Production Technology - VI - Modernmachining Processes

State any two applications of non-conventional machining methods.

Answer: Applications of non-conventional machining:

Non-traditional methods find wide application in aerospace, missile and nuclear industries, as they use difficult
to machine materials such as hastalloy, nitralloy, nimonics, carbides, stainless steel, heat-resisting steels and
many other high-strength-temperature-resistant (HSTR) alloys.

State any two disadvantages of Chemical machining process.

Answer: Disadvantages of chemical machining:

1. Etchant vapors are corrosive and may damage the equipment.

2. Needs adequate ventilation of the work area.
3. Metal removal rate is less.

State four applications of Chemical machining process.

Answer: Applications of chemical machining:

1. For decorative articles,

2. Manufacture of electronic printed circuit boards,
3. Aircraft parts,
4. Architectural panels.

State any three reasons for using the Non-conventional machiningprocesses.

Answer: Reasons for using the non-conventional machining processes:

The main reasons for using the non-traditional machining processes are:

● The hardness and strength of the work material is very high or the material is too brittle.
● The workpiece is too flexible, slender, or delicate to withstand the cutting and grinding forces.
● The parts are difficult to fixture, i.e. to clamp in work holding devices.
● The shape of the part is complex, including such features as internal and external profiles or small-
diameter holes in fuel-injection nozzles.
● Surface finish and dimensional tolerance requirements are more accurate than those obtained by
other processes.
● Temperature rise and residual stresses in the workpiece are not desirable or acceptable.

5) State any six advantages of Chemical machining process.

Answer: Advantages of chemical machining:

1. Metal removal from all the surfaces of a workpiece is possible at a time.

2. Intricate and complex shapes can be easily produced.
3. Surfaces produced are smooth and clean. No burrs are produced on the workpiece.
4. Very large workpieces can be machined in large tanks.
5. Hardness of material is not a limitation.
6. Cost is low
7. Extremely thin workpieces (0.375 mm) can be machined without distortion.
8. Tolerances of ± 0.075mm are obtainable in 12 mm deep cuts.
9. A number of workpieces can be machined at a time.

6) Explain the procedure of “Chemical Machining” with a neat sketch.

Answer: The procedure of CHM involves five basic steps as described below:

1. Cleaning: Material to be milled is cleaned to remove grease, oils, heavy oxides and other contaminants
that may interfere with the chemical action.
2. Masking: It is the application of a coating of appropriate maskant to the work surface. A maskant is the
material that resists chemical action. The maskant may be applied by dipping, spraying or by other
methods. A typical maskant commonly used is neoprene rubber with a resin base.
3. Scribing: Maskant coating is cured for some time. Afterwards the outlines of the portions to be removed
may be scribed or cut. If recessed patterns are required for example, the maskant is scribed with the aid
of templates that resemble the pattern. Cutout portions of the maskant are then peeled off by hand,
exposing the bare metal to the chemical milling solution.
4. Etching: The workpiece is submerged in a tank containing a liquid etching chemical. The etchant
attacks exposed surfaces of the workpiece and eats away the metal. The metal removal is usually
between 0.0125 to 0.025 mm per minute depending on the type of material. If a tapered form is to be
produced the submerged workpiece is to be raised from the etchant at a uniform rate.
5. Rinsing: After etching and checking for the proper depth, the metal is cleaned of all chemicals by
rinsing and the maskant is removed by hand, chemical stripping or mechanical brushing.

7) State any six differences between Traditional and Non-conventional

machining methods.

Answer: Differences between traditional non- conventional machining methods:

S. Traditional Machining
Machining
No.
(Modern Machining )
8) State any two advantages of non-conventional machining.

Answer: The non-conventional machining methods have several advantages over conventional methods
that include:
● They can produce complex shape on workpiece material,
● A very high accuracy as desired
● Not limited by hardness, toughness, and brittleness of material.

9) State any two disadvantages (limitations) of non-conventional machining.

Answer: The main disadvantages of non-traditional methods are: They are

● Time consuming,
● Generally more expensive and
● Require considerable technical know-how.

10) List the equipment used in USM process.

Answer: Equipment used in USM: The equipments used in Ultrasonic Machining are:

1. Electronic oscillator and amplifier

2. Transducer
3. Tool holder (Horn)
4. Abrasive slurry

11) List any two commonly used abrasives in USM along with their uses.

Answer: The commonly used abrasives are: Aluminium oxide, boron carbide, silicon carbide, and
diamond dust. Boron is the most expensive abrasive material and is best suited to cutting of tungsten carbide,
tool steel and gems. For cutting glass and ceramics, aluminium oxide is found as the best. Fresh abrasives cut
better and therefore the slurry has to be replaced periodically.
12) State any six advantages of USM process.

Answer: Advantages of USM:

1. USM is used for machining hard and brittle materials to complex shapes with good accuracy and
reasonable surface finish.
2. This process can be used for drilling of circular or non-circular holes.
3. It is not affected by the electrical or chemical characteristics of the work material.
4. Good surface finish and dimensional accuracy is possible.
5. No residual thermal stresses in the workpiece.
6. Less tooling cost.
7. The equipment is quite safe to handle and requires skilled labour only for setting tool.
8. It has no high speed moving parts. Working is not hazardous.

13) State any three applications of USM process.

Answer: Application of USM: The simplicity of the process makes it economical for a wide range of
applications such as:

1. It can perform machining operations such as drilling, grinding, profiling and milling on all materials,
both conducting and non-conducting.
2. Materials like glass, ceramic, germanium, titanium, tungsten and other hard carbides, gems, stones such
as ruby, etc. can be machined easily.
3. It is used in making tungsten carbide and diamond wire drawing dies and dies for forging and extrusion
processes.
4. It is especially suitable in making holes with curved axes, holes that are not round or of any shape which
a tool can be made.
5. Even threads can be cut out in the drilled holes.
6. It enables the dentist to drill a hole of any shape on teeth without creating any pain.

14) Explain about each of the equipment used in USM process with alegible
sketch.

Answer: Equipment used in USM: The equipments used in Ultrasonic Machining are:

1. Electronic oscillator and amplifier

2. Transducer
3. Tool holder (Horn)
4. Abrasive slurry

The Electronic Oscillator and Amplifier, also known as the ultrasonic generator, converts the available
electrical energy of low frequency to high frequency power of the order of 20 KHz, which is supplied to the
transducer.

The Transducer in USM is used to convert the electric energy into mechanical energy (vibratory motion)
by magnetostrictive principle. The transducer consists of a stack of nickel laminations that are wound with
a coil. When a high frequency current is passed through the coil, changes in the electromagnetic field produce
longitudinal strains in the laminations. These longitudinal strains are transmitted to the tool through a tool
holder. The tool oscillates linearly with the desired amplitude (0.01 to 0.06 mm) at ultrasonic frequencies of 15
to 25 kHz.
The Tool Holder is virtually a tapered shank, so called horn. The upper end of the tool holder is rigidly clamped
or brazed to the lower face of the magnetostrictive material, and its lower end is provided with means for
securing the tool. The tool which is smaller (few hundredths of a millimeter) than the size of the cavity is made
of low carbon steel or stainless steel, to the shape of the desired cavity is and is brazed tothe tool holder.
All these parts, including the tool act as one elastic body transmitting the vibrations to thetip of the tool.

The Abrasive Slurry is a mixture of abrasive grains and water of definite proportion. The abrasive slurry is
circulated by pumping to the work-tool interface and it requires cooling to take away the generated heat, to
prevent it from boiling in the gap. A refrigerated cooling system is used to cool the abrasive slurry to a
temperature of 50 to 60. A good method is to keep the slurry in a bath in the cutting zone.

15) State any two disadvantages of USM process.

Answer: Disadvantages of USM:

1. The metal removal rate is low.

2. The power consumption is high.
3. The depth of cylindrical holes produced is limited to 2.5 times the diameter of the tool.
4. Tool wear is high and sharp corners cannot be produced.

5. Flat surfaces cannot be produced at the bottom of the cavity because of the ineffective slurry
distribution.
6. The process is limited, in its present form to machine on surface of comparatively small size.

16) Explain the principle of “Ultrasonic Machining” with a neat sketch.

Answer: Principle of USM:

In ultrasonic machining a tool is made to vibrate or oscillate at ultrasonic frequency (20 to 30 kHz) in a direction
normal to the surface being machined. The tool, while oscillating would be pressed against the workpiece and
fed continuously. As the tool vibrates with a specific frequency, abrasive slurry, usually a mixture of abrasive
grains (boron carbide or silicon oxide) and water is made to flow under pressure through the tool-workpiece
interface. The impact force arising out of the vibration of the tool end and the flow of slurry through the
work-tool interface, actually causes thousands of microscopic grains to remove the work material by abrasion
or erosion. The tool has the same shape as the cavity to be machined.
17) Describe the process of USM with a legible sketch.

Answer: Description of Process of USM: The workpiece is held in a fixture, which is placed in a tank
filled with abrasive slurry. The electronic oscillator is switched on, so that it converts the available electrical
of low frequency to high frequency, and supplies them to transducer.

● The transducer generates the high frequency vibrations of the order of 20 to 30 KHz with amplitude of
the order of 0.02 mm.
● This vibration is transmitted to the tool through the tool holder. The tool shape is a close complementary
shape of the final surface to be generated.
● The tool, while oscillating would be pressed against the workpiece and fed continuously. Simultaneously
the abrasive slurry is pumped with the help of the pump between the tool and the work piece gap.
● Abrasive particles are driven into the work surface by the oscillating tool; and removes material from the
workpiece.
● Finally, the shape of the tool is impressed into the workpiece.

18) List the equipment used in EDM process.

Answer: Equipment used in EDM: The main elements of the EDM machines are:

1. Spark generator
2. Dielectric fluid
3. The electrode or tool
4. Servo-mechanism.

19) State any two functions of dielectric fluid used in EDM process.
Answer: In EDM process, the functions of dielectric fluid are:

1. It acts as an insulating medium.

2. It cools he spark region and helps in keeping the tool and workpiece cool.
3. It maintains a constant resistance across the gap.
4. It carries away the eroded metal particles.

20) Name any four mediums used as dielectric fluid in EDM process.

Answer: The various mediums which are used as dielectric fluids are:

1. Petroleum based hydrocarbon fluids,

2. Paraffin,
3. White spirit,
4. Transformer oil,
5. Kerosene,
6. Mineral oil or mixture of these. Occasionally,
7. Ethylene glycol and
8. Water miscible compounds are also used as dielectric fluids.

21) Name any four electrodes used in EDM process

Answer: Electrodes used in EDM: Various electrode materials used are

1. Graphite,
2. Copper, brass,
3. Copper graphite,
4. Zinc alloys,
5. Steel,
6. Copper tungsten,
7. Silver tungsten,
8. Tungsten carbide, etc.

22) State any two factors effecting the choice of electrode material inEDM.

Answer: Factors effecting the choice of electrode material: The various factors affecting the choice of
electrode material are:

1. Machining applications,
2. Material being machined,
3. Availability,
4. Cost and
5. The practical limitations inherent in processing the electrodes to the desired shape.

23) State any two advantages of EDM process.

Answer: Advantages of EDM:

1. EDM can be used for machining all electrically conducting meals and alloys irrespective of their melting
points, hardness, toughness or brittleness.
2. Any complex shape required in dies and mould can be easily produced to the required degree of
accuracy and finish, provided that, the shape of the tool is same as that required on the work piece.
3. Time of machining is less than conventional machining processes
4. Since there are no cutting forces acting on the tool, very delicate and fine work can be done using EDM
process.
5. By this process very thin sections can also be machined.
6. Surface finish obtained by this process is very good.
7. It is employed for extremely hardened workpiece. Hence, the distortion of the workpiece arising out of
the heat treatment process can be eliminated.
8. No mechanical stress is present in the process, as there is no physical contact between the tool and the
workpiece.

24) State any two disadvantages of EDM process.

Answer: Disadvantages of EDM:

1. Only electrically conductive materials can be machined by EDM.

2. The wear rate on the electrode is considerably higher. Sometimes, it may be necessary to use more than
one electrode to finish the job.
3. Perfectly square corners cannot be made by EDM.
4. Machining times are too long.
5. Power requirement is more than that of conventional process and hence will be more expensive.
6. Metal removal rate is slow.
7. Machining heats the workpiece considerably and hence cause change in surface and metallurgical
properties.

25) State any two applications of EDM process.

Answer: Applications of EDM:

1. EDM is widely used for machining burr free intricate shapes, narrow slots and blind cavities, etc. for
example, sinking of dies for moulding, wire drawing, forging extrusion and press tools.
2. This method is employed for blanking parts from sheets, cutting off rods of materials, flat or form
grinding, and sharpening of tools, cutters, and broaches.
3. EDM is particularly useful for machining of small holes, orifices or slots in diesel-fuel injection nozzles,
or in aircraft engines, air brake valves and so on.

26) State any six essential requirements of dielectric fluid used in EDMprocess.

Answer: The Essential Requirements of a Dielectric Fluid to be used in EDM Process are:

1. It should not react with the work material, the tool or the container.
2. Its flash point should be high so that there are no fire hazards.
3. It should de-ionize rapidly after the spark discharge has taken place.
4. It should not emit any toxic vapors or have unpleasant odors.
5. It should flush out the particles produced during the spark out of the gap.
6. It should have low viscosity.
7. It should be economical and easily available.
8. It should provide an effective cooling medium.

27) List any six requirements of good electrode (Tool).

Answer: The Requirements of a Good Tool (Electrode) are:

1. It should be a good conductor of heat and electricity

2. It should be available in variety of shapes.
3. It should be easily machinable to any shape at a reasonable cost.
4. It should resist the deformation during the erosion process.
5. It should produce efficient material removal rates from the workpieces.
6. It should have low erosion rate or good work to tool wear ratio
7. It should have high electron emission.
8. It should have high melting point.
 28) List the types of EDM processes and write about each of them in two to three
simple sentences.

Answer: Types of EDM Processes: The process described so far is generally termed as EDM die sinking.
The other processes, which are possible through EDM are

1. EDM Drilling used for drilling small holes, about 0.13 mm in diameter and as deep as 20 diameters,
with virtually no bending or drifting of hole.
2. EDM Milling can be used to machine complex shapes with simple cylindrical electrodes. This is very
similar to conventional milling process, with the cylindrical electrode acting like a milling cutter to
produce complex surface by eroding the surface.
3. Wire EDM is a process of producing complex 2- and 3- dimensional shapes using a simple wire, eroding
the material from an electrically conducting material. The electrode wire wound between the two spools
moves past the workpiece. The spark is struck between the moving electrode wire and the workpiece,
thereby removing the material. It is used for machining the sheet metal dies, extrusion dies and
prototype parts Fig. 3.8 illustrates wire EDM.
4. Electrical Discharge Grinding (EDG): The grinding wheel in Electrical Discharge Grinding (EDG) is
made of graphite or brass and contains no abrasives. Material is removed from the workpiece surface by
repetitive spark discharges between the rotating wheel and the workpiece.

29) Explain the principle of “Electric Discharge Machining” with a neatsketch.

Answer: Principle of “Electric Discharge Machining”:

● The EDM process involves a controlled erosion of electrically conductive materials by the initiation of
rapid and repetitive spark, discharges between the tool and workpiece separated by a small gap of about
o.o1 to 0.50 mm (i.e., spark gap). This spark gap is either flooded or immersed in a dielectric fluid
(electrically non-conducting). The workpiece is fully immersed in a dielectric fluid. It is made anode. The
tool is made the cathode. The electrical circuit consists of a variable resistance and capacitance. The
voltage is applied by a DC supply source. A suitable gap known as spark gap between the tool and the
work is maintained.

● Initially, the gap between the tool and the workpiece, which consists of the dielectric fluid, is not
conductive. Under the pulsed application of D.C, a high potential difference developed between the tool
and the workpiece, enable the spark discharge to pass between the tool and work through the dielectric
fluid, removing a very small amount of metal from the workpiece surface. At any given time, only one
spark will be made between the tool and the workpiece at the shortest path. As a result of this spark,
some volume of metal is removed from the tool and the workpiece. Then the spark will move to the next
closes distance. This process continues till the required material is removed from the workpiece.
 30) Describe the equipment used in EDM process with a legible sketch.

Answer: Equipment used in EDM:

Spark Generator: The power supply circuit used for spark generation in EDM can be classified into two
types: Relaxation circuit and Pulse generator circuit.

Earlier models of EDM machines were fitted with relaxation type of D.C generator . This system operates
on the principle of self oscillation. The spark generator supplies current to a condenser, which produces a
spark. The workpiece alternatively becomes a positive electrode (anode) or negative electrode (cathode)
respectively. On each reversal of polarity the tool is eroded more than the workpiece. Hence, the tool wear
is greater with this type of arrangement.

In modern machines, transistorized pulse generators circuits are available, in which reverse pulses are
eliminated. Fig. 3.7 shows a pulse generator circuit. This generator consists of electronic switching units which
lets the current pass periodically. Modern pulse generators possess the means of accurate controlover
discharge duration, pause time and the current. These factors determine the overcut and hence the accuracy
and surface finish. The tool wear is also greatly reduced.

Overcut is the distance the spark will penetrate the workpiece from the tool and remove metal from the
workpiece. Theoretically, it is slightly larger than the gap between the end of the tool and the workpiece.
The overcut is generally 0.025 to 0.2 mm on all surfaces.

Dielectric Fluid: A dielectric fluid is a medium that does not conduct electrically. The dielectric fluid is
circulated through the tool at a pressure of 0.35 N/mm 2 or less. To make it free from eroded metal particles,
it is circulated through a filter in reuse. The various mediums which are used as dielectric fluids are:
Petroleum based hydrocarbon fluids, paraffin, white spirit, transformer oil, kerosene, mineral oil or
mixture of these. Occasionally, ethylene glycol and water miscible compounds are also used as dielectric
fluids.

The electrode (Tool): In the EDM process, the shape of the electrode (tool) is impressed on the workpiece
in its complimentary shape. The shape and accuracy of the electrode plays a very important role in the final
accuracy of the workpiece machined.

Various electrode materials used are graphite, copper, brass, copper graphite, zinc alloys, steel, copper tungsten,
silver tungsten, tungsten carbide, etc. The various factors affecting the choice of electrode material are:
machining applications, material being machined, availability, cost and the practical limitations inherent in
processing the electrodes to the desired shape.

Servo Mechanism: As already mentioned, the gap between the tool and the work has a critical importance.
As the workpiece is machined, this gap tends to increase. For optimum machining efficiency, this gap should
be maintained constant. This is done by a servo-mechanism, which controls the movement of the electrode.
The servo-mechanism can either be electro-mechanical (Fig. 3.6) or hydraulic.

In the electro-mechanical system, the electrode is moved by a rack and pinion arrangement, which is driven
through reduction gearing from D.C servo motor. As the gap between the tool and the workpiece increases
because of their wear, the voltage across the gap drops. This voltage drop is automatically measured and a
feedback is given to the servo control which sends as signal to the servo-motor, which operates the electrode
downward until the gap reaches its critical value again.
 31) Describe the process of Electrical Discharge Machining (EDM) witha legible
sketch.

Answer: EDM Process Description: Fig. 3.6 illustrates the schematic layout of the electric discharge
machining system.

● The work piece and the tool are submerged in a dielectric fluid.
● The tool and work and also the tool slide servo – mechanism are connected into the D.C supply circuit.
The function of the servo-mechanism is to maintain a very small gap, i.e., spark gap (0.025 to 0.075 mm)
between the tool and the work.
● The spark is transient electric discharge across the gap between work and tool.
● The D.C power supply is fed to the spark generating circuit.
● When the potential difference (voltage) across the gap becomes sufficiently large, the dielectric fluid
becomes ionized and breaks down to produce an electrically conductive spark channel and, the tool and
work discharge current across the channel in the form of a spark.
● Each spark or electric discharge causes a focused stream of electrons to move with a high velocity, form
the cathode towards the anode, and ultimately creates compression shock waves on both the electrode
surfaces, particularly at high spots on the work piece surface, which are closest to the tool.
● When the voltage drops to about 12 volts, the spark discharge will extinguish and the di-electric fluid will
once again become de-ionized. The tool and work starts to recharge and the process repeats itself.
● The spark occurs in an interval of 10 to 30 microseconds. Thus thousands of spark discharge occur per
second across the gap between tool and work, which result in a local temperature of approximately
10,0000C.

At each discharge, heat transfer from high temperature spark to both tool and work, melts, partially vaporizes
and partially ionizes the metal in a thin surface layer. The metal is thus removed in this way from the
workpiece.

● The time interval between the sparks is so short that heat is unable to conduct into the tool and work.

32) Explain the principle of open loop NC system with a line diagram.

Answer: Open-loop NC System

In NC system, every control system may be designed as an open or a closed-loop control. The term loop
control means that there is no feedback in the total system and the action of the controller has no
information about the effect of the total system and the command signals that it produces. The controller
produces commands for actions of the motions of the NC machine tool.

The open-loop NC systems are of digital type and use stepping motors for driving the slides. A stepping
motor is a device whose output shaft rotates through by a fixed angle in response to an input pulse. The stepping
motors are the simplest way for converting electrical pulses into proportional movement. Eachpulse drives
the stepping motor by a fraction of one revolution called the step angle. Since there is no feedback from the
slide position, the system accuracy is solely dependent on the ability of the motor and accuracy of the
mechanical parts.

OR

Open loop NC system:

In the open loop system, there is no ‘feedback’ and no return signal to indicate whether the tool has reached
the correct position at the end of the operation, or not. Hence, there are no means of knowing whether
there is an error or not between the input command signal and the result achieved. An example of open loop
system is a co-ordinate drilling machine.

Then an Open-loop system, also referred to as non-feedback system, is a type of continuous control
system in which the output has no influence or effect on the control action of the input signal. In other
words, in an open-loop control system the output is neither measured nor “fed back” for comparison with the
input.

Here there is no provision to compare the actual position of the cutting tool with the input command value.
There is no monitoring of the actual displacement of the machine slide.

The control may indicate a movement of 50 mm where as the slide may have moved only 49.8mm. Open-
loop systems are less accurate compared to a closed loop system. Open-loop systems are less expensive
than closed-loop systems. Their maintenance is not complicated.

33) Explain the principle of closed loop NC system with legible diagram.

Answer: Closed loop NC system:

The closed-loop control measures the actual position and velocity of the axis and compares them with the
help of a comparator. The comparator is a device that compares the output signal with the signal received
from the feedback device. The difference between the actual and the desired values is the error. The control
system is designed in such a way as to eliminate or reduce to a minimum, the error, namely the system is of a
negative feedback type.

In NC system both the input to the control loop and the feedback signals may be a sequence of pulses. Each pulse
representing one BLU, i.e., 0.01 mm. The digital comparator correlates the two sequences and gives, by
means of a digital-to-analog converter (DAC), a signal representing the position error of the system and the
output of DC drives the DC motor. A closed loop system uses position sensors attached to the machinetable
to measure its position relative to the input value for the axis.
OR

Closed loop NC system:

In closed loop system, a ‘feedback’ is built into the system, which automatically monitors the position of the tool.
From the feedback signal to the control unit, it is known whether the tool has moved correctly to itsnew
position or not. If not, its position is automatically controlled until it is in the right position. Such a device
is known as a position feedback transducer. Common position feedback devices used on modern NC machines
are: shaft encoder, linear scales or Inductosyns. In the contour or continuous path system, velocity control
is also essential to ensure that the cutter path is as required by the profile. In this system, a velocity feedback is
provided by a transducer known as tacho-generator attached to the feed drive system. A closed loop system
is more expensive than an open loop system.

Here the actual output from the system is compared with the input signal. They are characterized by the
presence of feedback devices in the system. In this system the displacement can be achieved to a very high
degree of accuracy. The feedback from the monitoring device is compared with the input signal and the
slide position is regulated by the servo system until it agrees with the desired position.

Topic: 6.7 List the elements of NC machine.

34) Define the term ‘Numerical Control’.

Answer: Numerical Control:

● It can be defined simply as control by numbers.

● It can also be defined as a form of programmable automation in which the process is controlled by
numbers, letters and symbols. In NC, the numbers form a program of instructions designed for a
particular work part or job.
● Electronic Industries Association defines NUMERICAL CONTROL as “a system in which actions are
controlled by the direct insertion of numerical date at same point. The system must automatically
interpret at least some portion of these data.”

35) What is machine centre?

Answer: Machine Centre:

It is a NC machine which can accomplish a number of tasks such as milling, drilling, boring, reaming,
lapping etc.

36) List any four main elements of a NC machine tool.

Answer: Main elements of NC machine:

1. Program of instructions.
2. The control unit, also known as N.C. console or Director.
3. The drive units.
4. The Position feedback package.
5. Magnetic box.
6. Manual control.
 37) List any two elements of controller unit of a NC system.

Answer: Elements of controller Unit:

1. Tape reader,
2. A data buffer,

3. Signal output to the machine tool,

4. Feedback channel from the machine tool and
5. Data decoding control area.

38) State the functions of “Tape reader” and “Data decoding control area” of
NC system controller unit.

Answer: Tape Reader:

The tape reader is an electromechanical device used for winding and reading the punched tape containing
the program of instructions into the data buffer. It stores the input instructions in logical blocks of information.
A block of information represents one complete step in the sequence of processing elements. The output
signals are connected to the servomotors and other controls in the machine tool.

Data decoding control area: Data decoding control area coordinates the sequence of operations to be
carried out by the machine tool.

39) State any one function of ‘Feedback system’ and ‘Magnetic box’ of a NC
machine tool.

Answer: Feedback System: It is provided to check whether the required lengths of travel have been
obtained. This transducer sends the information of the actual position achieved to the control unit. If there
is any difference between the input command signal and actual position achieved, the drive unit is actuated
by suitable amplifier from the error signal.

The feedback system has the transducers that act as sensors. It is also called a measuring system. It consists
of position and speed transducers that continuously monitor the position and speed of the cuttingtool located
at any given moment.

Magnetic box: The command signals sent to the magnetic box control the other functions such as: spindle
motor starting and stopping, selecting spindle speeds, actuation of tool change, coolant supply etc.

40) State the functions of “Controller unit” of NC/CNC machines.

Answer: The controller unit (Machine Control Unit), also known as N.C. console or Director: In this
unit, the instructions for manufacturing the component are written in a coded, are read by tape reader. The
instructions undergo electronic processing and the control unit sends command signals to the drive units of
machine tool and to the electrical control cabinet called magnetic box.

OR

Machine control unit called the heart of the CNC machine. It performs all the control functions of the CNC
machine, there are various tasks performed by MCU are

● It reads the coded instructions given in it.

● Machine control unit decodes the coded instruction.
● This axis implements interpolation (linear, circular and helical) to generate motion commands.
● Machine control unit feeds the axis motion command to the amplifier circuit to drive the axis mechanism.
● It takes a feedback signal of position and speed for each drive axis.
● It implements the auxiliary control functions such as coolant or spindle on/off and tool change.

41) Write the information to be punched on a paper tape.

Answer: The information punched on the paper tape includes:

1. The co-ordinate values of the entire tool length.

2. The co-ordinate values are prefixed with certain codes indicating the type of movement of the tool
(point-to-point, straight line, contour) from one co-ordinate to the next.
3. The co-ordinate values are also suffixed with certain codes indicating the various machine functions,
such as start/stop. Spindle coolant etc. the co-ordinate values are also supplemented with other
functions such as feed rates, spindle speeds, etc.

42) List any two input medium used in NC Machines.

Answer: The input medium used can be

1. Punched cards
2. Magnetic disk
3. Tape /punched tape.

43) List the methods of input to the NC system.

Answer: Two methods are used to input the data to the NC system. These are

1. By manual entry of instructional data to the controller unit. This method is also called manual input data
(MDI) and is appropriate only for relatively simple jobs where the order will not be repeated.
2. By means of direct link with a computer. This method is called direct numerical control (DNC).

44) State the functions of any three elements of a NC machine tool.

Answer: Functions of elements of NC machine:

1. Program of instructions: it is detailed step-by-step set of directions which instructs the machine tool
what to do.
2. The controller unit (Machine Control Unit), also known as N.C. console or Director: In this unit, the
instructions for manufacturing the component are written in a coded, are read by tape reader. The
instructions undergo electronic processing and the control unit sends command signals to the drive units
of machine tool and to the electrical control cabinet called magnetic box.
3. The drive units: The command signals sent to the drive units of the machine tool control the lengths of
travel and the feed rates.
4. The Position feedback package: it is provided to check whether the required lengths of travel have
been obtained. This transducer sends the information of the actual position achieved to the control unit.
If there is any difference between the input command signal and actual position achieved, the drive unit
is actuated by suitable amplifier from the error signal.
5. Magnetic box: The command signals sent to the magnetic box control the other functions such as:
spindle motor starting and stopping, selecting spindle speeds, actuation of tool change, coolant supply
etc.
6. Manual control: Also called operator control, helps the operator to perform some functions manually
such as: motor start-stop, coolant supply control, axes movements, speed change, feed change etc.
7. Machine tool: NC machine centre is automated production equipment which can perform various
operations and has special features like automatic tool changer (ATC) and automatic pallet changer
(APC) which contribute to enhanced productivity.

45) Write about “Controller Unit” of NC system with a block diagram.

Answer: Controller Unit:

The controller unit consists of the electronics and hardware that read and interpret the program of instructions
and convert it into mechanical actions of the machine tool. The controller unit elements are tape reader,
a data buffer, signal output to the machine tool, feedback, channel from the machine tool anddata decoding
control area.

The tape reader is an electromechanical device used for winding and reading the punched tape containing
the program of instructions into the data buffer. It stores the input instructions in logical blocks of information.
A block of information represents one complete step in the sequence of processing elements. The output
signals are connected to the servomotors and other controls in the machine tool. Feedback data is fed back
to the controller from the machine tool to assure that the table and workpart has been properly located w.r.t
tool. Data decoding control area coordinates the sequence of operations to be carried out by the machine
tool.

The control panel contains the dials and switches to turn machine on and off, change tools, load and unload
the machine etc., and data displays, by which the operator runs the NC system.

46) Classify the NC machines.

Answer: Classification of N.C. Machines:

1. Based on control system features, NC machines are classified as

1. Point-to-Point system
2. Straight line system
3. Contour system

2. Depending on the feedback, NC machine systems are of two types

1. Open loop system

2. Closed loop system

47) Explain the working of Numerical Control machine tool.

Answer: Working of NC Machine Tool:

The first two steps, component drawing and process planning are similar in both operator controlled and
NC machine tools. In the operator controlled machine tools, the operator controls the cutter position during
machining. He also makes the necessary adjustments and corrections to produce the desired component.
However, in numerically controlled system, the place of the operator is taken by the data processing part of
the system and the control unit. In the data processing unit, the co-ordinate information regarding the
component is recorded on a tape by means of a teleprinter. Tape is fed to the control unit which sends the
position command signals to slide-way transmission elements of the machine tool. At the same time, the
command signal is constantly compared with the actual position achieved, with the help of position feedback
signal derived from automatic monitoring of the machine tool slide position. The difference in the two signals,
if any, is corrected until the desired component is produced.
48) State the functions of each elements of a NC machine tool.

Answer: Functions of elements of NC machine:

1. Program of instructions: it is detailed step-by-step set of directions which instructs the machine tool
what to do.
2. The controller unit (Machine Control Unit), also known as N.C. console or Director: In this unit, the
instructions for manufacturing the component are written in a coded, are read by tape reader. The
instructions undergo electronic processing and the control unit sends command signals to the drive units
of machine tool and to the electrical control cabinet called magnetic box.
3. The drive units: The command signals sent to the drive units of the machine tool control the lengths of
travel and the feed rates.
4. The Position feedback package: it is provided to check whether the required lengths of travel have
been obtained. This transducer sends the information of the actual position achieved to the control unit.
If there is any difference between the input command signal and actual position achieved, the drive unit
is actuated by suitable amplifier from the error signal.
5. Magnetic box: The command signals sent to the magnetic box control the other functions such as:
spindle motor starting and stopping, selecting spindle speeds, actuation of tool change, coolant supply
etc.
6. Manual control: Also called operator control, helps the operator to perform some functions manually
such as: motor start-stop, coolant supply control, axes movements, speed change, feed change etc.
7. Machine tool: NC machine centre is automated production equipment which can perform various
operations and has special features like automatic tool changer (ATC) and automatic pallet changer
(APC) which contribute to enhanced productivity.

49) Explain the Numerical Control procedure.

Answer: Numerical Control procedure:

1. Process planning

● This step is referred to as process planning and it concerned with preparation of route sheet.
● Route sheet is a listing of sequence of operations along with required machining data like speeds, feeds,
depth of cut tools used etc.
● It is called a route sheet because it also lists the machines through which the part must be routed in order
to accomplish the sequence of operation.

2. Part programming

● Part programming has knowledge about the machining process and they have been trained to programme
for numerically controlled machine tools.
● They are responsible for planning the sequence of operation performed by NC.
● There are two ways to develop programme for numerical control machine.
1. Manual part programming.

2. Computer assisted part programming.

● In manual part programming the machining instruction are prepared on a form called a part programme
menu script.
● It is a listing of relative cutter/workpiece position which must be followed to machine the workpiece.
● In computer assisted part programming much of the tedious computational work required is manual part
programming is transferred to the computer.
● This is especially suitable for complex workpiece geometrics and jobs with many machining steps.
● Use of computer will save the part programming time.

3. Tape preparation

● A punched tape is prepared from the part programmer’s process plan.

● In manual part programming the punched tape is prepared directly from the part programme menu
script.
● In computer assisted part programming, the computer interprets the list of part programming
instructions performs the necessary calculation to convert this into a detailed set of machine tool, motion
commands and then controls a tape punching device to prepare the tape for specific NC machine.

4. Tape verification

● After the punched tape has been prepared some method is usually provided for checking the accuracy of
the tape.
● Sometimes the tape is checked by running it through a computer programme which plots the various tool
movements on paper.
● In this way major errors in tape can be checked.
● Acid test of tape involves trying out on the machine tool to make a part.
● Foam or plastic material is sometimes used for this tryout.
● Programming errors are not uncommon and it may require two or three attempts before the tape is
supposed to be correct and ready to use.

5. Production

● Final step in the NC procedure is to use the part programme in production.

● This involves ordering the raw material, specifying and preparing the tooling.
● The operator function during production is to load the raw material and establish the starting position of
the cutting tool relative to workpiece.
● When machining of part is completed the operator removes it from machine and loads the next part.

50) Classify the NC Machines based on control system features.

Answer: Classification of N.C. Machines: Based on control system features, NC machines are classified
as

1. Point-to-Point system
2. Straight line system
3. Contour system.

51) Classify the NC Machines based on the feedback.

Answer: Classification of N.C. Machines: Depending on the feedback, NC machine systems are of two
types

1. Open loop system

2. Closed loop system

52) Explain the point to point positioning system of NC machine withline

diagram.

Answer: Point-to-Point system of NC machine:

Point-to-point machines move only in straight lines. They are limited to drilling, reaming, boring, etc. and
straight milling cuts parallel to a machine axis. When making an axis move, all affected drive motors run at
the same speed. When one axis motor has moved the instructed amount, it stops while the other motor continues
until its axis has reached its programmed location. The point-to-point positioning NC system is illustrated in
Figure.

Figure: Point-to-point (positioning) NC system

The simplest example of a point-to-point (PTP) NC machine tool is a drilling machine. In a drilling machine,
the work piece is moved along the axes of motion until the center of the hole to be drilled is exactly beneath
the drill. Then the drill is automatically moved towards the work piece, the hole is drilled and the drill
moves out in a rapid traverse feed. The work piece moves to a new point and the above sequence of actions
are repeated.

OR

Point-to Point system of NC Machine:

In this system the machining is done at specific positions. The work piece remains unaffected as the tool
moves from one position to the next position. This is the simplest. In figure after drilling the hole at position
A, the tool moves to position B, along the dotted line. A drilling machine is the best example of point-to
point systems.

Point-to-point is also called as positioning system. The speed or the path by which the movement is
accomplished is not important. Once the tool reaches the desired location, the machining operation is performed
in that location. In between two locations, no cutting takes place. These are the least expensive control systems.
Examples: NC Drill presses.

53) Explain the straight line system of NC machine with a line diagram.

Answer: Straight-cut NC Machine

Straight-cut control systems are capable of moving the cutting tool parallel to one of the major axes at a
controlled rate suitable for machining. It is, therefore, appropriate for performing milling operation to fabricate
work pieces of rectangular configurations. With this type of NC system it is not possible to combine
movements in more than a single axis direction. Therefore, angular cuts on the work piece wouldnot be
possible. An example of straight-cut operation is shown in Figure. An NC machine capable of straight-cut
movements is also capable of PTP movement.

Straight-cut (line) system of NC Machine:

This system is an extension of Point-to Point system. Here the tool moves at a controlled feed rate in one
axis direction at a time. The examples of straight line system are; stepped turning on lathe, pocket milling
etc.

OR

Straight cut control systems are capable of moving the cutting tool along one major axis. However it will
not be able to control the movement of tool in more than one major axis. This system enables milling along major
axis one at a time. It can perform PTP positioning also. Example: NC Milling Machine.

54) Explain the contour system of NC machine with a line diagram.

Answer: Continuous Path or Contour Path NC system

A continuous path machine has the ability to move its drive motors at varying rates of speed while positioning
the machine which facilitates cutting of arc segments and angles. The most common type of continuous path
operations are milling and lathe operations. In continuous path machine, the tool is cutting while the axes of
motion are moving, as for example, in a milling machine. All axes of motion might move simultaneously, each at
a different velocity. When a non-linear path is required, the axial velocity changes, even within the segment.
For example, cutting a circular contour requires a sine rate change in one axis, while the velocity of the
other axis is changed at a cosine rate. In contouring machines, the position of the cutting tool at the end of each
segment together with the ratio between the axial velocities determines the desired contour of the part and
at the same time the resultant feed also affects the surface finish. Figureshows continuous path NC system
for 2D operations.

Figure: Contouring (continuous path) NC system for two-dimensional operations

OR

Contour system of NC Machine:

In contour or continuous path system, there are continuous, simultaneous and co-ordinated motions of the
tool and the workpiece along different co-ordinate axes. The various profiles, contours and curved surfaces
are machined by this system.

This is the most complex and most flexible motion systems of all. Expensive compared to other two systems.
It is capable of doing PTP, straight and contour cuts. In essence the NC control will have the tool to move in more
than one major axis simultaneously. The path of the cutter is continuously controlled to generate the desired
geometry of the work piece.

These are also called continuous path NC systems. This system can machine any circular, conical or any
shape that can be mathematically definable. Example: NC Contouring Milling Machine, Turning Machines.

55) List the operations carried out on NC machines.

Answer: Operation on NC machines: On NC machines, normal operations that can carry on

conventional machines can also performed on NC machines like

1. Drilling machine operations like boring, counter boring, counter sinking, reaming, tapping etc.
 2. Turning operations on lathe like step turning, taper turning, knurling, thread cutting, facing, drilling,
boring etc.
3. Milling machine like surface milling, gang milling, straddle milling, contour milling, gear cutting etc.
4. Grinding operations etc
5. Gear Cutting etc
6. Welding operations like arc welding, resistance welding, spot welding, seam welding, TIG,MIG welding
etc
7. Electro-discharge machining operations.
8. Electron beam machining operations.
9. Laser cutting operations etc
10. Surface finishing operations like Lapping, Honing, etc.

56) State the difference between absolute system and incremental system.

Answer: In the absolute system, the co-ordinates of points are mentioned with respect to one reference
point, that is, datum. In the incremental system, the co-ordinates are written in the programme with respect
to the previous point.
57) Write short notes on “Absolute programming” for NC machines.

Answer: Absolute programming:

Absolute positioning is another type of programming system. In this, the tool locations are always defined
in relation to point zero. The position commands are given as absolute distances from the reference point.
The reference point can be defined outside the work piece or at a corner of the workpiece. The reference
point or point zero could be fixed or floating. When the point zero is fixed, the origin is always located at
the same position on the machine table. All locations must be defined by positive x and y coordinates relative
to that fixed origin. When the point zero is floating, the operation can set the point zero at any position
on the machine table. This point zero is decided based on part programming convenience.

Data in absolute dimension system always refer to a fixed reference point. This point has the function of a
coordinate zero point. The absolute dimensions are also known as ‘reference dimensions’. When describing
contours and positions, absolute dimensioning is used because the first incorrect dimensioning of an individual
point has no effect on the remaining dimensions. The absolute system is easier to check for errors. From
figure shown below:

Absolute system

X – Co-ordinate Y – Co-ordinate

Point A 5 5

Point B 10 15
Advantages of absolute programming:

1. In cases of interruptions that force the operator to stop the machine, the cutting tool automatically
returns to previous position. Since it always moves to the absolute coordinate called for and the
machining proceeds from the same block where it was interrupted.
2. Possibility of easily changing the dimensional data in the part program whenever required.
3. When describing contours and positions, it is always preferable to employ absolute dimensioning,
because the first incorrect dimensioning of an individual point has no effect on the remaining dimensions
and the absolute system is easier to check for errors.

58) Write short notes on “Absolute programming” for NC machines.

Answer: Incremental programming:

Incremental positioning is a programming system used to define the position of the tool in NC machine. In
an incremental system, the next tool location must be defined with reference to the previous tool location.
The dimensional data applied to the system will be a distance increment measured from the preceding point
at which the axis of motion was present.

Incremental dimensions are distance between adjacent points. These distances are converted into incremental
coordinates by accepting the last dimension point as the coordinate origin for the new point. Incremental
dimensions are also known as ‘Relative dimensions’ or ‘chain dimensions’. Mirror image programming is
facilitated with incremental systems. From figure shown below:

Incremental system:

X – Co-ordinate Y – Co-ordinate

Point A 5 5

Point B 5 10

Advantages of Incremental programming:

● If manual programming is used with incremental systems the inspection of the part program, before
punching the tape is easy. Since the end point, when machining a part is identical to the starting point,
the sum of the position, commands (for each axis separately) must be zero. A non-zero sum indicates that
an error exists.
● The performance of the incremental system can be checked by a closed-loop tape. The last position
command on the tape the table to return to the initial position.
● Mirror-image programming is facilitated with the incremental systems.
● Incremental dimension programming is advantageous for certain individual partial controls in a work
piece are repeated several times, and the associated program sections can be employed several times
without a coordinate shift.

59) State any three advantages for each of "Absolute programming" and
"Incremental Programming" of NC machines.
Answer: Advantages of absolute programming:

1. In cases of interruptions that force the operator to stop the machine, the cutting tool automatically
returns to previous position. Since it always moves to the absolute coordinate called for and the
machining proceeds from the same block where it was interrupted.
2. Possibility of easily changing the dimensional data in the part program whenever required.
3. When describing contours and positions, it is always preferable to employ absolute dimensioning,
because the first incorrect dimensioning of an individual point has no effect on the remaining dimensions
and the absolute system is easier to check for errors.

Advantages of Incremental programming:

● If manual programming is used with incremental systems the inspection of the part program, before
punching the tape is easy. Since the end point, when machining a part is identical to the starting point,
the sum of the position, commands (for each axis separately) must be zero. A non-zero sum indicates that
an error exists.
● The performance of the incremental system can be checked by a closed-loop tape. The last position
command on the tape the table to return to the initial position.
● Mirror-image programming is facilitated with the incremental systems.
● Incremental dimension programming is advantageous for certain individual partial controls in a work
piece are repeated several times, and the associated program sections can be employed several times
without a coordinate shift.

60) List any two disadvantages of CNC machines.

Answer:

Disadvantages of CNC machines:

1. Cost: CNC machines are more expensive and require greater initial investment.
2. Require skilled part programmer and operators.
3. Computer, programming knowledge required.
4. Maintenance is difficult.
5. Not suitable for small production.
6. Products sometimes need to have flashing removed.
7. Skills loss: As the demand for manual machine operators decreases. This could eventually lead to the
complete loss of long preserved skills.
8. Unemployment: Automation decreases the need for man power, fewer laborers are hired.

61) Under what conditions NC system is used?

Answer: A Numerical Control system is used when

● The number of components per component is large.

● Size of batches is medium.
● Batches are often replaced.
● Labor cost for the component is high.
● The component requires special tooling.
● Design changes are frequent.
● Ratio of cutting time to non-cutting time is high.
● A large variety of components are produced.
● The component requires highly skilled labor/operator.

62) State any six advantages of NC machines.

Answer: Advantages of NC Machines:

1. The lead time is reduced substantially.

2. The non productive time is reduced by utilizing automatic tool changers, pallet changers.
3. Higher machine utilization.
4. NC requires fixtures which are simpler and less costly to fabricate because the positioning is done by
the NC tape rather than jigs and fixtures.
5. Human error is greatly reduced.
6. Scrape rate rework is reduced.
7. Machining function of the NC tool can be easily changed by changing the coded tape.
8. Prototype/ small batches of components are easily produced with high accuracy.
9. Design changes can be easily incorporated.
10. Inspection costs are reduced due to improved quality.
11. A single machining centre with a NC can perform various operations done by different conventional
machines.
12. Space to house large number of machines is reduced.
13. Accuracy is dependent upon the program but not on operator thereby large batch, complex parts can
be easily produced.
14. Contouring or continuous path machining in 2D or 3D is possible.
15. Increased versatility and reliability results by utilization of NC program and NC machine.

(OR)

Advantages of NC machines

1. Increased Productivity.
2. Reduce tool Fixture storage cost.
3. Faster setup time.
4. Reduce part inventory.
5. Flexibility the speeds changes in design.
6. Better accuracy of parts.
7. Reduction in part handling.
8. Better uniformity of parts.
9. Better quality control.
10. Improvement in manufacturing control.

63) State any six disadvantages of NC machines.

Answer: Disadvantages of NC Machines:

1. NC machines require high initial cost.

2. Maintenance costs for NC machines are higher.

3. Part programmers and NC maintenance personnel have to be skilled and experienced persons.
4. In preparing the punched tape, part programming mistakes are common.
5. In conventional NC, the control system does not provide the opportunity to make changes in speeds and
feeds during the cutting process.
6. The punched tape and tape readers are the least reliable components of the NC machine.
7. Costly controller systems are utilized in NC machines.
8. The NC machines/system does not provide the management information i.e., piece counts, machine
break downs, tool changes etc.

64) State any six applications of NC machines.

Answer: Applications of NC Machines: NC machines are used for various applications. Some of the
applications, where NC machines are utilized are:
 1. Metal removal processes like milling, drilling, boring, turning, grinding, etc.
2. Press working machine tool.
3. Welding machines.
4. Inspection machines.
5. Assembly machines.
6. Tube bending.
7. Flame cutting.
8. Laser beam processes.
9. For parts, which are complex and it will not be possible to manufacture them very accurately on
conventional machines, due to human error involved.
10. For parts which are frequently subjected to design changes.
11. Repetitive and precision quality parts which are to be produced in low to medium batch quantity.
12. In situations where the investment on tooling and fixture inventory will be high if the parts are made on
conventional machine tools.
13. To cut down ‘lead time’ in manufacture.

65) What is CNC?

Answer: CNC:

CNC or “Computer numerical controlled” machines are sophisticated metal working tools that can create
complicated parts required by modern technology. CNC term refers to a large group of these machines that
utilize computer logic to control movements and perform the metal working.

OR

CNC is one in which the functions and motions of a machine tool or controlled by means of a prepared program
containing coded alpha-numeric data. CNC can contol the motions of the workpiece or tool, the input
parameters such as feed, depth of cut, speed, and the functions such as turning, spinning on /off,turning coolant
on/off.

66) What is CNC machining?

Answer: CNC Machining:

It is manufacturing process in which pre-programmed computer software dictates the movement of factory
tools and machinery.

67) List the elements of a CNC machine.

Answer: A CNC system consists of three basic components/elements:

1. Art program
2. Machine Control Unit (MCU)
3. Machine tool (Lathe, drill press, milling machine, etc.)

68) List the methods of listing the co-ordinates of points in NC system.

Answer: There are two methods of mentioning the co-ordinates of point while programming for an NC
system:

1. Absolute system.
2. Incremental system.
69) State any six advantages of CNC machines.

Answer: Advantages of CNC machines:

1. Reduced Lead Time:- Time between the receipt of a drawing by an engineer & manufacturer getting
ready to start a production on soft floor is called lead time.
2. Elimination of operator error:- The programme is checked before it goes to the machine so no error will
occur in the job.
3. Operator Activity:- Operator doesn’t require special skill for machining & single operator can operator
more than one machine.
4. Lower Labor Cost:- One operator can run two or more machines resulting in reduced labor cost.
5. Smaller batches:- Periodic machining of small batches is found to be economical & bring about rapid
stock turnover. Large storage facilities for work piece is not require.
6. Longer tool life:- Tools can be used at optimum speeds and feeds because of these functions are
controlled by the part programming.
7. Elimination of jig & fixtures:- Standard locating fixtures are not used on CNC machine and cost of
special jig & fixtures is frequently eliminated.
8. Flexibility in Change of Component Design:- The modification or changes in component design can be
readily accommodated by reprogramming and altering the concerned instruction.
9. Reduced Inspection:- Normally it is necessary to inspect the first component only.
10. Less Scrap:- Since operators error are eliminated, since the tools are operating under controlled
optimum condition the incidence of breakage should be very small.
11. Accurate Costing & Scheduling:- In CNC time taken in machining is predictable and result in greater
accuracy in estimating and more consistency in costing.

OR

1. The part program tape and tape reader are used only once to enter the program in to memory. This
results in improved reliability.
2. Tape editing at machine site: the NC tape can be optimized during tape tryout at the site of the
machine tool.
3. Greater flexibility: New options can be added to the system easily and at relatively low cost.
4. Metric conversion: CNC can accommodate conversion of tapes prepared in units of inches into
international system of units.
5. Total manufacturing system.
6. User written programs: these programs generally take the form of MACRO subroutines stored in CNC
memory which can be called by the part program to execute frequently used cutting sequences.
7. Complex contours/surfaces need to be machined.
8. Volume of production is very high.
9. Safer, higher productivity.
10. Less paper work, reduction in lead times.
11. Constant use with minimal maintenance.
12. Precision: The precision of a machine refers to how fine a tolerance it can produce.
13. High accuracy and better quality.
14. Versatility.
15. Simulated models or prototypes.
16. Reduce human error.
17. Reliable operation, reduced scrap rate, automatic material handling, just in time manufacture, lesser
floor space.

70) List any six applications CNC machines.

Answer: Applications of CNC Machines:

1. In the metal removal industry

2. In the metal fabrication industry
 3. In the electrical discharge machining industry
4. In the wood working industry
5. Laser welding in automobile industry
6. Laser machining and cutting
7. In aerospace industry
8. In instrumentation industry
9. Sheet metal press working machine
10. Tube bending machine
11. Cutting, Turning, Grinding, Punching , Milling, Boring, Spinning, Drilling, Welding, Bending, Pinning,
Sewing, Gluiing, Routing etc.
12. Co-ordinate measuring machine, electronic assembly, tape laying and filament winding machines for
composites etc.

71) Explain the working principle of Computerized Numerical Control (CNC)

machine with a legible sketch.

Answer: Computerized Numerical Control Machine (CNC):

In CNC system, a dedicated computer is used to perform all the essential functions as per the executive program
stored in the computer memory. The system directs commands to servo drives to drive the servomotor and
other output devices like relays, solenoids etc., to initiate the operations such as motor starting and stopping,
coolant on and off, tool changing, pallet changing etc., and other miscellaneous functions.

Once the system gives, it becomes necessary to ensure that the particular function has been completed.This
is done by “Feedback devices”. Continuous feedback device like linear scale, encoder, resolver etc, are used as
position feedback of the motor. Some sensors like proximity switch, limit switch, pressure switch, flow
switch and float switch etc are used as feedback devices. So that CNC system is called as “Closed Loop”
system. In case of failure in any failure feedback, the system generates a “Fault message”.

In the principles of CNC operation: Movement of x, y, z axes are controlled by a motor which supplies either
Alternating current or Direct current. Movement of the machine is done by giving commands. All the operations
are carried out by codes like speed, feed, depth of cut etc. For each operation separate code is available. The
warning system is available to save guard the various operations and components.

OR

The numerical control device in the computer through input device in numbers and character encoding way
after a series of processing, the recorded information via the servo system and the programmable controller
to the machine tool spindle and feed actuators issue instructions, machine body, in accordance with these
instructions, in conjunction with the test feedback device, such as the cutting tool relative to the workpiece
trajectory, feed speed and displacement to realize automatic control, so as to complete the workpiece
machining.

OR

CNC machines are faster in operation. In CNC machines the control unit is a micro computer. The complete
program to produce a component is input and stored within the memory of the computer. The information
for each operation is fed from the control unit to the motor etc., It is also possible for (i) Cycles of movements
(canned or fixed cycles), (ii) Repetitive movements (looping) to be activated with a single instruction. The
reduction in the amount of input information is one of the big advantages of CNC.

For example:

● Only one line of input information is required for the drilling of 30 holes equally spaced on a pitch
circle of 400mm.
● On an NC machine, for the same operation, 30 lines of instruction is necessary.

The computer can store a number of programs. The particular program is selected by setter/operator with
CNC machines it is possible to edit any part of the program at the control unit. For future use, a new punched
tape can be produced at the machine. The amended program can be saved on a magnetic disc,tape cassette
or other storage medium. CNC machine has a moving column configuration, automatic tool changing facilities,
tools stored in a chain-type magazine, two work tables (Work can be loaded on one table while a component
is being machined on the other table). swarf removal units, punched tape reader, a keyboard for inputting a
program directly into the control unit. It is possible to interface the control unit to a desktop computer. CNC
machines requires minimum of operator intervention. Unskilled personnel can be used to operate the machine.
CNC machines have the facilities for the manual override of feed rates. The override is useful to move the tool
on maximum feed for a ‘dry run’. The setter can input a new part program while machining is being carried
out on a different component. The movements that would result after each block can be checked by a graphic
simulation.

72) State any two important differences between DNC and CNC.

Answer: Differences between DNC and CNC:

1. DNC computers distribute instructional data and collect data from, a large number of machines. CNC
computers control only one machine or a small number of machines.
2. DNC computers occupy a location that is typically remote from the machines under their control. CNC
computers are located very near tot their machine tools.
3. DNC software is developed not only to control individual pieces of production equipment, but also to
serve as part of a management. Information system in the manufacturing sector of the firm. CNC
software is developed to augment the capabilities of a particular machine tool.

73) State any three differences between NC, CNC and DNC systems.

Answer: Differences between NC, CNC and DNC systems:

S.
CNC
No.
74) State the differences between NC and CNC machines.

Answer: Differences between NC and CNC machines:

S.
NC Machines CNC Machines
No.

75) Define “DNC”.

Answer: DNC:

Direct Numerical Control (DNC) can be defined as a manufacturing system in which a number of machines
are controlled by a computer through direct connection and in real time.

Direct numerical control, also known as distributed numerical control (DNC) is a common manufacturing
term for networking CNC machine tools; if the computer is connected to a number of machines it can distribute
programs to different machines as required.

It is a data communications system connecting a group of numerically controlled machines to a common

computer that has provision for on-demand distribution (downloading NC programs to the machines).

76) Write the principle of DNC in two simple sentences.

Answer: Principle of DNC machine:

One large computer is used to control more than 100 separate machines. The DNC computer is designed to
provide instructions to each machine tool on demand. When the machine need control commands, they are
communicated to it immediately. DNC involves data collection and processing from the machine tool back
to the computer.
 77) List the components of DNC machine.

Answer: Components of DNC:

1. Central computer
2. Bulk memory which stores the NC part programs,
3. Telecommunication lines
4. Machine tools.

78) State any six advantages of DNC machines.

Answer: Advantages of DNC:

1. Time sharing: The control of the more than on machine of the computer at one time.
2. Greater computational capability for functions such as circular interpolation etc.
3. Remote computer location- The computer is located in a computer type environment.
4. Elimination of tapes and tape reader at the machine for improved reliability.
5. Elimination of hardwired controlled unit on some systems.

6. Programs stored as cutter location data can be post processed for whatever suitable machine is assigned
to process the job.
7. Convenient editing and diagnostic features.

OR

Advantages of DNC machines:

1. It eliminates punched tapes & tape reader which are the weakest component in the NC system.
2. Large memory of DNC allows it to storage a large amount of part programme for subsequent use. It also
relatives the memories of NC control unit.
3. Same part programme can be run on the different machine at the same time without duplicating it at
individual machine.
4. Central DNC Computer can keep close control over the complete machine shop.
5. Individual machine performance report can be obtained on demand.
6. DNC uses a control Computer, which can be easily isolated from the machine shop & kept in suitable
environment.
7. The data related to manufacturing can be centrally maintained & updated, there by effectively managing
the inventory & scheduling.

79) Describe the working of Direct Numerical Control (DNC) machinewith a

neat sketch.

Answer: Working of Direct Numerical Control (DNC) machine:

A DNC consists of four basic components:

1. Central computer
2. Bulk memory, which stores the NC part programs
3. Tele communication lines
4. Machine tools.
The computer calls the part program instructions from bulk storage and sends them to the individual machines
as the need arises. It also receives data back from the machine. This 2-way information flow occurs in real
time, which means that each machines request for instructions must be satisfied almost instantaneously.
Similarly, the computer must always be ready to receive in function from the machines and to respond
accordingly. The remarkable feature of the DNC system is that the computer is servicing alarge number of
separate machine tools, all in real time.

Depending on the number of machines and the computational requirements that are imposed on the computer,
it is sometimes necessary to make use of satellite computers. These satellites are mini computers and they
serve to take some of the burden off the central computer. Each satellite controls several machines. Groups
of part program instructions are received from the central computer and stored in buffers. They are then
dispensed to the individual machines as required. Feedback data from the machines are also stored in the
satellite’s buffer before being collected at the central computer.

80) Define “CAD”.

Answer: CAD (Computer Aided Design):

CAD is defined as the use of computer systems to assist in the creation, modification, analysis or optimization
of the design. To accomplish the task of CAD process, CAD tools are to be utilized. CAD tools can be defined
as the intersection of three sets: geometric modeling, computer graphics and design tools.

81) State any two applications of CAD.

Answer: CAD is used in

1. Designing parts and assemblies,

2. Arranging equipment in a plant,
3. Creating renderings and animations of machines,
4. Analyzing stress and fluid flow etc.
5. Manufacturing
6. Planning
7. Computer aided analysis
8. Inventory control
9. Production planning.

82) State the six advantages of CAD.

Answer: Some of the benefits of computer aided designs are:

1. Productivity improvement in design

2. Shorter lead times
 3. Design analysis
4. Fewer design errors
5. Greater accuracy in design calculations
6. Standardization of design, drafting and documentation of procedure
7. Legibility of drawings
8. Improved procedures for engineering changes
9. Provides various benefits in manufacturing
10. Decrease design effort.
11. Code re-use.
12. Improved accuracy.
13. Easy to share and edit.

83) State any six disadvantages of CAD.

Answer: Disadvantages of CAD:

1. Work can be lost because of the sudden breakdown of computers.

2. Work is prone to viruses.
3. Work could be easily “hacked”
4. Time taking process to know how to operate or run the software.
5. High production or purchasing cost for new systems.
6. Time and cost of training the staff which will work on it.
7. Need of regular updating of software or operating systems.
8. Need less employment because of CAD/CAM systems.

84) Explain the procedure of CAD.

Answer: Procedure of CAD: The design process consists of following phases.

● Recognition of need
● Definition of problem
● Synthesis
● Analysis and optimization
● Evaluation
● Presentation

Recognition of need involves the identification of some defect in the current design or the perception of a
new product. Definition of the problem involves a thorough specification of the item to be designed. The
specification includes physical and functional characteristics, cost, quality and operating performance. Synthesis
and analysis are iterative phases in the design process.

A certain component or subsystem of the overall system is conceptualized by the designer, subjected to analysis,
improved through this analysis procedure, and redesigned. The process is repeated until the design has been
optimized within the constraints imposed on the designer. The components and subsystems are synthesized
into the final overall system by iterative process.

Evaluation is concerned with measuring the design against the specifications established in the problem
definition phase. This evaluation often requires the fabrication and testing of a prototype model to assess
operating performance, quality, reliability, and other criteria. The final phase in the design process is the
presentation of the design. This includes documentation of the design by means of drawing, material
specifications, assembly lists and so on. Specifically, the documentation requires a design database to be created.

85) Define the term “CAM”.

Answer: CAM (Computer Aided Manufacturing):

CAM can be defined as the use of the computer systems to plan, manage and control the operations of a
manufacturing plant through either direct or indirect computer interface with the plant’s production resources.
CAM tools consist of CAD tools, networking integration and automation concepts and manufacturing tools.

86) State any two advantages of CAM.

Answer: Advantages of CAM:

1. Maximizes the productivity,

2. Flexibility,
3. Less manufacturing lead time,
4. Increased reliability,
5. Less scrap, and
6. Best management control.

7. Helps to produce the products in a shorter lead time with the help of best manufacturing techniques.

OR

1. Reduction of lead time

2. Inventory reduction
3. Reduction in machine setup time
4. More efficient use of factory & ware house space
5. Reduction in direct & indirect labor
6. Reduction in costs that can be passed on to the final consumer
7. Leverage of computing power
8. Automation of manufacturing process
9. Making mass customization possible
10. Development of work standards by commercially available software packages
11. The simplification of the task of estimating the cost of a new product.

87) State any two limitations of CAM.

Answer: Limitations of CAM:

1. Computer errors are possible.

2. CAM software can be expensive
3. Training is expensive
4. Need a skilled workforce of engineers.

5. Computers and controllers to run the software and CNC machinery for manufacturing are expensive.

Topic: 6.18 Explain Planning and control.

 88) Write short notes on CAM in “Manufacturing Control” in threesimple
sentences.

Answer: Manufacturing Control:

Manufacturing Control is the computer system application that is used for managing and controlling the
physical operations. It includes:

● Process Monitoring and Control: It concerns with the observation and regulation of production
equipment and manufacturing process.
● Shop Floor Control: It concerns with collection of data from plant operations and this data is used for
controlling the production and inventory.
● Quality Control: It concerns with several approaches that is used for ensuring the maximum possible
quality levels.
● Inventory Control: It concerns with the maintenance of inventory for reducing the investment, cost of
storage, and to increase the customer service.
● Just In Time Production System: It concerns with the item delivery to customers or to exact machines
at the required time.

89) Write short notes on CAM on “Manufacturing Planning”.

Answer: Manufacturing Planning:

During this process, the computer is used in offline to deliver required information for providing effective
production planning and management. This production planning and management includes:

● CAPP (Computer Aided Process Planning): It concerns with the route sheets preparation and this
route sheets lists the set of operations and work centres which is needed for producing the products.
● Computerized Machinability Data System: It concerns with the machinability data generations like
feed, speed and more.
● Computer Assisted NC Part Programming: It concerns with the part program generation that is
required for NC/CNC machine tools.
● Development of Work Standards: It concerns with the standard time generation for jib.
● Estimation of Costs: It concerns with the production of total product costs.
● Production and Inventory Planning: It includes the maintenance of automatic stock items recording,
inventory records, maintaining priorities, production and capacity planning, and material requirements.
● Computer Aided Line Balancing: It concerns with the work element allocation with assembly line work
stations.

90) Define the term “High speed machining”.

Answer: High speed machining:

A process that combines lighter milling passes with high spindle speeds and high feed rates to achieve a
very high metal-removal rate, high-speed machining helps reduce cycle time, increase tool life and
increase shop productivity.

OR

Defining high-speed machining is difficult because it can be one of many operations, or a combination of
them. It can be defined as: Machining at a high cutting speed (vc), Machining with a high spindle speed (n),
Machining with a high feed rate (vf), Machining with a high removal rate (Q). High -speed machining is not
defined, however, as machining with a high material removal rate using a large axial depth of cut or large
radial depth of cut .
 91) What type of materials are suitable for high speed machining?

Answer: Material Choice: High-speed machining is popular in both the aerospace and die/mold sectors.
Because of this, the metals seen most commonly in these applications are titanium, steels (including stainless
steels), and aluminum.
92) State any two applications of High speed machining.

Answer: Applications of High Speed Machining:

1. Aircraft Industry
2. Mass production industries
3. Automotive components
4. Medical equipment and devices, etc.

93) What is micromachining?

Answer: Micromachining:

It is defined as the material removal at micro/nano level with no constraint on the size of the component
being machined

The term micromachining usually refers to the fabrication of micromechanical structures with the aid of
etching techniques to remove part of the substrate or a thin film. Silicon has excellent mechanical properties,
making it an ideal material for machining.

94) State any two disadvantages of micromachining.

Answer: Disadvantages of micromachining:

1. Higher fabrication steps involved and hence expensive.

2. Complex technology involving process of repetitive deposition of thin films.
3. The equipment required for micromachining is very costly than other cutting process.
4. Need highly skilled persons to operate micromachining systems.
5. Material limitations (including crystalline and reflective materials)
6. Reflected laser light can present safety hazard (in laser micromachining).

95) State any two purposes of micromachining.

Answer: Purposes of micromachining:

1. Shaping and sizing of a part.

2. Surface finishing a part.

96) State any four types of micromachining.

Answer: Types of micromachining:

1. Bulk micromachining,
2. Surface micromachining,
3. Laser micromachining,
4. Silicon micromachining,
5. Photolithography
6. Etching
7. LIGA process
8. Mechanical micromachining.

97) Define “Silicon micromachining”.

Answer: Silicon micromachining concerns a process that involves the removal of silicon materials using wet
chemical or dry plasma process in order to create 3-D silicon or non-silicon microstructures for making
functional devices such as micro-sensors, micro-actuators, biochips, etc.
98) Define “Laser micromachining”.

Answer: Laser micromachining is a laser enabled process used to make micrometer scale features in
materials. A pulsed laser deposits finite amount of energy into a material for precise and reproducible material
removal enabling the laser machining process to cut, scribe, drill, or ablate a material.
99) State the difference between Bulk and Surface micromachining.

Answer: Bulk micromachining is a process used to produce micro-machinery or micro-electromechanical

systems (MEMS). Whereas surface micromachining creates structures on top of a substrate, bulk
micromachining produces structures inside a substrate.
100) What is Etching? List the types.

Answer: Etching is traditionally the process of using strong acid or mordant to cut into the unprotected parts
of a metal surface to create a design in intaglio (incised) in the metal. In traditional pure etching, a metal
(usually copper, zinc or steel) plate is covered with a waxy ground which is resistant to acid.

The two major types of etching are wet etching and dry etching (e.g., plasma etching). The etching process
that involves using liquid chemicals or etchants to take off the substrate material is called wet etching.

101) State the difference between Isotropic and Anisotropic etching.

Answer: The differences between isotropic and anisotropic etching has to do with the shape that they carve
out under the etching mask. Anisotropic etching is when the plasma [ is perpendicular and occursin one
direction whereas isotropic etching occurs when the plasma etch is in all directions.
102) Explain the principle of ‘High Speed Machining’.

Answer: High Speed Machining:

The basic principle of High Speed Machining is same as that of conventional machining. But the addition of some
special features has made HSM demanding in the market. The high speed machines are usually multiple axis
machines and can perform almost all operations on a single machine which is not possible in any
conventional machine. All the tools are mounted on a single machine and operation like turning, boring,
milling, drilling and other machining operation can be easily done by a simple program which is written
on computer and fed into Computer Numerical Control (CNC) machine. Here the ratio of speed and feed is high
which leads to high surface finish and better accuracy than conventional machining. The difference in
conventional and high speed machining is that, in conventional machining accuracy depends on the skill and
experience of the person handling the job. Also it requires lot of brain effort to analyze the things. But in 21st
century high speed machining has taken over conventional machining mainly in the large scale sector.

Answer: Advantages of high speed machining over conventional machining:

 1. The accuracy of HSM is 100% if programmed correctly.
2. HSM gives good repeatability and is simple to use then conventional.
3. Parts can be produced to maximize accuracy and it also provides excellent positional accuracy unlike
conventional machining.
4. Less skilled trainer can operate the machine whereas conventional machining requires highly skilled
person.
5. Tooling cost is comparatively low than conventional.
6. There is no need of complex fixtures as that in conventional.
7. HSM reduces time of manufacturing the product.
8. Complex machines operations can be done with lot of ease and at a single machine itself.
9. There is no need to change tool for different operations as in conventional machining.
10. Can be operated for almost for very long hours say almost 24 hrs and can be left operated for months.
11. Latest design software's are available these days and HSM operator can design his own new ideas
12. High speed machining allows us to achieve higher removal rates which in turn improves our
productivity and lowers cost.
13. At higher speeds, cutting forces are lower and less heat is generated which in turn means less risk of
tool deflection or workpiece distortion. This is a crucial factor in any precision engineering, but is
especially important when working on components with thin walls or made from harder metals.
14. At higher speeds chips are smaller and are evacuated more easily, even when machining dry.
15. In high speed machining, you can achieve surface finishes with low friction, often and good as Ra~
0.2um
16. At higher speeds, cuts are shallower and the engagement time for the cutting edge is extremely short.
This allows for a productive cutting process of small sized components as well as finishing.
17. High speed machining is not without its risks and there are many factors including the machine, the
cutting tool, the material being used and the operator which all come into play.
18. Fewer operators needed: The shop needs nine operators per shift for the two machines. These
personnel tend to functions including setup, loading, and tool changing and chip removal. Replacing
one of the two gantries with a horizontal that needs only one operator delivers a savings of three
operators.
19. Reduced floor space.
20. Redundant tooling eliminated.
21. Tool savings: Tool preparation time is reduced significantly, plus there is an improvement in tool life.
22. Redundant fixtures eliminated: Two fixtures per part are no longer needed.
23. Reduced fixture maintenance.
24. Reduced hand blending: One operator per shift is no longer needed to perform this blending.
25. Assembly accuracy: Savings come from work that is no longer necessary because the more accurately
machined parts work in assembly the first time they are tried.
26. 50 percent reduction in WIP: Work-in-process goes down because the shop can efficiently machine
one piece at a time. Reduced WIP carrying costs: Assume 15 percent of the value of the inventory.
27. Reduced equipment maintenance: There are fewer spindles to service.

104) List any six disadvantages of High speed machining.

Answer: Disadvantages of high speed machining over conventional machining

1. High speed machines are more expensive as than manually operated machines.
2. Tools used for high speed machines are quite costly.

3. A part of machine which includes machine and tooling are expensive and requires extensive
justifications.
4. Repairing is expensive too.
5. High speed machines do not eliminate all the error.
6. Internal shapes cannot be machined in High speed machining.
7. Size limitations depend on the size of machine.
8. Higher acceleration and deceleration rates, and spindle start and stop result in faster wear of guide
ways, ball screws and spindle bearings, leading to higher maintenance costs.
9. HSM also requires specific process knowledge, programming equipment and interfaces for fast data
 transfer needed. Consequently, find suitably trained staff can be difficult.
10. HSM can involve a considerable "trial and error" period. Good work and process planning is necessary,
along with significant safety precautions and safety enclosing (bullet proof covers).
11. Tools, adapters and screws need to be checked regularly for fatigue cracks. Only tools with posted
maximum spindle speed can be used.

105) State any six advantages of Micro machining.

Answer: Advantages of Micromachining:

1. Micromachining offers a method for single process machining for smaller parts, so milling and turning
can be done on the same machine.
2. This reduces lead time
3. Allows parts to be machined more efficiently.
4. Easy capability of being automated.
5. Straight forward process monitoring.
6. Forceless and contact less process (Laser type)
7. Minor heat effected zone.
8. Marginal modifications to the microstructure.
9. High flexibility regarding design of tiny structure.
10. High machining speed.
11. High precision.
12. Constant machining quality
13. No additional tooling cost by wear.
14. No solvent chemicals used.
15. Material removal rate controllable down to the nanometer scale.