1st Sessional Paper Solution

RAMAKANT RANA http://www.ramakantrana.
com/CIM/
(Asst. Prof.) 1st Sessional Paper (Sep. 2016)
(Write your Roll No. immediately) Roll No.: __________________
Mid-Term Examination
September, 2016
7th Semester [B.Tech (MAE)] Subject: Computer Integrated Manufacturing
Paper Code: ETME-403
Time: 1 hour 30 min.
Max Marks: 30
NOTE:
1. Attempt three questions in total
2. Q. No. 1 is compulsory. Attempt any two more questions from remaining three questions.
Q 1. Answer the following questions:

i. Explain ANY TWO of the following: (4)
i. ATC along with its advantages
ii. Ball screw mechanism.
iii. Work Holding Devices
iv. Machining Centre
ii. What are Constructional features of CNC machines? (2)
iii. Explain ISO Specification Of Cutting Tools. (2)
iv. Explain the following codes: (2)
i. G01
ii. G03
iii. G90
iv. G91
Q 2. Write the program using G-Codes and M-Codes for CNC Turning (you are not
allowed to use canned cycle commands for this program, and step size should not be
more than 1.5mm): (10)
Q 3.
i. Classify the Cutting Tools on the basis of following: (6)
i. Setting up of Tool,
ii. Tool Construction and
iii. Cutting Tool Material
ii. Discuss the following: (4)
i. Personal / Distributed Network and
ii. Local Area Network
Q 4.
i. What is program Zero Point and also explain Axes Designation for CNC Turning and
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Milling part programming. (5)

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ii. Explain Canned Cycles of CNC Part-Programming with example(s). (5)
http://www.RamaKantRana.com/CIM/
RAMAKANT RANA http://www.ramakantrana.com/CIM/
Q1. i.i
Figure 1: ATC
An Automatic Tool Changer (ATC) is used in Computerized Numerical Control (CNC) machine
tools to improve the production and tool carrying capacity of the machine. ATC changes the
tool very quickly, reducing the non-productive time. Generally, it is used to improve the
capacity of the machine to work with a numbers of tools. It is also used to change worn out or
broken tools. It is one more step towards complete automation (Figure 1: ATC).
The tool change activity requires the following motions:

a. The spindle stops at the correct orientation for the tool change arm to pick the tool
from the spindle.
b. Tool change arm moves to the spindle.
c. Tool change arm picks the tool from the spindle.
d. Tool change arm indexes to reach the tool magazine.
e. Tool magazine indexes so that the tool from the spindle can be placed.
f. The tool is placed in the tool magazine.
g. The tool magazine indexes to bring the required tool to the tool change position.
h. Tool change arm picks the tool from the tool magazine.
i. Tool change arm indexes to reach the spindle.
j. New tool is placed in the spindle.
k. Tool change arm moves back to its parking position.
----(1 marks)
Advantages of automatic tool changer
 Increase in operator safety by changing tools automatically
 Changes the tools in seconds for maintenance and repair
 Increases flexibility
 Heavy and large multi-tools can easily be handled
 Decreases total production time
----(+1 marks)
2
VIDEO Help:
Page
https://www.youtube.com/watch?v=rrxHBsPyUj4
Q1 i.ii
Ball Screw
Ball screw is also called as Ball Bearing Screw or Recirculating Ball Screw. It consists of a
screw spindle, a nut, balls and integrated ball return mechanism a shown in Figure 2. The
flanged nut is attached to the moving part of CNC machine tool. As the screw rotates, the nut
translates the moving part along the guide ways. However, since the groove in the ball screw
is helical, its steel balls roll along the helical groove, and, then, they may go out of the ball nut
unless they are arrested at a certain spot. Thus, it is necessary to change their path after they
have reached a certain spot by guiding them, one after another, back to their “starting point”
(formation of a recirculation path). The recirculation parts play that role. When the screw shaft
is rotating, as shown in Figure 2, a steel ball at point (A) travels 3 turns of screw groove, rolling
along the grooves of the screw shaft and the ball nut, and eventually reaches point (B). Then,
the ball is forced to change its pathway at the tip of the tube, passing back through the tube,
until it finally returns to point (A). Whenever the nut strokes on the screw shaft, the balls repeat
the same recirculation inside the return tube.
---(2 Marks)
Figure 2: Ball Screw
When debris or foreign matter enter the inside of the nut, it could affect smoothness in
operation or cause premature wearing, either of which could adversely affect the ball screw's
functions. To prevent such things from occurring, seals are provided to keep contaminants out.
There are various types of seals viz. plastic seal or brush type of seal used in ball-screw drives.
Advantages of ball screws

1) Highly efficient and reliable.
2) Less starting torque.
3) Lower co efficient of friction compared to sliding type screws and run at cooler
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temperatures
4) Power transmission efficiency is very high and is of the order of 95 %.
5) Could be easily preloaded to eliminate backlash.
6) The friction force is virtually independent of the travel velocity and the friction at rest
is very small; consequently, the stick-slip phenomenon is practically absent, ensuring
uniformity of motion.
7) Has longer thread life hence need to be replaced less frequently.
8) Ball screws are well -suited to high through output, high speed applications or those
with continuous or long cycle times.
9) Smooth movement over full range of travel.
Disadvantages of ball screws

1) Tend to vibrate.
2) Require periodic overhauling to maintain their efficiency.
3) Inclusion of dirt or foreign particles reduces the life of the screws.
4) Not as stiff as other power screws, thus deflection and critical speed can cause
difficulties.
5) They are not self-locking screws hence cannot be used in holding devices such as vices.
6) Require high levels of lubrication.
VIDEO Help:
https://www.youtube.com/watch?v=kl6qNn9-nkk
Q1 i.iii
Work Holding Devices for CNC Machines
In the CNC machines, fixtures are still required to locate and hold the work pieces while
machining. The work holding devices should have the following uniqueness:
a. Work holding devices must have required accuracy and must have matching
reference surfaces with the reference system.
b. Work holding devices are allowed to perform a number of operations on different
faces in a single setting.
c. Work holding devices must enable quick loading and unloading.
d. Work holding devices must be fool-proofing to avoid incorrect loading of the job.
e. Work holding devices must be sufficient rigidity to fully withstand the cutting forces.
f. Work holding devices must be safe in use and loading and unloading.
g. Work holding devices must have a sufficient of clamping force for use of full roughing
cuts.
h. Work holding devices must be simple in construction maximum as possible.
Automatic pallet change over systems are used in modern CNC machines. These pallets
simply move for interchanging their positions on the machine table. While machining is being
done on a job kept on one pallet, the other pallets are accessible to the operator for clamping
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and unclamping raw material or finished product. This saves a lot of material handling and set
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up time, resulting in higher productivity.
Figure 3: Work holding devices

VIDEO Help:
https://www.youtube.com/watch?v=qots_2j_8gk
Q1 i.iv
CNC MACHINING CENTERS
The machining centre, developed in the late 50’s is a machine tool capable of multiple
machining operations on a work part in one setup under NC program control.
Classification
Machining centres are classified as vertical, horizontal, or universal. The designation refers
to the orientation of the machine spindle.
1. A Vertical Machining Centre has its spindle on a vertical axis relative to the work table. A
vertical machining centre (VMC) is typically used for flat work that requires tool access
from top. E.g. mould and die cavities, Large components of aircraft
2. A Horizontal Machining Centre (HMC) is used for cube shaped parts where tool access
can be best achieved on the sides of the cube.
3. A universal machining centre (UMC) has a work head that swivels its spindle axis to any
angle between horizontal and vertical making this a very flexible machine tool. E.g.:
Aerofoil shapes, curvilinear geometries.
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Figure 4 (a):Vertical Machining Figure 4 (b): Horizontal Machining Centre

Centre
Figure 4 (c): 5-Axis CNC Vertical machining Centre
VIDEO Help:
https://www.youtube.com/watch?v=yf7ucg-w5MQ
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Q1 ii
Constructional details of CNC machines
In general, a CNC machine tool consists of the following units:

1. Computers
2. Control System
3. Drive Motors
4. Tool Changers
According to the construction of CNC machine tools, it works in the following (simplified)
manner:-
1. The CNC machine controlled by the computer reads the program and translates it into
machine language, which is a programming language of binary notation used on
computers, not on CNC machines.
2. When the operator starts the execution cycle, the computer translates the binary codes
into electronic pulses which are automatically sent to the machine’s power units. The
control unit compares the number of pulses sent and received.
3. When the motor receives each pulse, they automatically transform the pulses into
rotations that drive the spindle and lead screw, causing the spindle to rotate and slide or
move the table. The part on the milling machine table or the tool in the lathe turret is
driven to a position specified by the program.
Briefly explain Computers, Control System, Drive Motors & Tool Changers.
VIDEO Help:
https://www.youtube.com/watch?v=ejQ84POvJaM
---(2 Marks)
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Q1 iii
---(2 Marks)
Q1 iv
G01 Rapid positioning
G03 Circular interpolation, counter clockwise
G90 Absolute programming
G91 Incremental programming
---(2 Marks)
VIDEO Help:
https://www.youtube.com/watch?v=AKhKPc-
_ywE&list=PLgxljY6GqukhpyC9iBMQ4A1GmlzThFvcz
G00 & G01 In Hindi
https://www.youtube.com/watch?v=8lDx9WcPz24
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Q2
Starting of the program
--- (2 Marks)
Facing and Turning
--- (+2 Marks)
Tapering
--- (+2 Marks)
Step Turning
--- (+2 Marks)
Ending of programme using M-Codes
--- (+2 Marks)
Q3 i (i.i, i.ii, i.iii)

Cutting tools are available in three basic material types: high-speed steel, tungsten
carbide, and ceramic. High-speed steel is generally used on aluminum and other nonferrous
alloys, while tungsten carbide is used on high-silicon aluminum, steels, stainless steels, and
exotic metals. Ceramic inserts are used on hard steels and exotic metals. Inserted carbide
tooling is becoming the preferred tooling for many CNC applications. For the full utilization of
CNC machines it is essential to pay due attention to the selection and usage of tooling, namely
tool holders, cutting tools and work holding devices. The tools for CNC machines must be
quickly changeable to reduce non-cutting time, preset and reset outside the machine, high
degree of interchangeability, increased reliability and high rigidity.
The cutting tools can be classified on the basis of setting up of tool, tool construction
and cutting tool material:
On the Basis of Setting up of Cutting Tool
a. Preset tools.
b. Qualified tools.
c. Semi qualified tools.
--- (2 Marks)
On the Basis of Cutting Tool Construction
a. Solid tools.
b. Brazed tools.
c. Inserted bit tools.
--- (+2 Marks)
On the Basis of Cutting Tool Material
a. High speed steel (HSS).
b. High carbon tool steel (HCS).
c. Cast alloy.
d. Cemented carbide.
e. Ceramics.
f. Boraon Nitride.
g. Diamond.
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h. Sialon.
--- (+2 Marks)
Q3 ii.i
Distributed Networking is a distributed computing network system, said to be

"distributed" when the computer programming and the data to be worked on are spread out
over more than one computer. Usually, this is implemented over a network.
Prior to the emergence of low-cost desktop computer power, computing was generally
centralized to one computer. Although such centers still exist, distribution networking
applications and data operate more efficiently over a mix of desktop workstations, local area
network servers, regional servers, Web servers, and other servers. One popular trend is
client/server computing. This is the principle that a client computer can provide certain
capabilities for a user and request others from other computers that provide services for the
clients. (The Web's Hypertext Transfer Protocol is an example of this idea.)
Enterprises that have grown in scale over the years and those that are continuing to grow are
finding it extremely challenging to manage their distributed network in the traditional
client/server computing model. The recent developments in the field of cloud computing has
opened up new possibilities. Cloud-based networking vendors have started to sprout offering
solutions for enterprise distributed networking needs. Whether it turns out to revolutionize
the distributed networking space or turns out to be another craze remains to be seen.
--- (2 Marks)
Q3 ii.ii
A Local Area Network (LAN) is a computer network that interconnects computers within
a limited area such as a residence, school, laboratory, university campus or office building and
has its network equipment and interconnects locally managed. By contrast, a wide area
network (WAN), not only covers a larger geographic distance, but also generally involves leased
telecommunication circuits or Internet links.
Figure 5: Local Area Network (LAN)

--- (+2 Marks)
Q4 i
10
Selection of Zero Point

In order to define certain points on a workpiece in this manner, you will first have to decide
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where to put the coordinate system on the workpiece, especially where to place the zero point.
For milling, the zero point (or reference point) of all dimensions may be placed anywhere on
the workpiece. Let's call this zero point 'workpiece zero' (WZ) or workpiece datum. To save trouble of
unnecessary calculations it is advisable to place workpiece zero at that point on a part drawing on which
most of the dimensions are based. See Figure 6 & 7. A workpiece datum maybe defined as a point, line
or surface from which dimensions are referenced. It major may not be within the workpiece area.
The symbol used to denote workpiece zero is:
Figure 6: Example of Zero Point Options on Workpiece
Figure 7: Examples of Component with Zero Point in Workpiece Centre
For turning operations the X axis zero is normally positioned on the centreline of the spindle
axis. The Z axis zero can be positioned on the front face of the workpiece or on the face of the
workpiece or on the face of the chuck. See Figure 8.
Figure 8: X0 Z0 Positions for Turning Operations
---(2 Marks)
Machine Axes
The primary axes of a machine are designated as X, Y, Z and can have positive or negative
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values.
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The Z-axis is always parallel to the main spindle of the machine (see Figure 9). It does
not matter whether the spindle carries the workpiece or the tooling, therefore the Z-axis can
be either vertical or horizontal. On milling, boring and drilling machines the spindle is the tool
rotating means while on cylindrical grinders and lathes the spindle is the work rotating means.
Positive Z-movement always increases the distance between the work and the tool. The X-axis
of motion is horizontal and parallel to the work-holding surface. If Z is horizontal, positive X is
to the right looking from the spindle towards the workpiece. If Z is vertical, when looking from
the spindle towards its supporting column, positive X is to the right.
The Y-axis of motion is perpendicular to both the X and Z axes. Positive Y is in the
direction which would make a right-handed set of coordinates.
CNC lathes only have two major axes X and Z. There is no Y-axis.
Figure 9 (a): X, Y, Z Axes for VMC Figure 9 (b): X, Y, Z Axes for HMC
Figure 9 (c): X, Y, Z Axes for Turning Centre

---(+3 Marks)
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Q4 ii
A Canned Cycle is a way of conveniently performing repetitive CNC machine operations.
Canned cycles automate certain machining functions such as drilling, boring, tapping,
pocketing, etc... Canned cycles are so called because they allow a concise way to program a
machine to produce a feature of a part. A canned cycle is also known as a fixed cycle. A canned
cycle is usually permanently stored as a pre-program in the machine's controller and cannot
be altered by the user.
Advantages
a. The conciseness of canned cycles allows for quicker and easier development of programs
at the machine.
b. As canned cycles reduce the number of blocks in a program, the storage space occupied
by the program is less and the programmer escapes the tedium of writing the same
instructions again and again. This reduces the potential for errors, and locating any errors
that do exist is easier in a shorter program.
c. Job setup is also facilitated by canned cycles. Some canned cycles exist which are designed
for use by machine tool operators for simple job set-up and measuring tasks.
---(2 Marks)
Examples of Canned Cycles
G73 High speed peck drilling cycle
G74 Left-hand tapping cycle
G76 Precision boring cycle
G80 Cancel any fixed cycle
G81 Drilling cycle
G82 Drilling cycle with dwell
G83 Peck drilling cycle
G84 Right-hand tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
---(+1 Marks)
Explanation of any one of the above code
---(+2 Marks)
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Q 1. Answer the following questions:

Milling part programming. (5)

ii. Explain Canned Cycles of CNC Part-Programming with example(s). (5)

The tool change activity requires the following motions:

Figure 2: Ball Screw

Advantages of ball screws

Disadvantages of ball screws

up time, resulting in higher productivity.

Figure 3: Work holding devices

Figure 4 (a):Vertical Machining Figure 4 (b): Horizontal Machining Centre

Figure 4 (c): 5-Axis CNC Vertical machining Centre

In general, a CNC machine tool consists of the following units:

Q3 i (i.i, i.ii, i.iii)

Distributed Networking is a distributed computing network system, said to be

Figure 5: Local Area Network (LAN)

Selection of Zero Point

Figure 6: Example of Zero Point Options on Workpiece

Figure 7: Examples of Component with Zero Point in Workpiece Centre

Figure 8: X0 Z0 Positions for Turning Operations

Figure 9 (c): X, Y, Z Axes for Turning Centre

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