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Assignment Topics With Materials UNIT-I Fundamentals of CAD/CAM
Assignment Topics With Materials UNIT-I Fundamentals of CAD/CAM
Diagram showing the various steps in the product cycle is presented in Figure.
The cycle is driven by customers and markets which demand the product. It is realistic to think of
these as a large collection of diverse industrial and consumer markets rather than one monolithic
market. Depending on the particular customer group, there will be differences in the way the product
cycle is activated. In some cases, the design functions are performed by the customer and the product
is manufactured by a different firm. In other cases, design and manufacturing is accomplished by the
same firm. Whatever the case, the product cycle begins with a concept, an idea for a product. This
concept is cultivated, refined, analyzed, improved, and translated into a plan for the product through
the design engineering process. The plan is documented by drafting Ii set of engineering drawings
showing how the product is made and providing a set of specifications indicating how the product
should perform.
The impact of CAD/CAM is manifest in all of the different activities in the product cycle, as
indicated in Figure. Computer-aided design and automated drafting are utilized in the
conceptualization, design, and documentation of the product. Computers are used in process planning
and scheduling to perform these functions more efficiently. Computers are used in production to
monitor and control the manufacturing operations. In quality control, computers are used to perform
inspections and performance tests on the product and its components.
As illustrated in Figure, CAD/CAM is overlaid on virtually all of the activities and functions of the
product cycle. In the design and production operations of a modem manufacturing firm, the computer
has become a pervasive, useful, and indispensable tool. It is strategically important and competitively
imperative that manufacturing firms and the people who are employed by them understand
CAD/CAM.
1. AUTOMATION AND CAD/CAM
Automation is defined as the technology concerned with the application of complex mechanical,
electronic, and computer-based systems in the operation and control of production. It is the purpose
of this section to establish the relationship between CAD/CAM and automation
Category Description
Before examining the several facets of computer-aided design, let us first consider the
general design process. The process of designing something is characterized by Shigley as an iterative
procedure, which consists of six identifiable steps or phases:-
l. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation
Synthesis and analysis are closely related and highly interactive 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 in a similar interactive manner.
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 drawings, material specifications, assembly lists, and so on. Essentially, the documentation requires
that a design database be created. Figure illustrates the basic steps in the design process, indicating its
iterative nature.
The general design process as defined by Shigley
l. Geometric modeling
2. Engineering analysis
3. Design review and evaluation
4. Automated drafting
These four areas correspond to the final four phases in Shigley's general design process, illustrated
in Figure. Geometric modeling corresponds to the synthesis phase in which the physical design project
takes form on the ICG system. Engineering analysis corresponds to phase 4, dealing with analysis and
optimization. Design review and evaluation is the fifth step in the general design procedure.
Automated drafting involves a procedure for converting the design image data residing in computer
memory into a hard-copy document. It represents an important method for presentation (phase 6) of
the design. The following four sections explore each of these four CAD functions.
5. BENEFITS OF CAD
l8. Provides the potential for using more existing parts and tooling
24. Better communication interfaces and greater understanding among engineers, designers,
drafters, management, and different project groups.
Surface model is an extension of wireframe but has advantages: less ambiguous, provide realism for
display with hidden lines, mesh, and shading
Surface Entities
Plane surface
Surface model is an extension of wireframe but has advantages: less ambiguous, provide realism for
display with hidden lines, mesh, and shading
2. Solid model
Solid Model is based on informationally complete (or spatial addressability), valid, and
unambiguous representation of objects and stores geometric data as well as topological
information of associated objects.
This representation permits automation and integration of tasks such as interference analysis,
mass property calculation, finite element modeling, CAPP (computer-aided process planning),
machine vision, and NC machining.
It is very easy to define an object with a solid model than other two previous modeling
techniques (curves and surfaces) because solid models do not need individual locations as with
wireframe models.
The above figure illustrates the difference between geometry and topology. The geometry that
defines the object is the lengths of lines, areas of surfaces, the angles between the lines, and the radius
and the center of the cylinder and the height. On the other hand, topology (sometimes called
combinatorial structure), is the connectivity and associativity of the object entities. It has to do with
the notion of neighborhood and determines the relational information between object entities. From a
user point of view, geometry is visible and topology is considered to be non-graphical relational
information that is stored in solid model databases and are not visible to users.
There are various basic building blocks, so called, primitives that can be combined in certain
boolean operations to construct complex models. They include This representation permits automation
and integration of tasks such as interference analysis, mass property calculation, finite element
modeling, CAPP (computer-aided process planning), machine vision, and NC machining. It is very
easy to define an object with a solid model than other two previous modeling techniques (curves and
surfaces) because solid models do not need individual locations as with wireframe models.
Constructive Solid Geometry (CSG): This is based on the topological notion that a
physical object can be divided into a set of primitives that can be combined in a certain order
following a set of rules (i.e. Boolean operations) to form the object. The basic elements are
block, cylinder, cone, sphere, wedge, and torus and building operations are Boolean
operations. The following bearing support was constructed with various primitives in a certain
sequence by CSG technique.
Sweep Representation: This is especially useful for two-and-half dimensional objects used
most frequently for extruded solids and revolved solids. This is based on sweeping of a section
along a path that may be linear, nonlinear, and hybrid operations. When the path is s
simple extrusion and when it is axisymmetric, it becomes the revolution. For nonlinear path, the
sweeping is done along a nonlinear curve in space. Cutting tool path simulation is one good
applications of this technique.The section may vary along the sweeping path. The following shows
suchan example with variable section.
4.Hermite bicubic surface
Bezier surface
UNIT-III NC CONTROL PRODUCTION SYSTEMS
1. NC PROCEDURE
To utilize numerical control in manufacturing, the following steps must be accomplished.
Process Planning. The engineering drawing of the workpart must be interpreted in terms of the
manufacturing processes to be used. this step is referred to as process planning and it is concerned
with the preparation of a route sheet. The route sheet is a listing of the sequence of operations
which must be performed on the workpart. 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 operations.
We assume that some of the operations will be performed on one or more NC machines.
Part programming. A part programmer plans the process for the portions of the job to be
accomplished by NC. Part programmers are knowledgeable about the machining process and they
have been trained to program for numerical control. They are responsible for planning the
sequence of machining steps to be performed by NC and to document these in a special format.
There are two ways to program for NC:
Manual part programming
Computer-assisted part programming
In manual programming, the machining instructions are prepared on a form called a part
program manuscript. The manuscript is a listing of the relative cutter/work piece positions which
must be followed to machine the part. In computer-assisted part programming, much of the tedious
computational work required in manual part programming is transferred to the computer. This is
especially appropriate for complex work piece geometries and jobs with many machining steps.
Use of the computer in thesea). Attendance & other issues
NC procedure
To utilize numerical control in manufacturing, the following steps must be accomplished.
l. Process Planning. The engineering drawing of the workpart must be interpreted in terms of
the manufacturing processes to be used. this step is referred to as process planning and it is concerned
with the preparation of a route sheet. The route sheet is a listing of the sequence of operations which
must be performed on the work part. 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 operations. We assume
that some of the operations will be performed on one or more NC machines.
Part programming. A part programmer plans the process for the portions of the job to be
accomplished by NC. Part programmers are knowledgeable about the machining process and they
have been trained to program for numerical control. They are responsible for planning the
sequence of machining steps to be performed by NC and to document these in a special format.
There are two ways to program for NC:
Manual part programming
In manual programming, the machining instructions are prepared on a form called a part
program manuscript. The manuscript is a listing of the relative cutter/work piece positions which must
be followed to machine the part. In computer-assisted part programming, much of the tedious
computational work required in manual part programming is transferred to the computer. This is
especially appropriate for complex work piece geometries and jobs with many machining steps. Use
of the computer in these situations results in significant savings in part programming time.
Tape preparation. A punched tape is prepared from the part
manual part programming, the punched tape is prepared directly from the part program manuscript on
a typewriter like device equipped with tape punching capability. In computer-assisted part
programming, the computer interprets the list of part programming instructions, performs the
necessary calculations to convert this into a detailed set of machine tool motion commands, and then
controls a tape punch device to prepare the tape for the specific NC machine.
Tape verification. After the punched tape has been prepared, a method isusually provided for
checking the accuracy of the tape. Some times the tape is checked by running it through a computer
program which plots the various tool movements (or table movements) on paper. In this way, major
errors in the tape can be discovered. The "acid test" of the tape involves trying it out on the machine
tool to make the part. A foam or plastic material is sometimes used for this tryout. Programming
errors are not uncommon, and it may require about three attempts before the tape is correct and
ready to use.
Production. The final step in the NC procedure to use the NC tape in production. This involves
ordering the raw workparts specifying and preparing the tooling and any special fixturing that may be
required, and setting up The NC machine tool for the job. The machine tool operator's function during
production is to load the raw workpart in the machine and establish the starting position of the cutting
tool relative to the workpiece. The NC system then takes over and machines the part according to the
instructions on tape. When the part is completed, the operator removes it from the machine and loads
the next part.
2. Fixed zero and floating zero
The programmer must determine the position of the tool relative to the origin (zero point) of
the coordinate system. NC machines have either of two methods for specifying the zero point. The
first possibility is for the machine to have a fixed zero. In this case, the origin is always located at the
same position on the machine. Usually, that position is the southwest comer (lower left-hand comer)of
the table and all tool locations will be defined by positive x and y coordinates.
The second and more common feature on modern NC machines allows the machine operator to set the
zero point at any position on the machine table. This feature is called floating zero. The part
programmer is the one who decides where the zero point
should be located. The decision is based on part programming convenience. For example, the
work part may be symmetrical and the zero point should be established at the center of symmetry.
Straight-cut system
Contouring NC
Contouring is the most complex, the most flexible, and the most expensive type of machine
tool control. It is capable of performing both PTP and straight-cut operations. In addition, the
distinguishing feature of contouring NC systems is their capacity for simultaneous control of more
than one axis movement of the machine tool. The path of the cutter is continuously controlled to
generate the desired geometry of the workpiece. For this reason, contouring systems are also called
continuous-path NC systems.
Straight or plane surfaces at any orientation, circular paths, conical shapes, or most any other
mathematically definable form are possible under contouring control. Figure illustrates the versatility
of continuous path NC. Milling and turning operations are common examples of the use of contouring
control. In order to machine a curved path in a numerical control contouring system, the direction of
the feed rate must continuously be changed so as to follow the path. This is accomplished by breaking
the curved path into very short straight-line segments that approximate the curve. Then the tool is
commanded to machine each segment in succession
Numerical control systems are widely used in industry today, especially in the metalworking
industry. By far the most common application of NC is for metal cutting machine tools. Within this
category, numerically controlled equipment has been built to perform virtually the entire range of
material removal processes, including:
Milling, Drilling and related processes Boring, Turning, Grinding, Sawing
Within the machining category, NC machine tools are appropriate for certain jobs and
inappropriate for others. Following are the general characteristics of production jobs in metal
machining for which numerical control would be most appropriate:
l. Parts are processed frequently and in small lot sizes.
It has been estimated that most manufactured parts are produced in lot sizes of 5O or fewer.
Small-lot and batch production jobs represent the ideal situations for the application of NC. This is
made possible by the capability to program the NC machine and to save that program for subsequent
use in future orders. If the NC programs are long and complicated (complex part geometry, many
operations, much metal removed), this makes NC all the more appropriate when compared to manual
methods of production. If engineering design changes or shifts in the production schedule are likely,
the use of tape control provides the flexibility needed to adapt to these changes. Finally, if quality and
inspection are important issues (close tolerances, high part cost, lOO% inspection required), NC
would be most suitable, owing to its high accuracy and repeatability.
In order to justify that a job be processed by numerical control methods, it is not necessary that
the job possess every one of these attributes. However, the more of these characteristics that are
present, the more likely it is that the part is a good candidate for NC.
In addition to metal machining, numerical control has been applied to a variety of other
operations. The following, although not a complete list, will give the reader an idea of the wide range
of potential applications of NC:
Pressworking machine tools Welding machines Inspection machines Automatic drafting Assembly
machines
Advantages of NC
Following are the advantages of numerical control when it is utilized in the type of
production jobs described.
l. Reduced nonproductive time. Numerical control has little or no effect on the basic metal,
cutting (or other manufacturing) process. However; NC can increase the proportion of time the
machine is engaged in the actual process. It accomplishes this by means of fewer setups, less time in
setting up, reduced work piece handling time, automatic tool changes on some machines, and so on.
In a University of Michigan survey reported by Smith and Evans, a comparison was made
between the machining cycle times for conventional machine tools versus the cycle times for NC
machines. NC cycle times, as a percentage of their conventional counterparts, ranged from 35% for
five-axis machining centers to 65% for presswork punching. The advantage for numerical control
tends to increase with the more complex processes.
Reduced fixturing. NC requires fixtures which are simpler and less costly to fabricate
because the positioning is done by the NC tape rather than the jig or fixture
Reduced manufacturing lead time. Because jobs can be set up more quickly with NC and
fewer setups are generally required with NC, the lead time to deliver a job to the customer is reduced.
Greater manufacturing flexibility. With numerical control it is less difficult to adapt to
engineering design changes alterations of the production schedule, changeovers in jobs for rush
orders, and so on.
Improved quality control. NC is ideal for complicated workparts where the chances of human
mistakes are high. Numerical control produces parts with greater accuracy, reduced scrap, and lower
inspection requirements.
Reduced inventory. Owing to fewer setups and shorter lead times with numerical control, the
amount of inventory carried by the company is reduced.
Reduced floor space requirements. Since one NC machining center can often accomplish the
production of several conventional machines, the amount of floor space required in an NC shop is
usually less than in a conventional shop.
Disadvantages of NC
Along with the advantages of NC, there are several features about NC which must be
considered disadvantages:
Higher investment cost. Numerical control machine tools represent a more sophisticated and
complex technology. This technology costs more to buy than its non-NC counterpart. The higher cost
requires manufacturing managements to use these machines more aggressively than ordinary
equipment. High machine utilizationis essential on order to get reasonable returns on investment.
Machine shops must operate their NC machines two or three sifts per day to achieve this high machine
utilization.
Higher maintenance cost. Because NC is a more complex technology and because NC
machines are used harder, the maintenance problem becomes more acute. Although the reliability of
NC systems has been improved over the years, maintenance costs for NC machines will generally be
higher than for conventional machine tools.
Finding and/or training NC personnel. Certain aspects of numerical control shop
operations require a higher skill level than conventional operations. Part programmers and NC
maintenance personnel are two skill areas where available personnel are in short supply. The problems
of finding, hiring, and training these people must be considered a disadvantage to the NC shop
PREPARATORY WORD (g-words): This word is used to prepare the controller for instructions that
are to follow. For example, the word gO2 is used to prepare the C controller unit for circular
interpolation along an arc in the clockwise direction. The preparatory word l& needed S9 that the
controller can correctly interpret the data that follow it in the block.
COORDINATES (x-, y-, and z-words): These give the coordinate positions of the tool. In a two-axis
system, only two of the words would be used. In a four- or five- axis machine, additional a-words and
V or b-words would specify the angular positions.
Although different NC systems use different formats for expressing a coordinate, we will
adopt the convention of expressing it in the familiar decimal form: For example, x + 7.235 ory-O.5ao.
Some formats do not use the decimal point in writing the coordinate. The + sign to define a positive
coordinate location is optional. The negative sign is, of course, mandatory.
FEED RATE (f-word): This specifies the feed in a machining operation. Units are inches per minute
(ipm) by convention.
CUTTING SPEED (s-word): This specifies the cutting speed of the process, the rate at which the
spindle rotates.
TOOL SELECTION (t-word): This word would be needed only for machines with a tool turret or
automatic tool changer. The t-word specifies which tool is to be used in the operation. For example,
tO5 might be the designation of a l/2-in. drill bit in turret position 5 on an NC turret drill.
MSCELLANEOUS FUNCTION (m-word): The m-word is used to specify certain miscellaneous or
auxiliary functions which may be available on the machine tool.
The work part of Example was relatively simple. It was a suitable application for manual
programming. Most parts machined on NC systems are considerably more complex. In the more
complicated point-to-point jobs and in contouring applications, manual part programming becomes an
extremely tedious task and subject to errors. In these instances it is much more appropriate to employ
the high-speed digital computer to assist in the part programming process. Many part programming
language systems have been developed to perform automatically cost of the calculations which the
programmer would otherwise be forced to do. This saves time and results in a more accurate and more
efficient part program.
1. Group technology
Group technology (abbreviated GT) is a manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of their similarities in manufacturing and design.
Similar parts are arranged into part families.
PART FAMILIES
A part family is a collection of parts which are similar either because of geometric shape and size or
because similar processing steps are required in their manufacture. The parts within a family are
different, but their similarities are close enough to merit their identification as members of the part
family.
Advantage derived from grouping workparts into families can be explained with reference to
Figures.
Figure shows a process-type layout for batch production in a machine shop. The various machine
tools are arranged by function. There is a lathe section, milling machine section, drill press section,
and so on. During the machining of a given part, the workpiece must be moved between sections, with
perhaps the same section being visited several times. This results in a significant amount of
material handling, a large in-process inventory, usually more setups than necessary, long
manufacturing lead times, and high cost. Figure shows a production shop of supposedly equivalent
capacity, but with the machines arranged into cells. Each cell is organized to specialize in the
manufacture of a particular part family.
Group technology (abbreviated GT) is a manufacturing philosophy in which similar parts are
identified and grouped together to take advantage of their similarities in manufacturing and design.
Similar parts are arranged into part families.
A part family is a collection of parts which are similar either because of geometric shape and
size or because similar processing steps are required in their manufacture. The parts within a family
are different, but their similarities are close enough to merit their identification as members of the part
family.
Advantage derived from grouping work parts into families can be explained with reference to
Figures. Figure shows a process-type layout for batch production in a machine shop. The various
machine tools are arranged by function. There is a lathe section, milling machine section, drill press
section, and so on. During the machining of a given part, the workpiece must be moved between
sections, with perhaps the same section being visited several times. This results in a significant
amount of material handling, a large in-process inventory, usually more setups than necessary, long
manufacturing lead times, and high cost. Figure shows a production shop of supposedly equivalent
capacity, but with the machines arranged into cells. Each cell is organized to specialize in the
manufacture of a particular part family.
Parts classification and coding systems divide themselves into one of three general categories:
l. Systems based on part design attributes
2.Systems based on part manufacturing attributes
3.Systems based on both design and manufacturing attributes
The basic code consists of nine digits, which can be extended by adding four more digits.
The first nine digits are intended to convey both design and manufacturing data. The
general interpretation of the nine digits is indicated in Figure. The first five s, l2345, are called
the "form code" and describe the primary design attributes of the part. The next four digits,
It indicates some of the attributes that would be of use to manufacturing (dimensions, work
material, starting raw workpiece shape and accuracy).
The extra four digits, ABCD, are referred to as the "secondary code" and are intended to
identify the production operation type and sequence.
The secondary code can be designed by the firm to serve its own particular needs.
3.THE MICLASS SYSTEM
MICLASS stands for Metal Institute Classification System and was developed by TNO, the
Netherlands Organization for Applied Scientific Research. It was started in Europe about five years
before being introduced in the United States in l974. Today, it is marketed in the United States by the
Organization for Industrial Research in Waltham, Massachussets. The MICLASS system was
developed to help automate and standardize a number of design, production, and management
functions. These include:
Standardization of engineering drawings
Selection of parts for processing on particular groups of machine tools Machine tool
investment analysis
The MICLASS classification number can range from l2 to 3O digits. The first l2 digits are a universal
code that can be applied to any part. Up to l8 additional digits can be used to code data that are
specific to the particular company or industry. For example, lot size, piece time, cost data, and
operation sequence might be included in the l8 supplementary digits.
The work part attributes coded in the first l2 digits of the MICLASS number are as follows:
MICLASS stands for Metal Institute Classification System and was developed by TNO, the
Netherlands Organization for Applied Scientific Research. It was started in Europe about five years
before being introduced in the United States in l974. Today, it is marketed in the United States by the
Organization for Industrial Research in Waltham, Massachussets. The MICLASS system was
developed to help automate and standardize a number of design, production, and management
functions. These include:
Standardization of engineering drawings
Selection of parts for processing on particular groups of machine tools Machine tool
investment analysis
The MICLASS classification number can range from l2 to 3O digits. The first l2 digits are a
universal code that can be applied to any part. Up to l8 additional digits can be used to code data that
are specific to the particular company or industry. For example, lot size, piece time, cost data, and
operation sequence might be included in the l8 supplementary digits.
The work part attributes coded in the first l2 digits of the MICLASS number are as follows:
The CODE system is a parts classification and coding system developed and marketed by
Manufacturing Data Systems, Inc. (MDSI), of Aim Arbor, Michigan. Its most universal application is
in design engineering for retrieval of part design data, but it also has applications in manufacturing
process planning, purchasing, tool design, and inventory control.
The CODE number has eight digits. For each digit there are l6 possible values (zero through
9 and A through F) which are used to describe the part's design and manufacturing characteristics. The
initial digit position indicates the basic geometry of the part and is called the Major Division of the
CODE system. This digit would be used to specify whether the shape was a cylinder, flat piece, block,
or other. The interpretation of the remaining seven digits depends on the value of the first digit, but
these remaining digits form a chain-type structure. Hence the CODE system possesses a hybrid
structure.
Benefits of group technology
Product design.
Tooling and setups.
Materials handling.
Production and inventory control.
Employee satisfaction.
Process planning procedures.
4. GENERATIVE PROCESS PLANNING SYSTEMS
Retrieval-type CAPP systems use parts classification and coding and group technology as a
foundation. In this approach, the parts produced in the plant aregrouped into part families,
distinguished according to their manufacturing characteristics. For each part family, a standard
process plan is established. The standard process plan is stored in computer files and then retrieved for
new workparts which belong to that family. Some form of parts classification and coding system is
required to organize the computer files and to permit efficient retrieval of the appropriate process plan
for a new workpart. For some new parts, editing of the existing process plan may be required. This is
done when the manufacturing requirements of the new part are slightly different from the standard.
The machine routing may be the same for the new part, but the specific operations required at each
machine may be different. The complete process plan must document the operations as well as the
sequence of machines through which the part must be routed. Because of the alterations that are made
in the retrieved process plan, these CAPP systems are sometimes also called by the name' 'variant
system."
Figure will help to explain the procedure used in a retrieval process planning system. The
user would initiate the procedure by entering the part code number at a computer terminal. The CAPP
program then searches the part family matrix file to determine if a match exists. If the file contains an
identical code number, the standard machine routing and operation sequence are retrieved from the
respective computer files for display to the user. The standard process plan is examined by the user to
permit any necessary editing of the plan to make it compatible with the new part design. After editing,
the process plan formatter prepares the paper document in the proper form.
If an exact match cannot be found between the code numbers in the computer file and the
code number for the new part, the user may search the machine routing file and the operation
sequence file for similar parts that could be used to develop the plan for the new part. Once the
process plan for a new part code number has been entered, it becomes the standard process for future
parts of the same classification.
GENERATIVE PROCESS PLANNING SYSTEMS
Generative process planning involves the use of the computer to create an individual process
plan from scratch, automatically and without human assistance. The computer would employ a set of
algorithms to progress through the various technical and logical decisions toward a final plan for
manufacturing. Inputs to the ~ tern would include a comprehensive description of the work part. This
may involve the use of some form of part code number to summarize the work part data, but does not
involve the retrieval of existing standard plans. Instead, the general CAPP system synthesizes the
design of the optimum process sequence, based an analysis of part geometry, material, and other
factors which would influence manufacturing decisions.
In the ideal generative process planning package, any part design could presented to the
system for creation of the optimal plan. In practice, cu generative- type systems are far from universal
in their applicability. They ter fall short of a truly generative capability, and they are developed for a
some limited range of manufacturing processes.
We will illustrate the generative process planning approach by means system called
GENPLAN developed at Lockheed-Georgia Company
The MRP processor operates on data contained in the MPS, the BOM file, and the inventory
record file. The master schedule specifies the period-by period list of final products required. The
BOM define what material and components are needed for each Product and inventory record files
gives the current and future inventory status of each product, component, and material. The MRP
processor computers how many of each component and raw material
Several complicating factors must be considered during the MRP computations. First the
quantities of component and subassemblies listed in the solution of Example 25.1 do not account for
any of those items that may already be stocked in inventory or are expected to be received as future
order. Accordingly, the computed quantities must be adjusted for any inventories on hand or on order,
a procedure called netting. For each time bucket, net requirements = gross requirements less on hand
inventories and less quantities on order.
Second, quantities of common use items must be combined during parts explosion to
determine the total quantities required for each component and raw material in the schedule. Common
use items are raw materials and components that are used on more than one product. MRP collects
these common use items from different products to achieve economics in ordering the raw materials
and producing the components.
Third, lead times for each item must be taken into account, The lead time for a job is the time
that must be allowed to complete the job from start to finish. There are two kinds of lead times in
MRP: ordering lead timed and manufacturing lead times. Ordering lead time for an item is the time
required from initiation of the purchase requisition to receipt of the item from the vendor. If the item is
raw material that is stocked by the vendor, the ordering lead time should be relatively short, perhaps a
few days or a few weeks. If the items is fabricated, the lead time may be substantial, perhaps several
form order release to completion, once the raw material for the item are available. The scheduled
delivery of end product must be translated into time-phased requirements for components and
materials by factoring in the ordering and manufacturing lead time.
Hardware components
Material handling system - means by which parts are moved between stations
Central control computer - to coordinate the activities of the components so as to achieve a
smooth overall operation of the system
Software and control functions
Human labor
2. INSPECTION
Inspection has become an essential part of any manufacturing system. It is the means of
rejecting nonconformities and assuring good quality products. The advent of technologically updated
inspection equipment helped to overcome the problems associated with traditional approaches.
Traditional approach used labor -intensive methods that resulted in the increase of manufacturing lead
time and production cost. Moreover, there is a significant delay in detecting an out of control limit.
Thus the products that are not conforming to the specified standards accrue to the additional cost of
scrap and rework.
New approach to quality control laid down conditions under which inspection should be carried out.
The new approach includes :
(i) Manual inspection method surrogated by 100% automated inspection.
(ii) Offline inspection performed later is replaced with online sensor systems to accomplish inspection
during or immediately after the manufacturing process.
(iii) Feedback control of the manufacturing operation in which process variable that determines
product quality are monitored rather than the product itself.
(iv) Statistical process control is ensured using software tools to track and analyze the sensor
measurement over time.
(v) Advanced inspection and sensor technologies, interfaced with computer based systems to automate
the operations of the sensor systems
The term inspection can be defined as the activity of examining the products, its components,
sub-assemblies, or materials out of which it is made, and to determine whether they adhere to design
specifications. The design specifications are prescribed by the product designer.
Inspection vs Testing
Quality control (QC) utilizes both inspection and testing procedures that are equally important
functional aspects of product whereas inspection is used to assess the quality and its design
specifications. The item tested in the QC testing is observed during actual operation or under
conditions that might be present during operation. For example, to know whether the product is
functioning properly, it is tested, by running it for a certain period of time.
Sometimes, testing procedures are of destructive nature, in which limited numbers of items are
sacrificed to ensure the quality of majority of items. Efforts are made to devise methods known as
nondestructive testing (NDT) and nondestructive evaluation (NDE) to save the expenses incurred
during destructive testing.
Automated inspection
In present scenario, manual inspection is largely replaced by automated inspection as errors are
reduced to great extent by automation of the process. Economic justification of an automated
inspection system depends on whether the savings in labour cost and improvement in accuracy
will be more than the investment and or development costs of the system.
Automated inspection is defined as the automation of one or more steps involved in the
inspection procedure. Automated or semi-automated inspection can be implemented in the
number of alternative ways.
Automated presentation of parts by an automatic handling system with manual examination
and decision steps.
Machine with manual loading parts into the machine doing, automated examination and
decision making.
Completely automated inspection system in which parts presentation, examination and
decisions are performed automatically.
3.Timing of Inspection
An important consideration in quality control is the determination of timings of the inspection
procedure. Three different options can be identified which are :
(a) off-line inspection,
(b) on-line/in-process, and
(c) on-line/post process inspection.
Off-line Inspection Methods
In off-line inspection, the inspection equipment is usually dedicated and does not make any physical
contact with machine tools. There is always a time delay between production and inspection. Manual
inspection is common that tend to promote the use of offline inspection that include:
(i) variability of the process is well within the design tolerance,
(ii) processing conditions are stable and the risk of significant deviation in the process is small, and
(iii) cost incurred during inspection is high in comparison to the cost of few defective parts.
The disadvantage of offline inspection is that the parts have already been made by the time
poor quality is detected. Sometimes by default a defective part may not be included into the
sample. A coordinate measuring machine (CMM) is an example of off-line inspection. CMM is
discussed in detail in the next section.
On-line/In-process and On-line/Post-process Inspection Methods
If the task of inspection is done as the parts are manufactured, then it is called as online inspection.
There are two variations of on-line inspection. If the inspection is performed during the manufacturing
operation, it is called on-line/in-process inspection. If the inspection is performed immediately
following the production process, it is called on-line/post-process inspection
(ii) The trigger actuates when there is an electrical contact between probe and metallic part
surface.
(iii) The trigger uses a piezoelectric sensor that generates a signal based on tension or
compression loading of the probe.
As contact exists between the probe and the surface of the object then with the help of
displacement transducer the coordinate position of the probe are accurately measured. Various
displacement transducers such as optical scales, rotary encoding, and magnetic scales etc are used in
CMM. Probe
On the basis of operating and controlling of CMM, it can be classified in the four following ways :
(i) manual drive,
contact with the part and the measurements are recorded in manual drive CMM. The three orthogonal
slides are designed to be nearly frictionless to permit the probe to be free floating in the x, y, and z-
directions. A digital readout provides the measurements that the operator can record either manually or
with paper printout. Only operator is allowed to carry out calculations on the data that includes the
enumeration of the center and hole diameter.
Data processing and computational capability for performing the calculations that are required
to evaluate a given part feature are provided by a CMM with manual drive CMM with computer-
assisted data processing. The different types of data processing and computations are ranging from
simple conversions between US customary units and metric to more complicated geometry
calculations, such as determining the angle between two planes. The probe is free floating and permits
the operator to bring it into contact with the desired part surfaces.
Electric motors are used in a motor driven CMM with the computer-assisted data processing to
drive the probe along the machine axes under the operator control. The motion is controlled by
joystick or similar devices. The collisions between the probe and the part are reduced by low-power
stepping motor and friction clutches.
CMM with direct computer control (DCC) operates just like a CNC machine tool. It is power
driven and the movements of the coordinate axes are controlled by a dedicated computer under
program control. Various data processing is performed by the computer and it also keeps record of the
measurements made during inspection. DCC CMM requires a part programming facility.
2. Explain Automation?
Category Description
Before examining the several facets of computer-aided design, let us first consider the
general design process. The process of designing something is characterized by Shigley as an iterative
procedure, which consists of six identifiable steps or phases:-
Recognition of need
Definition of problem
Synthesis
Analysis and optimization
Evaluation
Presentation
Synthesis and analysis are closely related and highly interactive 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 in a similar interactive manner.
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 drawings, material specifications, assembly lists, and so on. Essentially, the documentation requires
that a design database be created. Figure illustrates the basic steps in the design process, indicating its
iterative nature.
4. Benfits of CAD?
l. Improved engineering productivity
1. The Press-Pull tool will ________ the face of a solid model in the direction it faces.
A. taper
B. extrude
C. spiral
D. none of the above
Answer: Option B
2. The View toolbar will position the view of the 3-D solid toward the ________.
A. front
B. left side
C. SE isometric
D. all of the above
Answer: Option D
Answer: Option D
Answer: Option D
6. CAD programs which incorporate parametric modeling utilize a system in which the dimensions
control the ________.
A. size and shape of the model features
B. perspective of the model
C. shading used to render the model
D. all of the above
Answer: Option A
7. In order to create one solid model from two or more separate solid shapes the drafter will need to
position them and then ________.
A. use Union to join them
B. use the Join command
C. use the Add Parts tool
D. none of the above
Answer: Option A
Answer: Option A
9. When using SolidWorks, once an entity has been defined, it can only be changed by:
A. deleting it and starting over
B. changing the input value
C. editing
D. using the Cut Extrusion function
Answers:
1. B 2. D 3. C 4. D 5. D 6. A 7. A 8. A 9. C 10 a
7. Driverless trains, pallet trucks, unit load carriers are referred to ------------------------
8. Ease with which the system can be expanded to increase total production quantities is called----------
---------------------
9. EIA recommends the spindle speed be programmed in _ _ _ _ _ _ _ _ _ _ _ _
10. EIA standard feed rate code consists of letter F plus _ _ _ _ _ _ _ _ _ _ digits
Answer:
1. poly code 2. PFA 3. Fixed path 4. Overall 5. CUTTER 6. Self-guided 7. AGVS
8. Expansion Flexibility 9. rev/min 10. Five
UNIT-II
Two marks of questions with answers
1. What is hidden line removal?
Hidden line removal (HLR) is the method of computing which edges are not hidden by
the faces of parts for a specified view and the display of parts in the projection of a model into
a 2D plane.
creation of a component while work in the active part. Hence, the active part will be an
assembly part.
4. Define tolerance stack-up
Tolerance stack-up computations show the collective effect of part tolerance with
tolerances
to obtain total part tolerance, then evaluating that to the existing gap in order to see if the
design will work suitably.
5. Define Interference free matrix.
An interference-free matrix shows interference between two components, when one
component is moved, in a given assembly direction, into an assembled location, with another
component already in an assembled location. Assembly actions that result in interferences are
ferences are
The above figure illustrates the difference between geometry and topology. The
geometry that defines the object is the lengths of lines, areas of surfaces, the angles between
the lines, and the radius and the center of the cylinder and the height. On the other hand,
topology (sometimes called combinatorial structure), is the connectivity and associativity of
the object entities. It has to do with the notion of neighborhood and determines the relational
information between object entities. From a user point of view, geometry is visible and
topology is considered to be non-graphical relational information that is stored in solid model
databases and are not visible to users.
SOLID ENTITIES
There are various basic building blocks, so called, primitives that can be combined in
certain boolean operations to construct complex models. They include
Block
Cylinder
Cone
Sphere
Wedge
Torus
in which each edge occur just once; in turn each edge in the edge list points to the two vertices in the
vertex list defining the edge, and also to the one or two polygons to which the edge belongs).
To see why splines are important, lets consider the problem of designing an aircraft wing. Lets
assume that the Air Force is designing the latest and greatest jet fighter plane, and the wing is currently
being designed according to specifications that include and promote optimal behavior under extreme
turbulence due to mach speeds. To even complicate the design further, the wing has to look nice on the
rest of the jet so as to promote more military funding and generate recruits into the Air Force. There
are many different possible designs for a wing, some that are more optimal than others, and some that
are more aesthetically pleasing that others as well. To find a balance between optimizing the air flow
around the wing and how the shape looks is quite a task. Assume for a moment that your job as a
visualization specialist is to make use of the computer system that utilizes recorded data from an
aircraft testing facility.
Their system is able to relate the flow of turbulence around the wing of an aircraft to the shape
of the aircrafts wing. You are asked to create a piece of software using their model to allow an
efficient way for a designer to specify an optimal and aesthetically pleasing shape for the wing. The
relation between shape and turbulence is already completed, so it is your job to give global control to
the designer. Mainly, a way of specifying smooth curves on a computer screen is required, and splines
are the natural way of completing the task. In order to effectively represent a smooth curve on a
computer screen, we need to somehow approximate it. We come to this realization upon the simple
fact that a computer can only draw pixels, which have a predefined width and height.
If you get really close to an LCD screen and observe the tiny squares making up the outline of
at best. Rational Bezier Curves Now that we understand Bezier curves of degree k, we can consider
information than just a point {x, y, z} #3. The problem with just a regular point is that there is no
info on how to project it. Homogeneous coordinates exist in order to make the projective
transformation easier to work with [5]. The rational form has advantages in that it can represent a wide
range of curves, and surfaces (more on surfaces in a little while).
Curves could be in the form of circles, ellipses, parabolas, and hyperbolas; surfaces can be in
the form of spheres, ellipsiods, cylinders, cones, paraboloids, hyperboloids, and hyperbolic
paraboloids [1]. The only difference in Rational Bezier curves is that the coordinates that specify the
curve are in one dimension higher than their nonrational counterpart. For example, if we wish to
for the transition between regular and homogeneous coordinate space. Let h be a map from
homogenous coordinate space to regular space, then we define h as h(x, y, x, w)=(x/w, y/w, z/w)
5.Draw and explain CSG
OpenMOC uses constructive solid geometry (CSG) to represent complex reactor models in
software. The constructive solid geometry formulation is the method of choice for many advanced
modeling software packages, including some Computer-aided Design (CAD) implementations. CSG
allows complex spatial models to be built using boolean operations - such as intersections and unions -
of simple surfaces and building blocks termed primitives, as illustrated in Figure 1 [Wikipedia]. The
constructive solid geometry approach is well suited for reactor models which typically are highly
structured and contain repeating patterns. This is the case for commercial PWRs and BWRs whose
cores are built out of a rectangular lattice of fuel assemblies, each of which is a rectangular lattice of
fuel pins.
There are a number of benefits to using the CSG formulation. First, CSG enables simulation
codes to significantly reduce the memory footprint required to model the geometry. For example,
rather than representing each fuel pin explicitly in memory, a fuel pin primitive is represented by a
single data structure. A second major benefit to the CSG formulation is that it is a general and
extensible approach which allows for ray tracing routines to be written in an abstract fashion that is
independent of the primitives themselves. The constructive solid geometry formulation in OpenMOC
is predicated upon the use of several key objects which allow one to construct a spatial model from
simple primitives in a hierarchical fashion. The following sections describe each of these fundamental
objects in order of increasing complexity. The reader should note that the CSG formulation in
OpenMOC is presently only capable of describing the 2D -plane, though an extension to 3D
would be straightforward.
Section 4.1.1 develops the formulation for surfaces which are used to divide space into
separate unique halfspaces. Section 4.1.2 describes universes which represent the entirety of 2D (or
ure of cells. Section
4.1.3 describes cells which contain one or more surfaces that bound a subset of space filled by either a
material or a universe. Section 4.1.4 describes lattices which are used to create a bounded union of
universes through a series of coordinate transformations. A typical hierarchy for the way in which
surfaces, universes, cells and lattices are constructed to represent a reactor model in OpenMOC
.
Multiple choice questions with answers
1. When using SolidWorks, once an entity has been defined, it can only be changed by:
a. deleting it and starting over
b. changing the input value
c. editing
d. using the Cut Extrusion function
5. All of the following are processes (as opposed to input or output) in a manufacturing
business
a. Material
b. Planning
c. Documenting
d. Designing
6. All of the following operations can make use of the CAD database
a. Designing
b. Marketing
c. Producing
d. None of the above
10. Which of the following would be used to help determine the spacing between earpiece
and mouthpiece on a phone?
a. Dynamic analysis
b. Kinematic analysis
c. Finite Element analysis
d. Human Factors analysis
Answers:
1. Ability to change product composition while maintaining the same total production quantity is called
--------------------------------------:->
2. Ability to economically produce parts in high and low quantities is called--------------------------------
------------- :->
Answers
1. Product Mix Flexibility 2. Volume Flexibility 3. Mass production 4. Japanese industries 5. Enterprise
level 6. PFA 7. Rectangular 8.Agile manufacturing 9. Higher level language 10. Mass production
UNIT-III
Two marks of questions with answers
1. Define NC system?
NC is defined as a form of programmable automation in which the process iscontrolled
by alphanumeric data.
2. What is MCU?
MCU is a hardware system which reads, interprets and translates the programof
instructions into mechanical action of machine tool.
3. Define CNC?
CNC is defined as a NC system that utilizes a dedicated, stored computer program to
perform some or the entire basic NC functions.
4. Write any four application of NC system?
Application are in aero equipment; printed circuit boards; coil winding; automobile
parts; and blue print of complex shapes.
5. Define DNC?
Direct numerical control system is defined as a manufacturing system in which a
number of machine tools are controlled by a computer through direct connection and in real
time.
In manual programming, the machining instructions are prepared on a form called a part
program manuscript. The manuscript is a listing of the relative cutter/work piece positions which must
be followed to machine the part. In computer-assisted part programming, much of the tedious
computational work required in manual part programming is transferred to the computer. This is
especially appropriate for complex work piece geometries and jobs with many machining steps. Use
of the computer in these situations results in significant savings in part programming time.
Tape preparation
manual part programming, the punched tape is prepared directly from the part program manuscript on
a typewriter like device equipped with tape punching capability. In computer-assisted part
programming, the computer interprets the list of part programming instructions, performs the
necessary calculations to convert this into a detailed set of machine tool motion commands, and then
controls a tape punch device to prepare the tape for the specific NC machine.
Tape verification. After the punched tape has been prepared, a method isusually provided for
checking the accuracy of the tape. Some times the tape is checked by running it through a computer
program which plots the various tool movements (or table movements) on paper. In this way, major
errors in the tape can be discovered. The "acid test" of the tape involves trying it out on the machine
tool to make the part. A foam or plastic material is sometimes used for this tryout. Programming errors
are not uncommon, and it may require about three attempts before the tape is correct and ready to use.
Production. The final step in the NC procedure to use the NC tape in production. This involves
ordering the raw workparts specifying and preparing the tooling and any special fixturing that may be
required, and setting up The NC machine tool for the job. The machine tool operator's function during
production is to load the raw workpart in the machine and establish the starting position of the cutting
tool relative to the workpiece. The NC system then takes over and machines the part according to the
instructions on tape. When the part is completed, the operator removes it from the machine and loads
the next part.
to fabricate workpieces 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 workpiece
would not be possible. An example of a straight-cut operation is shown in Figure
Straight-cut system
Contouring NC
Contouring is the most complex, the most flexible, and the most expensive type of machine
tool control. It is capable of performing both PTP and straight-cut operations. In addition, the
distinguishing feature of contouring NC systems is their capacity for simultaneous control of more
than one axis movement of the machine tool. The path of the cutter is continuously controlled to
generate the desired geometry of the workpiece. For this reason, contouring systems are also called
continuous-path NC systems.
Straight or plane surfaces at any orientation, circular paths, conical shapes, or most any other
mathematically definable form are possible under contouring control. Figure illustrates the versatility of
continuous path NC.
4. Write down the application of the numerical control
APPLICATIONS OF NUMERICAL CONTROL
Numerical control systems are widely used in industry today, especially in the metalworking
industry. By far the most common application of NC is for metal cutting machine tools. Within this
category, numerically controlled equipment has been built to perform virtually the entire range of
material removal processes, including:
Milling, Drilling and related processes Boring, Turning, Grinding, Sawing
Within the machining category, NC machine tools are appropriate for certain jobs and
inappropriate for others. Following are the general characteristics of production jobs in metal
machining for which numerical control would be most appropriate:
Parts are processed frequently and in small lot sizes.
It has been estimated that most manufactured parts are produced in lot sizes of 5O or fewer. Small-lot
and batch production jobs represent the ideal situations for the application of NC. This is made
possible by the capability to program the NC machine and to save that program for subsequent use in
future orders. If the NC programs are long and complicated (complex part geometry, many operations,
much metal removed), this makes NC all the more appropriate when compared to manual methods of
production. If engineering design changes or shifts in the production schedule are likely, the use of
tape control provides the flexibility needed to adapt to these changes. Finally, if quality and inspection
are important issues (close tolerances, high part cost, lOO% inspection required), NC would be most
suitable, owing to its high accuracy and repeatability.
In order to justify that a job be processed by numerical control methods, it is not necessary that
the job possess every one of these attributes. However, the more of these characteristics that are
present, the more likely it is that the part is a good candidate for NC.
In addition to metal machining, numerical control has been applied to a variety of other operations.
The following, although not a complete list, will give the reader an idea of the wide range of potential
applications of NC Press working machine tools Welding machines Inspection machines Automatic
In a University of Michigan survey reported by Smith and Evans, a comparison was made
between the machining cycle times for conventional machine tools versus the cycle times for NC
machines. NC cycle times, as a percentage of their conventional counterparts, ranged from 35% for
five-axis machining centers to 65% for presswork punching. The advantage for numerical control
tends to increase with the more complex processes.
Reduced fixturing. NC requires fixtures which are simpler and less costly to fabricate because the
positioning is done by the NC tape rather than the jig or fixture
Reduced manufacturing lead time. Because jobs can be set up more quickly with NC and fewer setups
are generally required with NC, the lead time to deliver a job to the customer is reduced.
Greater manufacturing flexibility. With numerical control it is less difficult to adapt to engineering
design changes alterations of the production schedule, changeovers in jobs for rush orders, and so on.
Improved quality control. NC is ideal for complicated workparts where the chances of human mistakes
are high. Numerical control produces parts with greater accuracy, reduced scrap, and lower inspection
requirements. Reduced inventory. Owing to fewer setups and shorter lead times with numerical control,
the amount of inventory carried by the company is reduced.
Reduced floor space requirements. Since one NC machining center can often accomplish the
production of several conventional machines, the amount of floor space required in an NC shop is
usually less than in a conventional shop.
Disadvantages of NC
Along with the advantages of NC, there are several features about NC which must be
considered disadvantages:
Higher investment cost. Numerical control machine tools represent a more sophisticated
and complex technology. This technology costs more to buy than its non-NC counterpart. The higher
cost requires manufacturing managements to use these machines more aggressively than ordinary
equipment.
High machine utilization is essential on order to get reasonable returns on investment. Machine shops
must operate their NC machines two or three sifts per day to achieve this high machine utilization.
Higher maintenance cost. Because NC is a more complex technology and because NC machines are
used harder, the maintenance problem becomes more acute. Although the reliability of NC systems
has been improved over the years, maintenance costs for NC machines will generally be higher than
for conventional machine tools.
Finding and/or training NC personnel. Certain aspects of numerical control shop operations
require a higher skill level than conventional operations. Part programmers and NC maintenance
personnel are two skill areas where available personnel are in short supply. The problems of finding,
hiring, and training these people must be considered a disadvantage to the NC shop
PREPARATORY WORD (g-words): This word is used to prepare the controller for
instructions that are to follow. For example, the word gO2 is used to prepare the C controller unit for
circular interpolation along an arc in the clockwise direction. The preparatory word l& needed S9 that
the controller can correctly interpret the data that follow it in the block.
COORDINATES (x-, y-, and z-words): These give the coordinate positions of the tool. In a
two-axis system, only two of the words would be used. In a four- or five- axis machine, additional a-
words and V or b-words would specify the angular positions.
Although different NC systems use different formats for expressing a coordinate, we will adopt the
convention of expressing it in the familiar decimal form: For example, x + 7.235 ory-O.5ao. Some
formats do not use the decimal point in writing the coordinate. The + sign to define a positive
coordinate location is optional. The negative sign is, of FEED RATE (f-word): This specifies the feed
in a machining operation. Units are inches per minute (ipm) by convention.
CUTTING SPEED (s-word): This specifies the cutting speed of the process, the rate at which the
spindle rotates.
TOOL SELECTION (t-word): This word would be needed only for machines with a tool turret or
automatic tool changer. The t-word specifies which tool is to be used in the operation. For example,
tO5 might be the designation of a l/2-in. drill bit in turret position 5 on an NC turret drill.
MSCELLANEOUS FUNCTION (m-word): The m-word is used to specify certain miscellaneous or
auxiliary functions which may be available on the machine tool.
1) Arrange the below operations in operator controlled machine tool in correct order.
(A) Operator
(B) Process planing
(C) Machine tool
(D) Component drawing
(E) Completed component
2) The device, fed to the control unit of NC machine tool which sends the position command signals
to sideway transmission elements of the machine, is called as
a. controller
b. tape
c. feedback unit
d. none of the above
3) In NC (Numerical Control) machine tool, the position feedback package is connected between
a. The control unit of NC machine tool works in ON-line mode and the control unit of CNC machine
tool works in batch processing mode
b. The control unit of NC machine tool works in batch processing mode and the control unit of CNC
machine tool works in ON-line mode
c. The control units of both NC and CNC machines work in ON-line mode
d. The control units of both NC and CNC machines work in batch processing mode
5) In CNC machine tool, the part program entered into the computer memory
1. CNC control unit does not allow compensation for any changes in the dimensions of cutting tool
2. CNC machine tool are suitable for long run applications
3. It is possible to obtain information on machine utilization which is useful to management in CNC
machine tool
4. CNC machine tool has greater flexibility
5. CNC machine can diagnose program and can detect the machine defects even before the part is
produced
Answers:
1. Mono code 2. Chain type code symbol 3. FINI 4. Controlling throughout enterprise. 5. Drive Surface
6. Bar code 7. Cutter radius 8. Minimum inventory 9. Plain surfaces Mixed Code
UNIT-IV
Two marks of questions with answers
Because of the problems encountered with manual process planning, attempts have
been made in recent years to capture the logic, judgment, and experience required for this
important function and incorporate them into computer programs. Based on the characteristics
of a given part, the program automatically generates the manufacturing operation sequence. A
computer-aided process planning (CAPP) system offers the potential for reducing the routine
clerical work of manufacturing engineers. At the same time, it provides the opportunity to
generate production routings which are rational, consistent, and perhaps even optimal. Two
alternative approaches to computer-aided process planning have been developed. These are:
Retrieval-type CAPP systems (also called variant systems)
Second, quantities of common use items must be combined during parts explosion to
determine the total quantities required for each component and raw material in the schedule.
Common use items are raw materials and components that are used on more than one product.
MRP collects these common use items from different products to achieve economics in
ordering the raw materials and producing the components.
MICLASS stands for Metal Institute Classification System and was developed by TNO, the
Netherlands Organization for Applied Scientific Research. It was started in Europe about five years
before being introduced in the United States in l974. Today, it is marketed in the United States by the
Organization for Industrial Research in Waltham, Massachussets. The MICLASS system was
developed to help automate and standardize a number of design, production, and management
functions. These include:
Standardization of engineering drawings
Selection of parts for processing on particular groups of machine tools Machine tool investment
analysis
The MICLASS classification number can range from l2 to 3O digits. The first l2 digits are a universal
code that can be applied to any part. Up to l8 additional digits can be used to code data that are
specific to the particular company or industry. For example, lot size, piece time, cost data, and
operation sequence might be included in the l8 supplementary digits.
The CODE system
The CODE system is a parts classification and coding system developed and marketed by
Manufacturing Data Systems, Inc. (MDSI), of Aim Arbor, Michigan. Its most universal application is
in design engineering for retrieval of part design data, but it also has applications in manufacturing
process planning, purchasing, tool design, and inventory control.
The CODE number has eight digits. For each digit there are l6 possible values (zero through
9 and A through F) which are used to describe the part's design and manufacturing characteristics. The
initial digit position indicates the basic geometry of the part and is called the Major Division of the
CODE system. This digit would be used to specify whether the shape was a cylinder, flat piece, block,
or other. The interpretation of the remaining seven digits depends on the value of the first digit, but
these remaining digits form a chain-type structure. Hence the CODE system possesses a hybrid
structure.
steps describing each operation and identifying each work center. In any case, it is traditionally the
task of the manufacturing engineers or industrial engineers in an organization to write these process
plans for new part designs to be produced by the shop. The process planning procedure is very much
dependent on the experience and judgment of the planner. It is the manufacturing engineer's
responsibility to determine an optimal routing for each new part design. However, individual
engineers each have their own opinions about what constitutes the best routing. Accordingly, there are
differences among the operation sequences developed by various planners. We can illustrate rather
dramatically these differences by means of an example.
In one case cited, a total of 42 different routings were developed for various sizes of a
relatively simple part called an "expander sleeve." There were a total of 64 different sizes and styles,
each with its own part number. The 42 routings included 2O different machine tools in the shop.
The reason for this absence of process standardization was that many different individuals
had worked on the parts: 8 or 9 manufacturing engineers, 2 planners, and 25 NC part programmers.
Upon analysis, it was determined that only two different routings through four machines were needed
to process the 64 part numbers. It is clear that there are potentially great differences in the perceptions
among process planners as to what constitutes the "optimal" method of production.
In addition to this problem of variability among planners, there are often difficulties in the
conventional process planning procedure. New machine tools in the factory render old routings less
than optimal. Machine breakdowns force shop personnel to use temporary routings, and these become
the documented routings even after the machine is repaired. For these reasons and others, a significant
proportion of the total number of process plans used in manufacturing are not optimal.
4. Draw and explain Retrieval type CAPP system and Generative CAPP system?
RETRIEVAL - TYPE PROCESS PLANNING SYSTEMS
Retrieval-type CAPP systems use parts classification and coding and group technology as a
foundation. In this approach, the parts produced in the plant aregrouped into part families,
distinguished according to their manufacturing characteristics. For each part family, a standard
process plan is established. The standard process plan is stored in computer files and then retrieved for
new workparts which belong to that family. Some form of parts classification and coding system is
required to organize the computer files and to permit efficient retrieval of the appropriate process plan
for a new workpart. For some new parts, editing of the existing process plan may be required. This is
done when the manufacturing requirements of the new part are slightly different from the standard.
The machine routing may be the same for the new part, but the specific operations required at each
machine may be different. The complete process plan must document the operations as well as the
sequence of machines through which the part must be routed. Because of the alterations that are made
in the retrieved process plan, these CAPP systems are sometimes also called by the name' 'variant
system."
Figure will help to explain the procedure used in a retrieval process planning system. The
user would initiate the procedure by entering the part code number at a computer terminal. The CAPP
program then searches the part family matrix file to determine if a match exists. If the file contains an
identical code number, the standard machine routing and operation sequence are retrieved from the
respective computer files for display to the user. The standard process plan is examined by the user to
permit any necessary editing of the plan to make it compatible with the new part design. After editing,
the process plan formatter prepares the paper document in the proper form.
If an exact match cannot be found between the code numbers in the computer file and the
code number for the new part, the user may search the machine routing file and the operation
sequence file for similar parts that could be used to develop the plan for the new part. Once the
process plan for a new part code number has been entered, it becomes the standard process for future
parts of the same classification.
Generative process planning involves the use of the computer to create an individual process
plan from scratch, automatically and without human assistance. The computer would employ a set of
algorithms to progress through the various technical and logical decisions toward a final plan for
manufacturing. Inputs to the ~ tern would include a comprehensive description of the work part. This
may involve the use of some form of part code number to summarize the work part data, but does not
involve the retrieval of existing standard plans. Instead, the general CAPP system synthesizes the
design of the optimum process sequence, based an analysis of part geometry, material, and other
factors which would influence manufacturing decisions.
In the ideal generative process planning package, any part design could presented to the
system for creation of the optimal plan. In practice, cu generative- type systems are far from universal
in their applicability. They after fall short of a truly generative capability, and they are developed for a
some limited range of manufacturing processes.
showing how it is derived from the corresponding aggregate plan in the 2nd table. The master
production capacity.
Master Production Schedule
Products included in the MPS divide into 3 categories: (1) firm customer orders, (2) forecasted
demand, & (3) spare parts. Proportions in each category vary for different companies, & in some cases
one or more categories are omitted. Companies producing assembled products will generally have to
handle all three types. In the case of customer orders for specific products, the company is usually
obligated to deliver the item by a particular date that has been promised by the sales department. In
the second category, production output quantities are based on statistical forecasting techniques
applied to previous demand patterns, estimates by the sales staff, & other sources. For many
companies forecasted demand constitutes the largest portion of the master schedule. The third
category consists of repair parts that e
sent directly to the customer. Some companies exclude this third category from the master schedule
since it does not represent end products.
The MPS is generally considered to be a medium-range plan since it must take into account the
lead times to order raw materials & components, produce parts in the factory, & then assemble the end
products. Depending on the product, the lead times can range from several weeks to many months; in
some cases, more than a year. The MPS is usually considered to be fixed in the near term. This means
that changes are not allowed within about a six week horizon because of the difficulty in adjusting
production schedules within such a short period. However, schedule adjustments are allowed beyond
six weeks to cope with changing demand patterns or the introduction of new products. Accordingly,
we should note that the aggregate production plan is not the only input to the master schedule. Other
inputs that may cause the master schedule to depart from the aggregate plan include new customer
orders & changes in sales forecast over the near term.
Answers:
1.c 2.c 3.b 4.d 5.c 6.b 7.d 8.b 9.a 10.c
Fill in the blanks questions with answers
1. _ _ _ _ _ _ _ _ can be defined as computer based system for planning, scheduling and controlling
materials resources and supporting activities needed to meet the MPS :->Manufacturing resource
planning
2. _ _ _ _ _ _ _ is a computational technique that converts the Master schedule for end products intoa
detailed schedule for raw materials and components used in end products. :->Material Requirement planning
4. _ _ _ _ contains data on current and future inventory status of each component. :->Inventory
record file
10. A process plan that can be used by a family of component is called _ _ _ _ _ _ _ _ _ _ :->
Answers:
UNIT-V
Two marks of questions with answers
1. What is FMS?
FMS is a manufacturing system based on multi-operation machine tools, incorporating
(automatic part handling and storage).
2. What is Process planning?
Process planning consists of preparing a set of instructions that describe how to
fabricate a part or build an assembly which will satisfy engineering design specifications.
Process planning is the systematic determination of the methods by which product is to be
manufactured, economically and competitively.
3. Which is ideal state in computer based manufacturing applications?
Computer Integrated Manufacturing (CIM) is an ideal state in which computer based
manufacturing applications communicate information to coordinate design, planning and
manufacturing processes.
4. What is the role of process planning in CIM architecture?
The process planning function can ensure the profitability or non profitability of a part
being manufactured because of the myriad ways in which apart can be produced.
(ii) Offline inspection performed later is replaced with online sensor systems to
accomplish inspection during or immediately after the manufacturing process.
(iii) Feedback control of the manufacturing operation in which process variable that
determines product quality are monitored rather than the product itself.
(iv) Statistical process control is ensured using software tools to track and analyze
the sensor measurement over time.
(v) Advanced inspection and sensor technologies, interfaced with computer based
systems to automate the operations of the sensor systems
(vi) The term inspection can be defined as the activity of examining the products,
its components, sub-assemblies, or materials out of which it is made, and to
determine whether they adhere to design specifications. The design
specifications are prescribed by the product designer.
4. Give short notes on CMM:
contact with the part and the measurements are recorded in manual drive CMM. The three
orthogonal slides are designed to be nearly frictionless to permit the probe to be free floating in
the x, y, and z-directions. A digital readout provides the measurements that the operator can
record either manually or with paper printout. Only operator is allowed to carry out
calculations on the data that includes the enumeration of the center and hole diameter.
Data processing and computational capability for performing the calculations that are
required to evaluate a given part feature are provided by a CMM with manual drive CMM with
computer-assisted data processing. The different types of data processing and computations
are ranging from simple conversions between US customary units and metric to more
complicated geometry calculations, such as determining the angle between two planes. The
probe is free floating and permits the operator to bring it into contact with the desired part
surfaces.
5. Write down the benefits of CIM:
1. Increased machine utilization
2. Reduced direct and indirect labor
3. Reduce mfg. lead time
4. Lower in process inventory
5. Scheduling flexibility
CIM refers to a production system that consists of:
1. A group of NC machines connected together by
2. An automated materials handling system
3. And operating under computer control
The main benefit is the enhancement of production efficiency, whereby downtime is reduced
because the need to shut down the production line to set up for a different product is
eliminated. One disadvantage of FMS is its higher up-front cost and the time required to
carefully preplan the system specifications. Another possible drawback is the higher cost
associated with the need for specialized labor to run, monitor and maintain the FMS; however,
since the FMS is meant to increase production automation (i.e., reduce labor input), the result
is typically a net benefit in terms of cost. Common FMS layouts take the form of line, loop,
ladder, and open field.
FMScomponents
BASIC COMPONENTS OF FMS Workstations- They are typically CNC machine tools that
perform machining operation on families of parts. Automated Material Handling and Storage system-
They are used to transport work parts and subassembly partsbetween the processing stations,
sometimes incorporating storage into function. The processing or assembly equipment used in an
FMS depends on the type of work accomplished by the system.
In a system designed for machining operations, the principle types of processing station are CNC
machine tools. However, the FMS concept is also applicable to various other processes as well.
Following are the types of workstations typically found in an FMS.
Load/Unload Stations. The load/unload station is the physical interface between the FMS and the rest
of the factory. Raw work-parts enter the system at this point, and finished parts exit the system from
here. Loading and unloading can be accomplished either manually or by automated handling systems.
Manual loading and unloading is prevalent in most FMSs today. The load/unload station should be
ergonomically designed to permit convenient and safe movement of work parts. For parts that are too
heavy to lift by the operator, mechanized cranes and other handling devices are installed to assist the
operator.
A certain level of cleanliness must be maintained at the workplace. and air hoses or other washing
facilities are often required to flush away chips and ensure clean mounting and locating points. The
station is often raised slightly above floor level using an open-grid platform to permit chips and cutting
fluid to drop through the openings for subsequent recycling or disposal
TYPES OF FMS
performing unattended operations within a time period lengthier than one complete machine cycle. It
is skilful of dispensing various part mix, reacting to fluctuations in manufacture plan, and inviting
introduction of a part as a new entry. It is a sequence dependent production
manufacturing cell (FMC). It entails two or three dispensing workstations and a material handling
system. The material handling system is linked to a load/unload station. It is a simultaneous production
(typically CNC machining centers or turning centers) connected mechanically by a common part
handling system and automatically by a distributed computer system. It also includes non-processing
work stations that support production but do not directly participate in it e.g., part / pallet washing
stations, co-ordinate measuring machines. These features significantly differentiate it from Flexible
2. Which materials-processing technology gives the advantage of precision, accuracy and optimum use
of cutting tools, which maximise their life and higher labour productivity?
3. Before automating solely in search of cost savings, which one of the following is NOT a valid
consideration:
a) Is it worth getting rid of the human potential along with its cost?
b) Can the technology perform the task better (in a broader sense) or safer than a human?
c) What support activities does the technology need in order to function effectively?
d) Which is the most appropriate technology?
5. Technology that is peripheral to the actual creation of goods and services is sometimes called:
a) Complementary process technology
b) Indirect process technology
c) Focused process technology
d) Direct process technology
6. Which of the following is not true of computer numerically controlled (CNC) machines?
a) They give more accuracy and precision to the process.
b) They can give better productivity to the process.
c) They can eliminate operator error.
d)
7. What classification is given to robots which grip tools, for example, in various types of
metalworking operations, joining of materials, and surface treatment.
a) Process robots
b) Assembly robots
c) Tooling robots
d) Handling robots
8. What is the name of a system which brings together several technologies into a coherent system?
9. Which of the following process technologies is associated with low volume and high variety?
a) Dedicated systems
b) Flexible transfer lines
c) CNC Machines
d) Flexible manufacturing systems
10.Which of the following is not an advantage of industrial robots?
a) Can be used in hazardous conditions.
b) Gives greater accuracy and repeatability.
c) Can be used in hazardous conditions.
d) Flexibility in routing.
Answers:
4. _ _ _ _ _ _ _ _ _ _ _ _ _systems are designed to fill the gap between high production transfer
linesand low production NC Machines
5. _ _ _ _ _ _ layout type is generally appropriate for processing a large family of parts
7. _ _ _ _ _ _ _ _ _ _ _ _ is used to compute the raw material and component requirements for endproducts listed in
Master schedule
8. _ _ _ _ _ _ _ _ _ _ _ _ storage system used for batch and job shop production
9. _ _ _ _ _ _ _ _ _ _ _ _file contains the list of work stations through which each work part must
beprocessed in CIM.
10. _ _ _ _ _ _ _ _ _ _ _ station is, where loads are transferred into and out of AS/RS
Answers
1) CAPP 2) FMS 3) Production flow Analysis 4) FMS 5) Open Field 6) Part family