MasTech BM4-Manufacturing Systems

BM4-2 Control Systems

QUESTIONS
1. Give an explanation of the following terms:
Numerical control machine
Machining center
Tool storage
Open-loop control
Closed-loop control
Programmer Processor language
Machine control unit
Rectangular coordinates

Rectangular coordinates
Punched tape
Binary coded decimal
Tape format Point-to-point
Continuous path Interpolation APT
High-level languages
Fuzzy logic control
(16p)

2. What is meant by feedback?

(3p)

3. How does a player piano tape differ from numerical control tape?

(3p)

4. Make a schematic diagram of a two axis, closed-loop control system.

(3p)
5. How does a player piano tape differ from numerical control tape?

(3p)

4. Make a schematic diagram of a two axis, closed-loop control system.

(4p)
5. How does a machining center differ from a numerically controlled turret lathe?
(3p)
6. List the media for NC. Which is most common?

(3p)

7. What is more important in CNC equipment, accuracy or repeatability? Justify

your answer.
(3p)
8. Name some disadvantages of NC and CNC systems.

(3p)

9. What is the purpose of the parity check?

(3p)

10. Explain your interpretation of DNC.

(4p)

11. Write a paragraph about the machine control unit.

(5p)

12. What are the characteristics of a stepping motor?

(3p)

13. What types of operations are best suited for point-to- point commands?
(3p)
14. Why is a coordinate system necessary for numerical control?
(3p)
15. What is the importance of fixed zero and floating point?
(3p)
16. What is adaptive control and what is its purpose?
(3p)
17. Why does the first NC machine tool located in a plant have disproportionate
costs associated with it?
(4p)
18. Explain how the word address tape format works.
(3p)
19. What is linear interpolation? How does it work?
(3p)
20. What are the main types of statements in AFT? What is the purpose of each?
(3p)
21. What is the basis of an ANN controller?
(3p)
22. Write a fuzzy rule to control a car drivers behavior while driving near an
elementary school.
(4p)

PROBLEMS
1. Show the coordinate location in a three-dimensional place of x = 5, y = 3, and
z = 4.
(4p)
2. Sketch the following machines and show the X, Y, and 2 axes for each: drill
press, lathes, and milling machine.
(4p)
3. Design a numerical system that can be used to remove chips from a NC turret
lathe. (4p)
4. Make a schematic of tape and, with the binary coded decimal system, show
the numbers 0 to 9, end block, and six miscellaneous operations identified by the
first six letters of the alphabet. (4p)
5. Using the EIA standard program on a tape, facsimile the following:
Manufacturing Processes, The Year of 2421, 6 -k 7 = 13.
(4p)
6. The following sample was taken from 7/16 in.-diameter motion control
couplings made by a CNC machine tool. 0.4375, 0.4374, 0.4376, 0.4377, 0.4373,
0.4373, 0.4375, 0.4372, 0.4377, 0.4374 Determine the repeatability of the
machine. If the CNC manufacturers claim an accuracy of 0.1%, what would you
say about their claim?
(4p)
7. A stepping motor is connected to a leadscrew of 0.13- in. pitch. Determine the
size of each step angle in the motor, the rotational speed of the motor, and the
linear travel rate of the table if the pulse frequency is 200 pulses/s and the
number of step angles required, is 245 pulses/rev.
8. Prepare a schematic of BCD tape for the following: X = 30.720, Y = 2.000, Z =
0.500, feed = 0.025 in./min, coolant on, coolant off, end block. Repeat using the
word address format. (4p)
9. Prepare a schematic of the binary coded decimal tape for the following: x =
22.750, y = 1.250, z = 2.117, feed = 0.015 in./min, coolant on, coolant offi end
block. Repeat using the word address format.
(4p)
10. Prepare a tape schematic for the following: X = 15.005, Y = 0.005,Z = 1.275,
feed = 0.009 ipr, coolant on, coolant off, end of block. Repeat using the word
address format.
(4p)
11. A two-flute, 0.5 in.-diameter cutter is used to cut out and rough shape the
bracket shown in Figure 11. Write an APT program to produce the part if the
cutting speed is 75 ft/min and the feed rate, f t, is 2 mil/cutter rev.
(5p)
(Hint: Number of turns, N = 12 V/ D; feed, ipm = N X ft X teeth.)

12. Explain each line of the following program and sketch the workpiece contour.
(5p)
PROGRAM O0002
N005
N010
N015
N020
N040
N045
N050
N055
N025
N030
N035
N060
N065
N070

G54 G90 s350 M03

G00 x-.625 y-.25
G43 H01 Z-.25
G01 x5.25 F3.5
G01 X.75
G03 x-.25 y3.25 R1.0
G01 y.75
G03 x.75 y-.25 R1.0
G03 x6.25 y.75 R1.0
G01 y3.25
G03 x5.25 y4.25 R1.0
G060 z.1
G91 G28 z0
M30

13. Write an NC program to manufacture the brake mount of Figure 13. The raw
material is 1/8-in. steel plate, all holes are through, all fillets are 1/8 radius.
Choose a proper diameter for the cutting and drilling tools. Recom- mend and use
adequate cutting speeds (V) and feed rates (f t). (5p)
(Hint: N = 12 V/ D; feed, ipm = N x ft x teeth.)