its advantages, and its potential applications. We will also discuss the
challenges associated with the development of this machine and the future of the technology.
Design and Development:
The design and development of the Semi-Automatic hybrid turning-milling machine
are the primary focus of this project report. We will provide a detailed analysis of the machine's
components, including the control system, spindle, cutting tools, and sensors. We will discuss
the challenges associated with the design and development of the machine, including the need
for advanced software and hardware. We will also discuss the role of simulation and testing in
the development of the machine.
Advantages:
The Semi-Automatic hybrid turning-milling machine offers several advantages over
traditional machines. These advantages include higher accuracy, greater flexibility, and
improved efficiency. The machine can produce complex parts with high precision, reducing the
need for additional machining and improving the quality of the finished product. The machine
can also work with a wide range of materials, making it more versatile than traditional
machines. The Semi-Automatic hybrid turning-milling machine is also more efficient, thanks to
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its ability to perform multiple operations in a single setup, reducing the time and cost of
production.

Applications
The Semi-Automatic hybrid turning-milling machine has several potential
applications in various industries, including aerospace, Semi-Automotive, and medical. In
aerospace, the machine can be used to produce complex components for aircraft and spacecraft,
such as engine parts and structural components. In the Semi-Automotive industry, the machine
can be used to produce transmission and engine components. In the medical industry, the
machine can be used to produce implants and prosthetics with high precision and accuracy.
3.2 Future Work:
The significant advancements in the Semi-Automatic hybrid turning-milling
machine, there is still a need for further improvement. One area where work is ongoing is the
development of advanced sensors and algorithms that can detect and correct errors in real-time.
This will improve the accuracy of the machines further, reduce scrap rates, and improve overall
efficiency. Another area of ongoing work is the development of new cutting tools that can
handle a wider range of materials and designs. This will further increase the flexibility of the
machines and allow manufacturers to use them in even more applications.
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Chapter 4
METHODOLOGY
4.1 General layout
Design
Define Specifications
Of Product
Study alternative
Mechanism For product and
Selecting convenient
Prepare General Layout
Configuration
Prepare Assembly And
Detailed Drawings
Fabrication
Figure: 4.1 General layout
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4.2 Detailed description
Phase I: Literature Survey and theoretical calculations
In this phase an extensive literature survey is carried out. It involves collection of
literature from various available resources. The required theoretical background needed to
understand working Semi-Automatic turning milling and the technologies going to be used in it
will be studied. Also program generating for command and power calculations for motor are to
be studied.
Phase II: System Design–Controller design and development
Design and development of electric circuit from connection of motor to PCB kit and
also of safety circuits is to be done. Based on the theoretical data and available resources will
be developed and manufactured as per required specification. And the required tests will be
carried out.
Phase III: Design & development of Actual model
This task will be carried out successful working of the prototype with the prototype
development. Cad model will be made for the product. Also the dimensions will be justified.
The main body of the machine that is the milling disc is connected to the tailstock and the
spindle motor with the help of pulley will be declared will be manufactured and assembled.
Phase IV: Design and connection of the electronic circuit
In this phase the design and connection of the required electric components are carried out.
With the help of simulation software and data available on the market it is totally depended on
the budget of the project sponsored.
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Phase V: Final tests and performance analysis
Different types of tests like working reverse forward function, working minutes on
one discharge cycle will be tested. Time required for the various operation cycles will be tested.
1. Details of design, working and processes
Write the details of design, working and processes about your project.
5.1 Components

Ball screw:
When selecting a ball screw for a medium duty lathe machine, there are several
criteria that you should consider
1. Load Capacity
2. Accuracy
3. Speed
4. Durability
5. Lubrication:
6. Cost:
When selecting a ball screw, it is important to consult with the manufacturer or a
qualified engineer to ensure that the ball screw meets all necessary requirements for the specific
lathe machine and application.

Servo Motor BCH, No Oil Seal, W Key, 20-Bit Encoder, W/O Brake-
Straight Con
1.
Power Supply:
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2. Individual Drive:
3. Mechanical Features:
i. Mounting
ii. Enclosures
iii. Transmission of Drive
iv. Permissible Vibration
v. Noise Level
4. Electric Features:
i. Starting Characteristics
ii. Running Characteristics
iii. Speed Control
5. The Capacity of Motor:
Two basic considerations are involved in fixing the size of the motor:
(a) The motor should be capable of delivering the load torque requirements,
(b) The temperature rise of the motor should be within the safe value for the
insulation class.
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As stated above, the capacity of motor is selected on the basis of power spent on
cutting operation or on the basis of rise in temperature, or over loading whichever results
in higher capacity.
Figure: 5.1 Servo Motor
Range compatibility
Lexium 23 Plus
Product or component type
Servo motor
Device short name
BCH
Maximum mechanical speed
5000 rpm
[Us] rated supply voltage
220 V
Network number of phases
three phase
Shaft end
Keyed
Torque constant
0.49 N. m/A
Shaft diameter
14 mm
Shaft length
24.5 mm
Key width
5 mm
Maximum axial force Fa
98 N
Maximum radial force Fr
245 N
Table: 5.1 Motor Specifications
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Figure: 5.4 servo motor with mounting
Here, we used 2 three phase servo motors. Both are connected by for axial movement
x axis and y axis ‘Both the motors are connected to the axis with the help of pulley. And the
setup is built according to the requirement of the company.
As the motor gets the signal to turn on it will make movement in respective axis with
the help of setup bulled with ball crew and pulley. This change in movement is order according
to the worker, it gets controlled by the G code M code as like CNC do .the software used in this
system is machine 3.drivers are used to convert digital signal into analog as the signal needed
by the motor.

LXM23D and BCH Servo drive system
The LXM23 product family consists of two servo drive models that cover different
application areas. Together with Lexium BCH servo motors as well as a comprehensive range
of options and accessories, the drives are ideally suited to implement compact, highperformance drive solutions for a wide range of power requirements. This product manual
describes the LXM23D servo drive and the BCH servo motor.
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Figure: 5.5 Servo drivers

Servo drive and servo motor combination
Table: 5.1
Table: 5.1 Servo drivers and motor combination

Relay circuit and working
This 4 Road/Channel Relay Module (with light coupling) 12V module meets the
safety standard as control areas and load areas have the isolation groove. Optical coupling
isolation module.
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The triggering of 4 Road/Channel Relay Module is reliable, more stable. The
double FR–4 circuit board design, high-end SMT process. It has power and relay
operation instructions.
Figure: 5.6 Relay Board

Contactor circuit and working
When a relay is used to switch a large amount of electrical power through its
contacts, it is designated by a special name: contactor. Contactors typically have multiple
contacts, and those contacts are usually (but not always) normally-open, so that power to the
load is shut off when the coil is de-energized. Perhaps the most common industrial use for
contactors is the control of electric motors.
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Figure: 5.7 AC3 8A Contactors
The top three contacts switch the respective phases of the incoming 3-phase AC
power, typically at least 480 Volts for motors 1 horsepower or greater. The lowest contact is an
“auxiliary” contact which has a current rating much lower than that of the large motor power
contacts, but is actuated by the same armature as the power contacts. The auxiliary contact is
often used in a relay logic circuit, or for some other part of the motor control scheme, typically
switching 120 Volt AC power instead of the motor voltage. One contactor may have several
auxiliary contacts, either normally-open or normally-closed if required.

E-stop (emergency stop)
Figure: 5.8 Emergency Stop
It is a simple, highly visible button designed to shut down operations on heavy and/or
dangerous equipment.
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Used to save lives in industrial operations, E-stops shut down equipment
immediately.

Tool we developed
Extra attachment required for gang milling
Figure: 5.9 Cutters
5.2 Working of Semi Auto Lathe
A turning retrofit for a semi-automatic machine involves adding new components or
upgrading existing ones to improve the functionality, precision, and productivity of the
machine. The process of retrofitting a semi-automatic turning machine may involve the
following steps:
1. Evaluation:
The first step in the retrofitting process is to evaluate the current state of the semiautomatic turning machine. This includes assessing the current functionality, precision, and
productivity of the machine and identifying areas for improvement.
2. Design:
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Based on the evaluation, a design is created for the retrofit components, which may
include new or upgraded components such as a CNC controller, servo motors, and drives. The
design should consider the specifications of the existing machine, as well as the requirements
of the new components.
3. Installation:
The new components are installed onto the existing machine, which may require
removing some parts and integrating new parts. The installation process should be conducted
with care, following the design specification to ensure the proper fit and function of the retrofit
components.
4. Calibration and Testing:
Once the installation of the new components is complete, the machine is calibrated
and tested to ensure that it operates according to the design specifications. This includes testing
the machine for accuracy, precision, and functionality. The testing process may require
adjustments to be made to the calibration and fine-tuning of the machine.
5. Training and Maintenance:
Once the retrofit is complete, the machine operators and maintenance personnel
should receive training on the new features and components. It is essential to maintain the
machine, which requires regular cleaning, lubrication, and inspection of the components.
Overall, the goal of a turning retrofit for a semi-automatic machine is to enhance its
capabilities by incorporating advanced components, improve its performance, reduce
downtime, and extend its useful life. Retrofitting a machine can be a cost-effective alternative
to purchasing a new machine while still achieving the necessary improvements.
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5.3 Challenges:
The development of the Semi-Automatic hybrid turning-milling machine comes with
several challenges. One of the most significant challenges is the need for advanced software
and hardware to control and operate the machine. The software and hardware need to be able to
handle complex operations, such as real-time monitoring and error detection, to ensure the
machine's accuracy and reliability. Another challenge is the need for skilled operators and
technicians to operate and maintain the machine properly.
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Chapter 6
RESULT
6.1 Observations
Table: 6.1before retrofitting
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Table: 6.2 after retrofitting
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Chapter 7
CONCLUSION
In this literature survey, we have reviewed some of the recent research papers, patents,
and technical reports related to semi-automatic turn-mill machines. The reviewed literature
demonstrates the potential of turn-mill machines for producing complex parts with high
precision and accuracy. The proposed methods and systems can improve the machining
efficiency, reduce the machining time, and enhance the overall productivity of the machine.
In conclusion, the Semi-Automatic hybrid turning-milling machine is an advanced
manufacturing technology that offers several advantages over traditional machines. The
machine can produce complex parts with high precision, reduce the need for additional
machining, and improve the quality of the finished product. The machine also has several
potential applications in various industries, including aerospace, Semi-Automotive. However,
the development of the machine comes with several challenges, including the need for
advanced software and hardware and skilled operators and technicians. With ongoing work, the
Semi-Automatic hybrid turning-milling machine will continue to improve, enabling
manufacturers to produce complex parts more efficiently and accurately.
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Chapter 8
REFERENCES
a.
https://robu.in/product/4-roadchannel-relay-module-light-coupling-12v/
b.
https://www.youtube.com/watch?v=UUBg10eD8GQ
c.
https://robu.in/product/4-roadchannel-relay-module-light-coupling-12v/
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