DADI Institute of Engineering and Technology

1. Draw a neat sketch of Boiler and explain its types?

Definition of Boiler: A boiler is a closed vessel that is designed to convert water into steam
or hot water under pressure. It is used in various industries for heating, power generation, and
process applications. Understanding the working principles of boilers is essential for efficient
and safe operation.

Importance of Boilers: Boilers are essential in a wide range of applications, including:

1. Power Generation: Boilers are used in thermal power plants to produce steam, which
drives turbines to generate electricity.
2. Heating: Boilers are used for space heating in residential and commercial buildings.
3. Industrial Processes: Many industries rely on boilers for processes like chemical
manufacturing, food processing, and textile production.
4. Steam for Mechanical Work: Boilers are used in various mechanical applications,
including propulsion in ships and locomotives.

Basic Principles of Boiler Operation

1. Heat Generation
 The primary function of a boiler is to generate heat by burning a fuel (such as natural
gas, coal, oil, or biomass) or through a nuclear reaction (in the case of nuclear
boilers).
 Heat is transferred to the water or working fluid to raise its temperature and generate
steam or hot water.
2. Heat Transfer
 Heat is transferred from the combustion chamber or heating source to the water in the
boiler through conduction, convection, and radiation.
 Conduction: Heat transfer through direct contact with hot surfaces.
 Convection: Heat transfer through the movement of fluid (water or steam) within the
boiler.
 Radiation: Heat transfer through electromagnetic waves.

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3. Water Circulation
 Boilers are equipped with a system for the circulation of water or steam to ensure
even heating and to prevent overheating.
 In water tube boilers, water circulates through tubes, and in fire tube boilers, water
surrounds the tubes.
4. Steam Generation
 When water is heated, it undergoes a phase change to become steam. This steam is
then collected in a steam drum or space for further use.
5. Pressure Control
 Boilers operate under controlled pressure to ensure that the generated steam or hot
water is suitable for the intended application.
 Pressure is maintained by a combination of safety valves and control systems.

Types of Boilers
1. Fire Tube Boilers: In fire tube boilers, hot gases flow through tubes immersed in
water. They are simple, compact, and suitable for small applications.
2. Water Tube Boilers: Water tube boilers have water-filled tubes and hot gases
flowing around them. They are used in large industrial applications, including power
generation.

3. Steam Boilers vs. Hot Water Boilers: Boilers can be designed to produce either
steam or hot water, depending on the application.

2. Explain Refrigeration system and explain the advantages and disadvantages of the
Refrigeration system?

Definition:
Refrigeration is the process of removing heat from a space or substance to lower its
temperature. The primary purpose is to preserve and cool perishable items, create a
comfortable environment, and facilitate various industrial processes.

Basic Components of a Refrigeration System:

1. Compressor
Function: Raises the pressure and temperature of the refrigerant gas.
Types: Reciprocating, rotary, screw, and centrifugal compressors.

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2. Condenser
Function: Releases heat absorbed by the refrigerant into the surrounding environment,
causing the refrigerant to condense.
Types: Air-cooled and water-cooled condensers.
3. Expansion Valve
Function: Controls the flow of refrigerant into the evaporator and reduces its pressure.
Types: Thermostatic expansion valve (TEV), electronic expansion valve (EEV).
4. Evaporator
Function: Absorbs heat from the space being cooled or from the substance being refrigerated.
Types: Air-cooled and water-cooled evaporators.
5. Refrigerant
The refrigerant is a substance that undergoes phase changes between liquid and gas to absorb
and release heat.

Refrigeration Cycle:
1. Compression
The refrigerant is compressed in the compressor, raising its temperature and pressure.
2. Condensation
The high-pressure, high-temperature refrigerant gas is condensed in the condenser, releasing
heat.
3. Expansion
The high-pressure liquid refrigerant passes through the expansion valve, where its pressure is
reduced.
4. Evaporation
The low-pressure liquid refrigerant evaporates in the evaporator, absorbing heat from the
surroundings.

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Performance Factors:
1. Coefficient of Performance (COP):
COP is a measure of the efficiency of a refrigeration system and is defined as the ratio of the
heat removed (cooling effect) to the work input.
2. Refrigeration Capacity:
Refrigeration capacity is the amount of heat absorbed by the evaporator in a given time.
3. Temperature Control:
Precise temperature control is essential for various applications, and it is achieved by
adjusting the set points and using appropriate controls.

Advantages Dis advantages

Low operation and maintenance costs High energy consumption

Energy efficient system Limited cooling capacity

Suitable for large spaces Expensive to install

Long lifespan Requires regular maintenance

Easy installation and repair Not environmentally friendly

3. Describe the principal parts and functions of a Four Stroke Petrol engine with a neat
sketch?

A four-stroke engine is an internal combustion engine that completes four distinct

strokes (intake, compression, power, and exhaust) in two revolutions of the crankshaft.
The concept of the four-stroke cycle was introduced by Nikolaus Otto in the 1870s,
revolutionizing the efficiency and performance of internal combustion engines.

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Basic Operating Principles:

1. Intake Stroke:
The intake valve opens, and the piston moves down the cylinder, drawing in a mixture of air
and fuel. To prepare the engine for combustion by filling the combustion chamber with a
combustible mixture.
2. Compression Stroke:
Both intake and exhaust valves are closed, and the piston moves up the cylinder, compressing
the air-fuel mixture. It also involves Increasing the pressure and temperature of the mixture,
preparing it for the combustion.
3. Power Stroke:
The spark plug ignites the compressed air-fuel mixture, causing a rapid expansion of gases
that forces the piston down the cylinder. This is the primary stroke that produces mechanical
work, converting chemical energy into mechanical energy.
4. Exhaust Stroke:
The exhaust valve opens, and the piston moves up the cylinder, expelling the burnt gases
from the combustion chamber. To clear the cylinder of exhaust gases and prepare for the next
intake stroke.
Components of a Four-Stroke Petrol Engine:

1. Cylinder:
 Description: The combustion chamber where the power stroke occurs.
 Number: Engines can have a varying number of cylinders (e.g., 4-cylinder, 6-
cylinder).
2. Piston:
 Description: A cylindrical component that moves up and down within the
cylinder.
 Function: Transfers the force generated during the power stroke to the
crankshaft.
3. Crankshaft:
 Description: A shaft connected to the pistons, converting linear motion into

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rotational motion.
 Function: Transfers the rotational force to the transmission and eventually the
wheels.
4. Camshaft:
 Description: A shaft with lobes that control the opening and closing of the
engine's valves.
 Function: Regulates the timing and duration of valve opening.
5. Valves:
 Description: Intake and exhaust valves control the flow of air and fuel into the
cylinder and the expulsion of exhaust gases.
 Function: Facilitates the intake, compression, power, and exhaust strokes.
6. Spark Plug:
 Description: A device that produces an electric spark to ignite the air-fuel
mixture.
 Function: Initiates combustion in the power stroke.
Advantages of Four-Stroke Petrol Engines:
1. Efficiency:
 The four-stroke cycle allows for better thermal efficiency compared to two-
stroke engines.
2. Smooth Operation:
 The engine's operation is generally smoother due to a more evenly distributed
power delivery.
3. Lower Emissions:
 Four-stroke engines typically produce fewer emissions compared to two-
stroke engines.

4. Classify the differences between SI and CI engines?

DIFFERENCE SPARK IGNITION (SI) COMPRESSION IGNITION (CI)

Ignition Method A spark plug is used to ignite the The fuel ignites spontaneously due to high
fuel-air mixture. temperature and pressure caused by
compressing the air in the combustion
chamber.

Combustion The combustion process in SI In CI engines, the combustion process is

Process engines is initiated by an electric initiated by the high pressure and
spark that ignites the fuel-air temperature created by compressing the
mixture. The combustion of the fuel- air in the combustion chamber. The fuel is
air mixture is a rapid process that injected into the combustion chamber in a
generates a flame front that fine mist, which ignites spontaneously due
propagates through the combustion to the high temperature and pressure. The
chamber. The flame front burns the combustion of the fuel generates heat and
fuel-air mixture, generating heat and pressure, which produces the power that
pressure, which produces the power drives the engine.
that drives the engine.

Compression SI engines have a lower CI engines typically have a compression

Ratio compression ratio of around 10:1 ratio between 15:1 to 20:1

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Fuel Type SI engines primarily use gasoline as CI engines typically use diesel fuel, diesel
fuel; Gasoline is a lighter fuel that fuel is heavier and requires higher
evaporates quickly this is why SI temperatures for ignition this is why CI
engines require spark plugs to ignite engines rely on the heat generated by
the fuel-air mixture. compressing the air to ignite the fuel.

Fuel Injection In SI engines, fuel is typically In CI engines, fuel is injected directly into
injected into the intake manifold or the combustion chamber under high
directly into the combustion pressure, usually using a fuel injector.
chamber, mixed with air, and then
ignited by the spark plug.

Power Output SI engines are known for their high- CI engines are known for their high torque
and Torque power output, especially at high output, making them suitable for heavy-
speeds, due to their ability to rev duty applications that require towing,
higher and produce more hauling, or powering large machinery.
horsepower.

Cold Starting SI engines typically have better cold CI engines, on the other hand, may require
starting performance compared to CI additional measures such as glow plugs or
engines. This is because the spark intake air heaters to aid in cold starting.
plug can easily ignite the fuel-air
mixture in SI engines, even at low
temperatures.

Maintenance SI engines generally require more CI engines, on the other hand, tend to
frequent maintenance due to the have longer service intervals and require
wear and tear on spark plugs, less frequent maintenance due to their
ignition systems, and other simpler ignition system and lower RPM
components. operation.

Cost SI engines tend to be less expensive CI engines require more robust

to manufacture and purchase construction to withstand the higher
compared to CI engines. compression ratios and pressures, as well
as the higher heat generated during
combustion. Additionally, the complex
fuel injection system in CI engines adds to
the overall cost.

5. Classify the differences between 2stroke and 4stroke engines?

TWO STROKE ENGINE FOUR STROKE ENGINE

1. A two-stroke engine cannot be lubricated by 1. A four-stroke engine can be lubricated by oil in
oil in an oil sump. an oil sump.
2. Fuel supplied to a two-stroke engine is 2. Here, fuel is consumed every four strokes and
mixed with oil so that it can coat the cylinders the oil of a four-stroke engine does not burn with
and bear the surfaces along its path. the fuel, it is recycled back around the engine.

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3. A two-stroke engine has a simpler design. 3. A four-stroke engine has a bit complex design
but is also environment-friendly.
4. A two-stroke engine has no valve train, 4. A four-stroke engine does have a value train,
timing gears, cams or pushrods. timing gears, cams and pushrods.
5. In a two-stroke engine, there is one 5. In a four-stroke engine, there are two
revolution of the crankshaft during one revolutions of the crankshaft during one
operational cycle. operational cycle.
6. The piston moves during one operational 6. The piston moves during one operational cycle
cycle by demonstrating two strokes. by demonstrating four strokes.
7. A two-stroke engine produces higher torque. 7. A four-stroke engine produces lesser torque.
8. It uses a port for the inlet of the air-fuel 8. It uses a valve for the inlet of the air-fuel
mixture and an outlet for exhaust gasses. mixture and an outlet for exhaust gasses.
9. A two-stroke engine has lesser thermal 9. A four-stroke engine has higher thermal
efficiency. efficiency.
9. Two-stroke engines are cheaper and are 9. Four-stroke engines are expensive and tough to
simple to manufacture. manufacture.
10. Two-stroke engines can be used at any 10. Four-stroke engines can only be used in the
angle because the lubrication of the piston upright position because they require the
comes from the fuel itself. crankshaft to be partially submerged in oil for
lubrication of the pistons.

6. What are components of electric and hybrid vehicles?

Electric Vehicle (EV) Components:

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1. Battery Pack
 The battery pack is the heart of an electric vehicle.
 It stores electrical energy in the form of chemical energy.
 Lithium-ion batteries are commonly used due to their high energy density.
 The battery pack's capacity is measured in kilowatt-hours (kWh), and it determines
the vehicle's range.
2. Electric Motor
 The electric motor is responsible for converting electrical energy from the battery into
mechanical energy to drive the vehicle.
 It is usually a three-phase AC induction motor or a permanent magnet synchronous
motor.
 The motor's power is measured in kilowatts (kW) and determines the vehicle's
acceleration and speed.
3. Power Electronics
 Power electronics are used to control the flow of electricity from the battery to the
electric motor.
 They include inverters, converters, and controllers that manage voltage, current, and
frequency.
 Power electronics also enable regenerative braking.
4. Charger
 The charger is responsible for converting AC power from an electrical outlet into DC
power to charge the battery.
 Charging speeds can vary, and the charger's capacity is measured in kilowatts.
5. Onboard Charger
 The onboard charger is a component that's integrated into the vehicle.
 It allows the vehicle to be charged at various power levels, depending on the available
charging infrastructure.
6. Thermal Management System
 Electric vehicles require efficient thermal management to control the temperature of
the battery and other components.
 Liquid or air cooling systems are used to maintain optimal operating temperatures.

Hybrid Vehicle Components

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1. Internal Combustion Engine (ICE)

 Hybrid vehicles have an ICE, which can be gasoline or diesel-powered.
 The ICE can provide propulsion power and recharge the battery.
2. Electric Motor/Generator
 Hybrid vehicles have an electric motor/generator, which can assist the ICE or act as a
generator to recharge the battery.
 The electric motor in hybrids is usually smaller than that of pure EVs.
3. Battery Pack
 Hybrid vehicles have a smaller battery pack compared to pure EVs.
 The battery in hybrids is used for storing energy during regenerative braking and
electric-only driving at low speeds.
4. Power Split Device
 The power split device is a crucial component in most hybrid powertrains.
 It allows for the blending of power from the ICE and electric motor in various ratios
for propulsion.
5. Transmission
 Hybrid vehicles often have a continuously variable transmission (CVT) or a
specialized transmission to manage power flow between the engine and electric
motor.
6. Regenerative Braking System
 Hybrid vehicles use regenerative braking to recover energy during braking.
 The system converts kinetic energy into electrical energy, which is stored in the
battery.

7. Explain briefly about Casting and its types?

Casting is a manufacturing process in which a liquid material, often metal or plastic,

is poured into a mold cavity to create a solid object of the desired shape. The material is
introduced in a fluid state and takes the shape of the mold as it solidifies.

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Key Steps in Casting:

1. Pattern Creation:
 A pattern, typically made of wood, metal, or plastic, represents the final object's shape. It
is used to create the mold.
2. Mold Formation:
 The mold is a hollow cavity that replicates the desired shape of the final product. It can be
made from materials like sand, metal, or ceramics, depending on the casting method.
3. Pattern Placement:
 The pattern is placed in the mold, leaving a void that will be filled with the molten
material.
4. Pouring:
 The molten material (such as metal or plastic) is poured into the mold through a sprue,
allowing it to flow and fill the entire cavity.
5. Solidification:
 The molten material cools and solidifies inside the mold, taking the shape of the cavity.
6. Removal:
 After solidification, the casting is removed from the mold, and excess material (if any) is
trimmed or machined.

Process of Casting
The casting process, specifically sand casting, involves the following steps:
1. Place the mold pattern, which determines the size and shape of the casting, in the
sand. The sand (which includes additives) will take the shape of the pattern.
2. Establish a gating system, consisting of a pouring cup and gates, to direct the molten
metal into the mold cavity.
3. Remove the mold pattern from the sand once the sand has taken its shape.
4. Pour the molten metal, heated to the appropriate temperature, into the mold cavity
through the gating system. The metal can be one of many elements or alloys such as:
iron, steel, aluminum, and bronze.
5. After pouring, the molten metal is left to cool and solidify within the mold. The
cooling time varies depending on the type of metal used.
6. Once the metal has cooled and solidified, open the mold to remove the newly formed
metal casting. The mold patterns are typically reusable, but the molds themselves
need to be remade for each casting.

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Types of Casting:

1. Sand Casting:
 Description: One of the oldest and most common casting processes. A mold is made of
sand, and the molten metal is poured into the cavity.
 Applications: Large and intricate parts, such as engine blocks and sculptures.
2. Investment Casting:
 Description: Also known as precision casting or lost-wax casting. A wax pattern is coated
with a ceramic shell, and the wax is melted out before pouring the molten metal.
 Applications: Aerospace components, jewelry, and dental appliances.
3. Die Casting:
 Description: Molten metal is injected into a mold cavity under high pressure. The mold is
reusable and often made of steel.
 Applications: Mass production of small to medium-sized parts, such as automotive
components.
4. Centrifugal Casting:
 Description: The mold is rotated at high speed, and molten metal is poured into the
spinning mold. Centrifugal force distributes the metal evenly.
 Applications: Pipes, cylinders, and other symmetrical objects.
5. Continuous Casting:
 Description: Molten metal is poured into a continuous mold and solidifies into a long,
continuous shape. This is commonly used for producing metal sheets, rods, and beams.
 Applications: Steel and aluminum production.

8. Explain briefly about classification of joining process?

Joining processes in manufacturing involve the assembly and bonding of materials to

create finished products. These processes play a crucial role in various industries by
connecting components to form structures, ensuring integrity, and enhancing the functionality
of products.

Classification of Joining Processes

Joining processes can be categorized into various methods based on the type of material,
the nature of the connection, and the applied techniques. Some common joining methods
include:
1. Welding:
 Arc Welding: Utilizes an electrical arc to melt and fuse metals. Methods include
MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and Stick welding.
 Resistance Welding: Uses electrical resistance to generate heat for joining, e.g., spot
welding, seam welding.
 Gas Welding: Uses a combustible gas and oxygen to create a flame for fusion.

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Arc welding and gas welding

2. Brazing and Soldering:
 Brazing: Joins metals with a filler metal that melts at a higher temperature than
solder but lower than the base metal.
 Soldering: Uses a low-temperature filler metal (solder) to join metals, commonly
used for electronics.

3. Adhesive Bonding:
 Gluing: Uses adhesives to bond materials together, providing high-strength and
corrosion-resistant connections.
 Structural Adhesives: Used in aerospace, automotive, and construction industries
for load-bearing applications.

Adhesive bonding process

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4. Mechanical Fastening:
 Bolts and Nuts: Assembles parts using bolts threaded through holes in components,
secured with nuts.
 Riveting: Utilizes rivets to create a permanent connection, widely used in aircraft
construction.

Bolt & nut and riveting

5. Screwing and Threaded Connections:
 Screws and Threads: Creates connections by using screws or threaded elements,
offering ease of assembly and disassembly.

6. Press-Fit and Interference Fit:

 Press-Fit: Fits parts together with a tight tolerance, using force to secure the
connection without additional fasteners.
7. Weld-Bonding:
 Combines welding and adhesive bonding for a strong, durable connection.

Advantages of Joining Processes

1. Versatility: Joining processes can be applied to a wide range of materials, including
metals, plastics, ceramics, and composites.
2. Structural Integrity: When performed correctly, joining methods can create strong
and reliable connections.
3. Dissimilar Material Joining: Joining allows for the assembly of different materials,
expanding design possibilities.
4. Lightweight Structures: Suitable for applications where weight is a critical factor.
5. Corrosion Resistance: Joining processes like adhesive bonding can create corrosion-
resistant connections.

9. Explain briefly about Machining Process and the classifications of Machining

process?
 Definition: Machining is a material removal process used in manufacturing to shape,
size, and finish work pieces to precise specifications. It involves the use of cutting
tools to remove unwanted material from a work piece, leaving behind the desired
shape and surface finish.

Classification of Machining Processes

Machining processes can be categorized into several types, including:
1. Turning:
 A rotating work piece is cut using a single-point cutting tool.
 Commonly used for cylindrical components such as shafts and bolts.

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2. Milling:
 A rotating cutter removes material from a work piece to create various shapes,
slots, and features.
 Versatile and suitable for a wide range of applications.
3. Drilling:
 Creates holes in work pieces using rotary or non-rotary cutting tools.
 Essential for manufacturing components with holes, like engine blocks and
aircraft wings.
4. Grinding:
 Uses abrasive wheels to achieve high-precision surface finishes.
 Common in the production of parts requiring tight tolerances, such as bearings
and cutting tools.
5. Broaching:
 A cutting tool with multiple teeth removes material in a linear motion.
 Used for shaping keyways and other internal features in components.

6. Sawing:
 Cutting operations that remove material by using a saw or saw blade.
 Common in industries such as metalworking and woodworking.
7. Electrical Discharge Machining (EDM):
 Uses electrical discharges to remove material from the workpiece.
 Ideal for machining conductive materials and complex geometries.

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8. Laser Cutting:
 Utilizes a high-energy laser beam to cut or engrave materials.
 Precise and versatile, used in industries like aerospace and electronics.
9. Chemical Machining:
 Involves selective material removal through chemical reactions.
 Used for creating intricate and delicate parts.
Advantages of Machining Processes
1. High Precision: Machining can achieve tight tolerances and excellent surface
finishes.
2. Material Versatility: Suitable for a wide range of materials, including metals,
plastics, and composites.
3. Customization: Allows for the production of highly customized and complex
components.
4. Good for Prototyping: Machining is often used in product development and
prototyping.
5. Material Removal: Effective for removing damaged or unwanted material, restoring
or reshaping parts.

10. Explain briefly about CNC machine?

CNC (Computer Numerical Control) machines are automated manufacturing systems that
use computer software and digital control to perform various machining and fabrication
operations. These machines are widely used in modern manufacturing for their precision,
efficiency, and versatility.

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Types of CNC Machines

1. CNC Milling Machines:
 Used for milling, drilling, and cutting operations.
 Versatile, with multi-axis configurations for complex parts.
2. CNC Turning Machines:
 Used for turning, facing, and threading cylindrical work pieces.
 Ideal for creating axially symmetric parts like shafts and bolts.
3. CNC Drilling Machines:
 Specialized for drilling holes in work pieces.
 Used in industries like aerospace and automotive for precision hole-making.
4. CNC Grinding Machines:
 Employed for high-precision grinding of surfaces and profiles.
 Common in the production of tools, dies, and precision components.
5. CNC Laser Cutting Machines:
 Use high-powered lasers for cutting materials like metal, plastic, and wood.
 Suitable for intricate and precise cutting operations.
6. CNC Electrical Discharge Machines (EDM):
 Utilize electrical discharges to shape materials.
 Ideal for machining conductive materials and producing complex geometries.
7. CNC Water jet Cutting Machines:
 Employ high-pressure water jets mixed with abrasive particles for cutting a
wide range of materials.
 Suitable for heat-sensitive materials and intricate designs.

Advantages of CNC Machines

1. Precision and Accuracy: CNC machines can achieve high levels of precision and
accuracy, ensuring consistent, quality parts.
2. Repeatability: They can repeat operations with minimal variation, making them ideal
for high-volume production.
3. Versatility: CNC machines can be reprogrammed for different tasks, reducing the
need for specialized equipment.
4. Complex Geometries: They can produce intricate and complex parts that are
challenging to make using conventional methods.
5. Reduced Labor Costs: Automation reduces the need for manual labor, leading to
cost savings.

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1. Control Unit: The brain of the CNC system, consisting of a computer and software
that interprets the CNC program and sends instructions to the machine.
2. Machine Tool: The physical equipment that performs machining operations, such as
milling, turning, or grinding.
3. Tooling: Cutting tools and fixtures used in the machine to shape the work piece.
4. Work piece: The material or component being machined.
5. Work holding: Devices like chucks, vises, and clamps used to secure the work piece.
6. Axes: CNC machines have multiple axes (typically three to five) that move the tool or
work piece in various directions. Common axes include X, Y, and Z.

CNC Programming
 CNC machines are programmed using G-codes and M-codes. G-codes dictate the
tool's motion, while M-codes control auxiliary functions like coolant or spindle speed.
 CNC programming involves specifying the tool path, tool changes, cutting speeds,
and feed rates in a text-based program. CAM (Computer-Aided Manufacturing)
software is often used to generate CNC programs from 3D CAD models.
Quality Control
1. Tool Inspection: Regularly check and replace cutting tools to maintain high-quality
machining.
2. Work piece Inspection: Use measuring instruments to verify the dimensions of
machined parts.
3. Process Monitoring: Continuously monitor the CNC machine's performance to
detect issues and maintain quality.

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