AMT 2-marks, ALL.rtf

8/9/2019 AMT 2-marks, ALL.rtf

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ADVANCED MANUFACTURING TECHNOLOGY 2- MARKS QUESTION AND

ANSWER

UNIT-I

1. What is the need for unconventional machining processes? High production rateLow cost of productionBetter surface integrity,

High surfacenish

2. What are the characteristics of UCM processes? erformance is independent of strength !arrier Use di"erent #inds of energy in direct form $n general, low M%% !ut !etter &uality products

Comparatively high initial investment cost

3. 'i"erentiate the conventional and unconventional machining processesin terms of principles(

$n conventional processes, the material is removed in the form of chips!y the advancing cutting tool that plastically deforms )shearing* the materialahead(

$n the case of the UCM processes,energy )+lectrical, Chemical, hermo-+lectric, Mechanical* in its direct form is utili.ed for the material removal andso there is no physical contact !etween the wor#piece and tool(

4. What are the various types of energy sources used in non-traditional machining

techni&ues? /ive e0amples for each(

-neumatic pressure- 12M-Hydraulic pressure- W2M, U3M, 1W2M-Corrosion- CHM, CHB, CM-High current density in electrolytes- +CM-High voltage- +'M )for spar#ing*4-$BM, +BM )ioni.ing*4-LBM)creating avalanche in la.ing medium*4-1M )for ioni.ing the plasma gases*

5. Classify the di"erent types of unconventional machining processes

!ased on the mechanical energy(1!rasive 2et Machining )12M*Water 2et Machining )W2M*Ultrasonic Machining )U3M*1!rasive Water 2et Machining )1W2M*

6. $dentify the mechanism of material removal, transfer media and energysource for +'M(

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%emoval- 6usion of materials !y arcs

ransfer media - +lectron stream

+nergy source - High voltage

7. $dentify the mechanism of material removal, transfer media andenergy source for +CM( Mechanism of material removal- $ondisplacement

ransfer media - +lectrolyte

+nergy source - High current

8. $dentify the mechanism of material removal, transfer media andenergy source for +BM( Mechanism of material removal-7apori.ation

ransfer media - +lectron stream


9. $dentify the mechanism of material removal, transfer media andenergy source for LBM( Mechanism of material removal-7apori.ation

ransfer media - 1mplied coherent light radiation


10. $dentify the mechanism of material removal, transfer media andenergy source for 1M( Mechanism of material removal-7apori.ation

ransfer media - $onised gas stream


11. $dentify the mechanism of material removal, transfer media andenergy source for U3M( Mechanism of material removal-+rosion

ransfer media - High velocity particles

+nergy source - Hydraulic pressure

12. $dentify the mechanism of material removal, transfer media andenergy source for 12M( Mechanism of material removal-+rosion

ransfer media - High velocity particles

+nergy source - neumatic pressure13. $dentify the mechanism of material removal, transfer media and

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energy source for W2M( Mechanism of material removal-+rosion

ransfer media - High velocity water 9et

+nergy source - Hydraulic pressure

1. What is the principle !ehind a!rasive 9et machining?

1 9et of inert gas consisting of very ne a!rasive particles stri#es thewor# piece at high velocity )usually !etween 8::-;:: mciency4 1lso the

cutting capacity decreases after the rst application( 6urther, cost of the

a!rasive is also low(

!. Why is 12M not suita!le for soft materials?1!rasive particles used in 12M can penetrate and em!ed with softmaterials(

6. ame the a!rasive materials that are used for the 12M( he common a!rasives used for the 12M process are=

'olomite

3odium Bicar!onate /lass !eads 3ilicon car!ide 3ilicon itride 1lumina

7. Mention the a!rasives used for di"erent applications

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A"#$%&'( A))*&+$,&

1luminium o0ideCleaning, cutting andde!urring

3ilicon car!ide1s a!ove !ut for hardermaterials

/lass !eads Matt polishing, cleaning

Crushed glass eening, cleaning

3odium !icar!onateCleaning, cutting for softmaterials

8. ame di"erent gases used in 12M( Which of this is most widely used? 'ry air Car!on-di-o0ide itrogen Helium

1ir is most widely used owing to easy availa!ility and little cost(

9. What is the e"ect of the grain si.e on the material removal rate )M%%*in the 12M?

6iner grain si.es are less irregular in shape, and hence, posses lessercutting a!ility( Moreover, ner grains tend to stic# together and cho#ethe no..le( he most favoura!le grain si.es range from 5: to A: m(Larger particle si.es remove the material faster(

10. What is the e"ect of 9et velocity on the M%% in 12M?

he #inetic energy of the a!rasive 9et is utilised for metal removal !yerosion( he 9et velocity is a function of the no..le pressure, no..le

design, a!rasive grain si.e and the mean num!er of a!rasives per unit

volume of the carrier gas( $n general with increase in the 9et velocity,

the M%% increases(

12. What is the e"ect of the a!rasive powder ow rate on the M%% in

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12M?

$ncreasing the ow rate increases the removal rate !ecause more

a!rasive particles are availa!le for cutting( However as the powder

ow rate is increased, the mass fraction of a!rasive in the 9et is also

increasing( 1s the mass fraction increases, the a!rasive velocity

decreases, thus reducing the removal rate(

13. What are common materials used for the no..le in 12M?3apphire and tungsten car!ide are the common materials for theno..le(

1. Why are mas#s used in 12M? Which material is used for fa!rication ofmas#s?

Mas#s are used to control over spray or to produce large holes andintricate detail without having to move the no..le and trace the

shape( Mas#s can !e fa!ricated from ru!!er or metal, each havingits advantage and disadvantage( While the ru!!er mas#s are easy tofa!ricate, they give poor edge denition( he metal mas#s givemuch !etter denition !ut erode faster

15. Mention the process capa!ilities )process characteristics* of 12M Low M%% $ntricate details can !e produced arrow slots Low tolerances Minimi.ation of taper

hin-sectioned, !rittle material, inaccessi!le areas 1lmost no surface damage

16. What are the advantages and limitations of 12M?

Advantages:

Machining of very hard materials

Heat sensitive materials can !e machined the gas streamdissipates generated heat when cutting heat-sensitivematerials

6ragile materials can !e machined the small loadstransmitted to the wor#piece allow the cutting of fragilepieces

7ery low capital cost and low power consumption o part shatter or vi!ration he no..le can !e directed towards small, di>cult-to-reach

areas

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Limitations: Low material removal rate 3tray cutting can occur and hence accuracy is not good

+0cessive taper on deep cuts may also !e a disadvantage,although the amount of taper can !e reduced !y tilting theno..le

3hort no..le stando" when used for cutting ossi!ility of a!rasive particles !ecoming em!edded in the

wor#piece o..le wear rate is high rocess tends to pollute the environment

17. Mention some typical applications of 12M in engineering( %emoving ash and parting lines from in9ection moulded parts 'e!urring and polishing plastic, nylon and teon components Cleaning metallic mould cavities which otherwise may !e

inaccessi!le Cleaning o0ides from metal surfaces Cleaning metallic smears from ceramics

13. lease identify the principle of +CM( How does it di"er fromelectroplating?

rinciple of +CM - electrolysis( When a '(C potential is applied across two

electrodes separated !y a small gap and an electrolyte is pumped through

the small gap, the constituents of the anode wor# piece material goes into

the solution and not plate on the cathode tool( +lectroplating is thereverse of +CM where the cathode is plated !y the depleted metal from

the anode(

1. What is 6aradayDs rst law?

he amount of chemical changes produced !y an electric current )or theamount of su!stance deposited or dissolved* is proportional to the&uantity of electricity passed(

1!. What is 6aradayDs second law?

he amount of di"erent su!stances deposited or dissolved !y the same&uantity of electricity are proportional to their chemical e&uivalentweights(

1/. +0plain the parameters controlling the M%% in +CM( )%ef( ((%ao andBenedict*

M%% in +CM is primarily controlled !y current density( When all other

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varia!les are held constant, the tool penetration rate is directly

proportional to the current density( Current density is not only controlled

!y the amount of current !ut also !y the si.e of the gap !etween the tool

and the wor#piece(

6eed rate= a high feed rate results in a higher M%%( $t also decreasesthe e&uili!rium machining gap resulting in improvement of the surfacenish and tolerance control

he velocity and the electrolyte ow through the gap is also animportant parameter a"ecting the surface nish and removal rate

17. What are the various process parameters of +CM?

he process parameters that have a control on the performance of the

+CM process is= 6eed rate, current density, voltage, electrolyte

concentration )low concentration of the electrolyte decreases the

machining gap and results in a !etter surface nish and ner tolerance

control* and electrolyte temperature )low temperature of the electrolyte isconducive to a !etter surface nish and tolerances*, velocity and ow of

electrolyte(

18. What are the various process characteristics of the +CM? Material %emoval %ate the M%%s with +CM are su>ciently large and

compara!le with that of the conventional methods( M%% of 5Em@


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21. What are the di"erent types +CM operations?

+lectro Chemical Milling )+CM* +lectro Chemical/rinding )+C/* +lectro ChemicalHoning)+CH*+lectroChemical'e!uringC'* +lectrochemicalturning )+C* +lectro chemical trepanning )+Cr* etc(,

22. +numerate some typical e0amples where +CM process can !ee"ectively adopted(

'eep hole drilling having L


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+C/ is a process that com!ines the +CM with the mechanical grindingoperation to remove material( $t uses a grinding wheel with an electricallyconductive a!rasive !onding agent(

Applications:

3ingle largest use for +C/ is in the manufacturing andremanufacturing of tur!ine !lades and vanes for aircraft tur!ineengines /rinding of tungsten car!ide tool inserts %e-proling worn locomotive traction motor gears Burr-free sharpening of hypodermic needles Machining of fragile or very hard and tough material honeycom!, thin walled tu!es and s#ins High M%%Ds when grinding hard, tough, stringy, wor#-hardena!le

or heat sensitive materials

28. +0plain the di"erence !etween the +C/ and conventional grinding?

$n +C/, there is a grinding wheel similar to a conventional grinding wheel

e0cept that the !onding material is electrically conductive(

Conventional grinding produces components with good surface nish

and dimensional tolerances !ut such components are also associated with

!urrs, comparatively large heat a"ected .one )H1I*, and thermal residual

stresses( hese defects are not found in electrochemically ground

wor#pieces(

29. What are the advantages of +C/ over conventional grinding?

Higher M%% %educe cost of grinding )higher cost of e&uipment compensated !y

higher M%%, reduced consumption of e0pensive diamond wheels* %educed heating of wor#piece resulting in less thermal damage 1!sence of !urrs on the nished surface $mproved surface nish with no grinding scratches %educed pressure of wor# against the wheel and so delicate parts

can !e manufactured without distortion

30. $dentify any two advantages and limitations of electrochemicalgrinding )+C/* Advantages

• o thermal damage to wor#piece• +limination of grinding !urn• 1!sence of wor# hardening• Long-lasting wheels less truing• Higher M%%4• 3ingle pass grinding - reduced cost of grinding4• 1!sence of !urrs on the nished surface4• $mproved surface nish with no grinding scratches4

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• %educed pressure of wor# against the wheel no distortion4• $n +C/, the +CM action is e>cientLimitations High capital cost < Higher cost of grinding wheel4 Corrosive environment High preventive maintenance cost olerance achieved are low4 'i>cult to optimi.e due to the comple0ity of the process4 on-conductive materials cannot !e machined ot economical for soft materials noncompetitive removal rates

compared toconventional methods for readily machina!le metals

%e&uires disposal and ltering of electrolytes

Applications: the process is easily adapta!le to cylindrical parts fortrueing the inside surfaces(

35. What are the functions served !y the electrolyte in the +CM process?

Medium for current to ow a#es away heat generated

%emoves reaction products

36. What is the principle of +'M?

+'M process involves a controlled erosion of electrically conductive

materials !y the initiation of rapid and repetitive spar# discharges

!etween the tool and wor#piece separated !y a small gap( he controlled

pulsing of the direct current !etween the tool and the wor#piece produces

the spar# discharge( Heat transfer from the spar# to !oth the tool and

wor#piece ma#es the latter to melt and partially vaporise and partially

ioni.e the metal in a thin surface layer(

37. What causes the material to !e removed from the wor# piece surface?)Kr* How does the dielectric assist in removing the material from thewor# piece?

'ue to the inertia of the surrounding uid, the pressure within the spar#!ecomes &uite large and may possi!ly assist in !lasting the moltenmaterial from the surface leaving a fairly at and shallow crater(

38. What are the principle components of +'M process?

ower supply, 'ielectric system, electrodes= wor#piece and tool and servosystem )tool feed*

39. What is the use of dielectric in +'M process? spar# conductor that must ioni.e under an applied voltage deioni.e the spar# gap after the discharge has occurred e"ective cooling medium )coolant* carry the swarf particles away from the wor#ing gap )Bushing

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medium*40. What the dielectric uids commonly used in +'M?

etrolium !ased hydrocar!on uids(aran, white sprite, transformer oil(Nerosine, mineral oil(+thylene glycol and water misci!le compounds(

41. List the desira!le characteristics of a dielectric( he following are the desira!le characteristics of a dielectric=

$t should have su>cient and sta!le dielectric strength to serve as aninsulation !etween the tool and wor# till the !rea#down voltage isreached

$t should deionise rapidly after the spar# discharge has ta#en place $t should have low viscosity and good wetting capacity to provide an

e"ective cooling mechanism and remove the swarf particles fromthe machining gap $t should !e chemically neutral so as not to attac# the electrode,wor#piece, ta!le or the tan#(

$t should not emit any to0ic vapours or have any unpleasant odour( $t should have high ash point so as to avoid any re ha.ards(

$t should maintain its properties over a wide range of temperature,contamination !y de!ris and products of decomposition( $t should !e economical and easily availa!le(

42. What is tool wear in the +'M process?

artial removal of the tool material form the tool surface while machiningthe wor#piece due to the discharge spar# produced !etween the tool andthe wor#piece(

43. How does tool wear occur in the +'M?

'ue to the spar#ing action, the intense heat generated near the .one

melts and evaporates the materials in the spar#ing .one( 3ince the tool is also within this zone, it also gets eroded(

44. How to minimise tool wear in +'M?

ool wear can !e minimi.ed !y using a tool material that has a highmelting point and high thermal conductivity( 1lso !y properly conguringthe tool design, tool wear can !e minimi.ed(

45. lease identify the characteristics of an electrode material in order toserve as a good tool(

$t should !e a good conductor of electricity and heat $t should !e easily machina!le to any shape at a reasona!le cost $t should produce e>cient material removal rates from the

wor#pieces $t should resist the deformation during the erosion process $t should e0hi!it low electrode )tool* wear rates $t should !e easily availa!le in a variety of shapes

46. ame some of the tool material used in +'M?

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• Copper, !rass, alloys of Iinc Otin(• Hardend plain car!on steel• Copper tungsten, silver tungsten, tungsten• Copper graphite and graphite(

47. Why is graphite the most preferred electrode material in +'M?

/raphite has very high melting point )@F8F C*( $t does not melt rathervapori.es( 1t the same time, the tool wear is minimum(

48. How does the melting temperature of wor# material a"ect the M%% in+'M?

Wor# materials having higher melting temperature have lower M%%Ds(

49. What is the e"ect of capacitance in +'M?

$ncreasing the capacitance causes the discharge to increase and increase!oth the pea# current and discharge time(

50. 'ene wear ratio$t is the ratio of volume of wor# removed to the volume of tool removed(

51. 'ene over cut

$t is the distance !y which the machined hole in the wor# piece e0ceedsthe electrode si.e and is determined !y !oth the initiating voltage and thedischarge energy(

52. . ame the !est electrode material for nish operations on a small diemade of WC !y the +'M process(

Best electrode material for nish machining a small die made of WC steel( 3teel is used !ecause it can match the parting planes of the moulds

in which half the mould is used as the electrode and the other half is used

as the wor#piece(

53. +0plain why tool shape in the +'M process should !e complementaryto the nal form? 3ince the arc is always struck at a pointbetween the workpiece that is closest from the tool )electrode*,the complementary tool surface will !e reproduced in the wor#piece(

54. What are the factors upon which the material removal rate and surface

roughness depends? $ncrease in +##(, # %)$# '*,$( increases M%% and produces

higher surface roughness $ncrease in %)$# #(4(+5 results in improved surface nish !utthe M%% can !e maintained

Low inter electrode gap )$+/* results in lower M%%, higher surfacenish and !etter accuracy

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55. What are the design factors to !e considered while selecting themachine tool?

um!er of parts to !e produced( 1ccuracy( 3i.e of wor# piece( 3i.e of electrode( 'epth of cavity(

56. . Why is a servo-controlled system re&uired in +'M?

+'M re&uires that a constant arc gap !e maintained !etween theelectrode and the wor# piece to o!tain ma0imum machining e>ciency( herefore +'M tool incorporates some form of servo control(

57. What are the various applications of +'M?

Mould ma#ing industry manufacture moulds for plastics ool and die industry- manufacture e0truding, heading, drawing,forging and die lasting dies(

1erospace and electronic industry to ma#e prototypes and productionparts- made of di>cult to machine material3mall or odd shaped holesMiniature parts and parts made from thin or fragile materials )delicate*

58. What is meant !y Wire cut +'M? he principle and wor#ing of an W+'M is similar to the +'M !ut instead of using a solid electrode, a wire )a!out :(:A-:(@:mm diameter* is used asan electrode in +'M(

59. What are salient features of W+'M?W+'M uses a small diameter wire as tool electrode, which produces avery narrow #erf in the wor#( Because of this reason, very sharp cornerscan !e easily produced(

60. lease identify various applications of Wire cut +'M(Wire cut +'M is used for the manufactureof=

'ies

ress tools+lectrodes

61. What are the di"erent types of the electrical circuits that are used for

electro spar# machining?%(C( Circuits%otary impulse generatorulse controlled circuitsHy!rid circuits

62. What is an arc gap?Kptimum distance !etween the tool and the wor#piece so that spar# canrun and cause useful erosion(

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63. How is the arc gap controlled in +'M?

3ervo mechanism is used to control the arc gap average voltage ismeasured and as long as it is within a certain limit, no correction signal isfed to the feed drive(

64. What are the limitations of +'M process? Low material removal rate Knly electrically conductive materials can !e

machined ool electrode wear is very high More time in the fa!rication of the electrodes( High cost involved(

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UNIT-2

CNC MACHINES1. ame any two mechanisms that are availa!le to provide the rotational

inde0ing motion for transferring wor# parts(

(i) /eneva mechanism(ii) Cam mechanism

2. What is the use of art feeding devices ?

his is a mechanism that removes the components from the hopper oneat a time for delivery to the assem!ly wor# head( he hopper and partsfeeder are often com!ined into one operating mechanism(

3. What is 1daptive control ?

$t is !asically a feed !ac# system in which the operating parametersautomatically adopt themselves to the actual conditions of the process(

4. What are the features of C1' !ased C programming ?5. What are the di"erent types of Wor#part ransfer mechanisms?

Wal#ing !eam transfer mechanism

6. 'ene C system?C is dened as a form of programma!le automation in which theprocess is controlled !y alphanumeric data(

7. What is MCU?MCU is a hardware system which reads, interprets and translates theprogram of instructions into mechanical action of machine tool(

8. List out any four advantage of using C?

$ncreased e0i!ility(

%educed setup time(

roduction of comple0 part(

+limination of special 9igs and 0tures(

Less scrap

9. What are the limitations of using C?

%elatively high price(

More complicated maintenance, a special crew is desira!le(

Highly s#illed and properly trained programmers are needed(

10. What are all the pro!lems encountered with C system?

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art programming mista#es(

on-optional speeds and feeds(

ro!lem with punched tape and tape reader(

ro!lem with controller and management information(

11. D(6( CNCCC is dened as a C system that utili.es a dedicated, storedcomputer program to perform some or the entire !asic C functions(

12. W#&,( ,( $& +,&% CNC

Machine tool control(

$n-process compensation(

$mproved programming and operating features(

'iagnostics

13. W$, $#( ,( +,&% :&$%,&+ %5%,( & NC $+&(,*%

o identify the reason for a down time occurrence so that maintenancepersonal should ma#e repairs fast( o alert to signs that indicate the imminent failure of certaincomponent which are considered unrelia!le

14. L&%, ,( :&;(#(+(% "(,


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15. L&%, ,( :&;(#(+(% "(,


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a( Housed MCU

!( 3wing around MCU

c( 3tand alone MCU(

5J( di 'ene 'C?'irect numerical control system is dened as a manufacturing systemin which a num!er of machine tools are controlled !y a computerthrough direct connection and in real time(

19. List the main component of 'C?Main component area( Central computer(

!( Bul# memory(

c( elecommunications lines(

d( Machine tools(

20. Write the functions of 'C?

$t will ta#e some of the !urden of the main computer(

+ach satellite computer(

21. List out the types of CC machine?CC machine can !e classied as=

i. Machining centers

ii. Lathe machines

iii. 'rilling machine

iv. urning centers

v. Milling machines

vi. /ear shaping

vii. CC gear ho!!ling

22. 'ene the term Basic unit length? he minimum possi!le incremental movement is called the Basic unitlength )BLU*( he BLU might !e on the order of :(:5 mm in typicalmachine tool system(

23. Write the functions of guideways( he functions of sideways=

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a( o control the line of action of the carriage


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d( o improve smoothness(

e( Iero stic# slip

8F( What is actuating system? Write the various types of actuating system

used in CC?1ctuation systems are used to convert the rotational movement intotranslation movement( he two types of actuation systems used in CCare=a( 3crew and nut, and

!( %ac# and pinion(

8( What are the advantages of !all screws sideways over conventionalsideways(

a( Ball screws have longer life(

!( Higher accuracy can !e maintained(

c( Low frictional resistance and hence used for carrying heavier loadsat faster rate(

d( Low power re&uirement for driving(

8J( What is meant !y feed drive? List the di"erent types of feed drives(

6eed drive is used to provide motion to the slide as per the motioncommands( 6eed drives are classied as follows=$( 3ervo motors,a( 1C servo motor,

!( 'C servo motor,

c( Brushless 'C servo motor$$( 3tepper motors, and

$$$( Linear motors(

@:( What is the function of 1C?

he function of 1C is to change the tool once the particular operationis over and the ne0t tool is automatically changed and positioned formachining !ased on the tool se&uence given in part program(

@5( What is machining center? Write the di"erent types of machining centre(How it di"ers from conventional CC milling machines?

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he centers which consists of multi function CC machines e&uippedwith 1C which are capa!le of carrying out milling, reaming, tapping,!oring, counter !oring and allied operations without operatorintervention is called machining centre('i"erent types of machining centers are=

a( Hori.ontal machining centre,!( 7ertical machining centre,

c( Universal machining centre(

@8( What are the functions of feed!ac# drives? he functions of feed!ac# drives are=a. o convert one form of physical &uantity li#e speed, displacement,

etc(, into

electrical signals(

b. his electrical signal is then compared with the reference signal tochec# whether

the desired motion of tool


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%eason= $nductosyn is a precision feed!ac# device for the accuratemeasurement and control of angles or distances with inductivecoupling !etween conductors separated !y a small space

@E( What is a rotary type encoder? Where it is used?1n encoder is a rotary transducer that provides continuous or discretesignal value of an angular or linear movement( $t is used in the CC atthe end of the slide screw directly or through gearing timer !elt(

@F( What is the role of optical grating in CC drive?1n optical grating is a glass strip mar#ed with series of e&ually spacedtransparent opa&ue lines( hey are used as transducers on machinetools( his is used to measure the position of the ta!le(

@( What is $nductosyn?

$nductosyn is a analogue type position !ac# device which is used forthe, measurement of control angle and


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UNIT-3

1. 'ene numerical control(umerical control is a form of programma!le automation in which the

mechanical action of machine tool or other processing e&uipment arecontrolled !y a program containing alphanumeric data num!ers, lettersand sym!ols(

2. What are the di"erent types of dimensioning system used?

a. 1!solute dimensioning or !aseline dimensioning system(

b. $ncremental dimensioning or delta dimensioning system(

3. What is B$? What is the use of it?

a. Bit is an a!!reviation of Binary digit which can !e 5 or :(Usesin !inary coded decimal system(

4. What is !loc#? Write the signicance of it?

a. Bloc# is the !asic unit of a part program input to the control( $tcontains ade&uate information for the machine to perform amovement and for functions(

5. What $s / code? How / codes are represented?

a. $t is the series of com!ination of P5‟s and P:‟s($t represents anum!er or an alpha!et or any sym!ol(

6. Write the di"erent types of tape programming format?

a. he following are the types of tape programming format(b. Word address format,

c. a!le se&uential format,

d. 6ined !loc# format(

7. +0plain the functions of codes /8 and M@:(

a. /8 Q Mirroring

b. M@: Q +nd of data(8. 3tate the function of post processor in C1(

a. ost processor is separate computer program which has !eenused to prepare the punched tape for a specic machine tool(

9. List out some of the important C languages(

a. 1

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b. 1'1

c. +R1

d. Compact $$

e. %KM

f. C$U%$$

10. What are the four statements used in 1 language?

a. /eometric statements

b. Motion statements

c. ost processor statements

d. 1u0iliary statements(

11. How can you represent an 1 geometric statement?

a. 3ym!ol Q /eometry


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15. List any four post processor statements(

a. CKKL1


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1. ame the 6KU% !asic ro!ot congurations( Cartesian coordinate system Cylindrical coordinate system olar or spherical coordinate system

%evolute coordinate system

4.List out the types of 9oint otation(i. Linear 9oint,ii. %otational 9oint,iii. wisting 9oint,iv. %evolving 9oint(

@( What is meant !y a wor# envelope?

he wor# envelope is descri!ed !y the surface of the wor# space( $tdepends upon the num!er of types of 9oints, physical types of 9oints and lin#sand the range of various 9oints(

4.3#etch a ro!ot and name its parts(1.Manipulator )%o!ot arm*

2.+nd e"ector

3.Controller

4./ripper

5.1ctuator

5.What is meant !y wor#space?

he space in which the end point of the ro!ot arm is capa!le ofoperating is called as wor#space in other words, reach a!ility of ro!ot armis #nown as wor#space(

6.List the various types of ro!ot drive system for industrial ro!ots1.+lectric drive=

(a)'C motor4 )!* 3ervomotor4 )c* 3tepper motor2.neumatic drive3.Hydraulic drive

( 3#etch and indicate the type of any rotating 9oints used inro!ots( (or) 3#etch a twisting 9oint( %otational )%*=

J( What are the typesof hydraulic actuators usedin ro!otics?

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1.3tate any two techni&ues used for o!9ect recognition(a) emplate matchingb)3tructural echni&ue

2.Write a!out Hall +"ect sensors(

When a !eam of charged particles passes through a magnetic eldforces act on the particles and the !eam is deected from the straight linepath a current owing in a conductor is li#e a !eam of moving charges andthus can !e dened !y magnetic eld

3.Classify the ro!ots according to the drive system(1.neumatic drive2.Hydraulic drive3.+lectric drive

)a*'C Motor(b)3ervo motor(c)3tepper motor

;( List any two important advantages and disadvantages of a pneumaticgripper(

Advantages of pneumatic gripper:1. $ts light weight design(2. $t is possi!le to distri!ute the pressure uniformly the entire

area(3.Control is simple

4.ic# up time is very fast(Disadvantages:1. $t is not suita!le for heavy loads(2.3ometime is re&uired to !uild the pressure(

E( ame any four pro0imity sensors used in ro!otics

3ensor, which senses the presence or a!sence of the o!9ect withouthaving physical contact !etween the o!9ects

$* $nductive 3ensor2)Capacitive 3ensor

3)Ultrasonic 3ensor4)Magnetic 3ensor

7.3#etch the screw-actuated mechanical gripper(

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What are the limitations of adhesive grippers?0 1dhesive su!stances losses his tac#iness on repeated usage(1 %elia!ility is diminished with successive operations

5:( 'i"erentiate !etween touch and force sensors(

T+ %(%#= $t senses the presence or a!sence of the o!9ect !yhaving physical contact !etween the o!9ects(

F#+( %(%#%= 6orce sensors are used primarily for measuring thereaction forces developed at the interface !etweenmechanical assem!lies

55( List the types of drives used in ro!ots( +lectric drives Hydraulic drives neumatic drives

12.What is a %CC device? 6or what purpose is it used in a ro!ot?%CC device means %emote( Center Compliance devices(U%(%= )i* %CC device are commonly used in automated assem!ly

applications to provide Compliance for misalignment during assem!ly(

(ii) he compensator is a (compliance device that enhancesthe e0i!ility and relia!ility of a ro!ot

13.What is a mechanical gripper?

1 mechanical gripper is an end e"ector that uses mechanical ngeractuated !y mechanism to grasp an o!9ect(

Mechanical grippers are used to transfer parts from one location toanother or to assem!le parts(

14.What is the properties :f stepper motor? 3tator wiring )num!er of coils and wire loads*( um!er of steps in a complete rotation( Kperating voltage and current( 1mount of force generated )tor&ue*( Ma0imum rotation speed )steps per second*(

15.3tate the advantage and limitation of hydraulic drive(

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Advantage:i. %o!ustii. 3elf lu!ricationiii. $t can also provide precise control at low speeds(iv. High e>ciency and high power to si.e ratio(

v. Hydraulic ro!ots are more capa!le of withstanding shoc#loads(

Disadvantage:

1. +0pensive2. High maintenance

3. ot energy e>cient4. oisy5. ot suited for clean air environments

• Write the !asic principle of servo motor(0 1 servomotor is used within position control )or* speed control

feed!ac# control system(1 1n electrostatic motor is !ased on the attraction and repulsion of

electrical charge(

• /ive some e0amples of ro!ot end e"ector(0 /ripper1 ools2 Welding e&uipment

3 +nd of arm tooling

• What are the types of grippers?T0 Mechanical nger grippers(1 neumatic grippers(2 Hydraulic grippers(3 Collect gripper(4 Magnetic gripper(5 7acuum gripper(

5( 'ene a tactile sensor and list the types( actile sensor is device that indicates the contact !etween themselvesand some other solid o!9ects(

0 'igital )ouch* 3ensor1 1nalogue )6orce* 3ensor

2.List the two !asic types of ro!otprogramming method(

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a( Lead through methods!( e0tual ro!ot languagesc.Mechanical rogramming

3.3tate the wor#ing principle of a touch sensor(

ouch sensors in sensors, which senses the presence or a!sence of theo!9ect !y having physical contact !etween the o!9ects( When the !utton ispressed, an electrical circuit is closed inside the sensors( his lets electricityow( When the !utton is released, the circuit is !ro#en and no electricityows( ouch sensors send a signal when physical contact is made(

65. What is the function of a frame gra!!er?

1 frame gra!!er is an electronic device that captures individual,digital still frames from an analog video signal or a digital videostream(

$t is hardware device used to capture and store the digital image(

66. What are the limitations of hydraulic drive systems?

0 +0pensive1 High maintenance2 ot energy e>cient3 oisy4 ot suited for clean-air environments(

67. What is the purpose of thresholding in analysis?

hresholding is a !inary conversion techni&ue in which each pi0el isconverted into a !inary value either !lac# or white(

7.Mention use of machine vision system((i) his can !e used to replace, machining for applications li#ewelding, machining to maintain relationship !etween tool andwor#((ii) Machine vision systems are used for printed circuit !oard((iii) his is for the recognition of o!9ect from its image((iv)1chieve 5:: accuracy(

8.+numerate the di"erence !etween open loop and closed loop controlsystem

O)( *) +,#* %5%,(C*%(: *) +,#*%5%,(

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$t is !eing relatively simple More comple0

Low cost More cost

/reater chance of !rea#downs as a

/ood relia!ility

conse&uence of the greater

num!er of components

he disadvantage is that they are

often%elatively accurate in matching the

actual toinaccurate since there are nocorrection for

the re&uired valueserror

J( What is meant !y template matching?

emplates of the parts to !e recogni.ed are stored in the vision systemmemory( he images recorded !y the vision camera are compared with thetemplates stored in memory to determine if a matching part is present(

5:( What is a teach pendant?

he teach pendant is usually a small handheld control !o0 withcom!inations of toggle switches, dials and !uttons to regulate the ro!otTsphysical movementTs and program capa!ilities

55(Classify the position sensors(Main types of position sensors are:

$ncremental 1!solute

Some other devices which are used as position sensors. %esistive position sensors( Linear varia!le di"erential transformer )L7'* +ncoders( otentiometer( %esolver

12.Brief on the wor#ing of inductive type pro0imity sensor( $nductive pro0imity sensors operate under the electrical principle of

inductance( $nductance is the phenomenon where uctuating current, which !y

denition has a magnetic component induces an electromotive force)emf* is a target o!9ect( o amplify a devices inductance e"ect, a sensor manufacturer twistswire into a tight coil and runs a current through it(

13.What is triangulation?

riangulation is a process !y which the location of radio transmittercan !e determined !y measuring either the radial distance, or thedirection of the received signal from two )or* three di"erent points( riangulation is sometimes used in cellular communication to pin pointthe geographic position of a user(

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14.What is smoothing in vision system?

3moothing in vision system is often used to reduce noise withinan image )or* to produce a less pi0elated image(

Most smoothing methods are !ased on low pass lter

15.What are the desira!le features of sensor?

5(Cost 8(+ase ofoperation

@(

Kperatingrange ;( 1ccuracy

A(recision E(%elia!ilityTF( 3peed of response ( Cali!ration

16.List the dierent types of tactile sensor. 'igital )ouch* 3ensor 1nalogue )6orce* 3ensor

17.What are the applications of Machine Vision System $nspection $dentication 7isual serving and navigation

18.What are the various techni!ues in image processing and analysis $mage data reduction 3egmentation 6eature e0traction K!9ect recognition

1.What are 1ctuators?

1ctuators are the devices used for converting hydraulic energy )or*electrical energy into mechanical energy(

$n other words, actuators perform a function 9ust opposite to that of thepumps(

he pressuri.ed hydraulic uid delivered !y the hydraulic pump issupplied to the actuators, which converts the energy of the uid intomechanical energy(

his mechanical energy is used to get the wor# done( he hydraulicactuators produce linear, rotary, or oscillating motion(

2.What is transformation?

ransformations of frames introduced to ma#e modeling the relocationof o!9ects easier(1n o!9ect is descri!ed with respect to a frame located

in the o!9ect, and this frame is relocated with a transformation( he transformation is the result of a se&uence of rotations and

translations, which are recorded with a transformation e&uation

3.What is meant !y a teach pendent?

he teach pendent is usually a small hand held control !o0 withcom!ination of toggle switches, dials and !uttons to regulate the ro!otTsphysical movements and program capa!ilities(

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A( 'ene the term Tfeature e0traction V

ransforming the input data into the set of feature is calledfeature e0traction( 1 feature area, diameter, perimeter, is a singleparameter that permits ease of comparison and identication(

6.3tate any two techni&ues used for o!9ect recognition(a) emplate matchingb)3tructural echni&ue

7.What the !enets of this o" line programming? %educed down time for programming( rogramming tools ma#e programming easier( +na!les concurrent engineering and reduces product lead time( 1ssists cell design and allows process optimi.ation(

8.+0plain the reasons for dening points in a program( o dene a wor#ing position for the end-e"ector o avoid o!stacles

9.What is 1/7?

1utomated guided vehicle )1/7* is an independently operated self-propelled vehicle guided along dened pathways in the oor( $t is normallypowered with !atteries( $t is mainly used for handling material from oneplace to other place(

2. List out di"erent types of image compression techni&ue('iscrete image transforms in image data compressionHierarchical and progressive compression techni&uesComparison of compression methods

"#. De$ne degrees of freedom

$t is dened as one of the varia!les re&uired to dene the motion of a !ody in space( +ach 9oint in a ro!otic system gives the ro!ot onedegrees of freedom(

"%. What is teach pendant

he teach pendant is usually a small handheld control !o0 withcom!ination of toggle switches, dials and !uttons to regulate the ro!otTsphysical movements and program capa!ilities(

5( What is continuous path programming?$t is the types of programming were the motion cycle involves smooth

comple0Curvilinear movements of ro!ot arm(

8( What is teach pendant?

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he teach pendant is usually a small handheld control !o0 withcom!inations of toggle switches, dials and !uttons to regulate thero!otTs physical movements and program capa!ilities(

@(List any two important considerations for ro!ot safety( +nvironmental condition(

Location and installation re&uirement( , Human errors( Mode of operation

A( What is the purpose of structured lighting?

he intersection of the sheet with o!9ects in the wor# spaceyields a light stripe which is viewed through Ta television cameradisplaced a distance from the light source( he stripe pattern is easilyanaly.ed !y a computer to o!tain range information(

6.What are the general characteristics that ma#e potential ro!ot application

technicallypractical and economically feasi!le?Ha.ardous or uncomforta!le wor#ing conditions%epetitive operations'i>cult handling 9o!sMulticast operation3election of the application(

3election of the ro!ot('etailed economic analysis and capital authori.ation(lanning and engineering the installation($nstallation(

8.What is meant !y image analysis?

$mage analysis ids the collection of processes in which a capturedimage that is prepared !y image processing is analy.ed in order to e0tractinformation a!out the image and to identify o!9ects or facts a!out the o!9ector its environment(

10./ive two applications of ro!ot in machining( 'rilling4 /rinding4 %eaming4 apping

'e!urring

15.List out types of A &V vehicles.

1. o wing vehicles3.Unit load vehicles allet truc# vehicles4.6or# truc# vehicles5.Light load vehicles

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17.1ssem!lyline vehicles What are types of ro'ots commonly used for machine loading and unloading operation

1.3ervo control ro!ot )point to point*2.on-servo ro!ot )pic# and place ro!ot*

18.Write two aspects of the safety issue in ro'otics.1.%edundancy2.Bac# up system

UNIT-!

1. W$, &% ($, "5 C(***$# $$+,#&/rouping the production e&uipment in to Machine cells ,where eachcell speciali.es in the production of a particular family is called Cellularmanufacturing

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2. W$, &% G#) ,(+*5$t is a manufacturing philosophy in which similar parts are identiedand grouped together to ta#e advantage of their similarities in designand production(

3. W$, &% $ >$#, $&*51 part family is a collection of parts that are similar !ecause ofgeometric shape and si.e or !ecause similar processing steps arere&uired in their manufacture(

4. W$, $#( ,( :&;(#(, ,5)(% FMS *$5,%i. $n-lineii. Loopiii. Ladderiv. Kpen eldv. %o!ot centered cell

5. C(, ,( "((6,% ,$, $#( (?)(+,(: # $ FMS.i. Higher machine utili.ationii. %educed manufacturing lead timeiii. %educed wor# in progressiv. /reater e0i!ility in production schedulingv. Higher la!our productivityvi. uic#er response to mar#et changesvii. %educed space re&uirementsviii. +0panda!ility for additional processes or added capacityix. %educed num!er of tools and machines re&uired(

What are the various components of6. W$, &% FMS

1 e0i!le manufacturing system is a highly automated / machine cell, consisting of group of processing wor#stations )Usually CC machine tools* ,interconnected !y an automated material handling and storage system , andcontrolled !y a distri!uted computer system(

7. W$, $#( ,( "((6,% FMSi. $ncreased machine utili.ationii. 6ewer machines re&uirediii. /reater responsiveness to change

iv. %educed inventory re&uirementsv. Lower manufacturing lead timesvi. %educed direct la!or re&uirements and higher la!or productivityvii. Kpportunity for unattended production

8. W$, $( FMS @(?&"*(i. he a!ility to identify and distinguish among the di"erent part or

product styles processed !y the system(ii. uic# changeover of operating instructions

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iii. uic# change over of physical setup(9. W$, $#( ,( '$#&% ,5)(% FMS

i. F*(?&"*( $$+,#& :*(ii. F*(?&"*( $$+,#& +(**iii. F*(?&"*( $$+,#& #)iv. F*(?&"*( $"#&+$,&- $+&& $%%("*5 %5%,(

10. W$, $#( ,( '$#&% +)(,% $ FMSi. Wor# stationsii. Material handling and storage systemsiii. Computer control system( $n addition even through an 6M3 is highly

automatediv. eople are re&uired to manage and operate the system(

11. W$, &% ($, "5 $ D(:&+$,(: FMS R$: #:(# FMS

A :(:&+$,(: FMS &% :(%&(: , )#:+( $ *&&,(: '$#&(,5 )$#, %,5*(% $: ,( +)*(,( &'(#%( )$#,% , "( $:( ,( %5%,( &%


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L($ )#:+,& +$ "( :(6(: $% $ $:$),$,& $%%)#:+,& & #:+( , #(+$%, 3. >#:+( , #:(#

. L< &#$,& +,(, . H& &#$,& +,(,

!. S&*( ,&( %$*(% !. C,&& #(*$,&%&)

/. >#&+& "5 )#:+,& +%, /. >#&+& "5 +%,(# '$*(

19. W$, &% G#) ,(+*5

G#) ,(+*5 &% $ $$+,#& )&*%)5 &


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20. D(6( ,( ,(# >$#, $&*5.

A )$#, $&*5 &% $ +**(+,& )$#,% ,$, $#( %&&*$# (&,(# "(+$%( ((,#&+ %$)( $: %&B( # "(+$%( %&&*$# )#+(%%& %,()% $#(#(4(: & ,( $$+,#(.

21. W$, &% ,( $:'$,$( FMS '(# ,( ,(# ,5)(% $$+,#&%5%,(%

F*(?&"*( $$+,#& %5%,(% $#( :(%&(: , 6** ,( $) "(,ART A

1. T( $,$,(: (*((,% ,( )#:+,&% %5%,( +$ "(%()$#$,(: &, ,


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vi. To improve product quality.

vii. To reduce manufacturing lead lime.

4. G&'( ,( +*$%%&6+$,& $,$,& .

i. 6i0ed automationii. rogramma!le automationiii. 6le0i!le automationiv. $ntegrated automation

5. W$, : 5 :(#%,$: # ,( ,(# A,$,(: >#:+,&L&(

A $,$,(: )#:+,& *&( +%&%,% %('(#$* $+&(% #$#, ((:& :('&+(%

T&% &% $ (+$&% ,$, #('(% ,( +)(,% # ,())(# ( $, $ ,&( # :(*&'(#5 , ,( $%%("*5


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I, &% "$%&+$**5 $ ((: "$+ %5%,( &


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24. D(6( >$#, $&*&(% .

A )$#, $&*5 &% $ +**(+,& )$#,% ,$, $#( %&&*$# (&,(#"(+$%( ((,#&+ %$)( $: %&B( # "(+$%( %&&*$#)#+(%%& %,()% $#( #(4(: & ,( $$+,#(.

25. W$, $#( ,( $))*&+$,&% GT 26. D(6( = A,$,& .

A,$,& +$ "( :(6(: $% $ ,(+*5 ++(#(:


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