lab_manual_web.pdf

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Download links http://www.anitsmechanical.blogspot.in http://www.rajaroytutorials.blogspot.in Page 1 CONTENTS CAD EXPERIMENTS I. DRAWING EXPERIMENTS USING AUTO CAD 1) Knuckle Joint 2) Cotter joint with sleeve II. 3D MODELLING EXPERIMENTS USING SOLID WORKS 1) Oldham coupling 2) Screw jack 3) Universal coupling III. ANALYSIS EXPERIMENTS 1) Static analysis of beam using ANSYS 2) Static analysis of truss using ANSYS 3) Static analysis of plate using SOLID WORKS IV. CAM EXPERIMENTS 1) Manual part programming & Machining using Auto CAD for CNC Turning 2) Manual part programming using Auto CAD for CNC Milling 3) Robot programming through computer V. VIVA QUESTIONS VI. OBJECTIVE TYPE QUESTIONS

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    CONTENTS

    CAD EXPERIMENTS

    I. DRAWING EXPERIMENTS USING AUTO CAD 1) Knuckle Joint 2) Cotter joint with sleeve

    II. 3D MODELLING EXPERIMENTS USING SOLID WORKS

    1) Oldham coupling 2) Screw jack 3) Universal coupling

    III. ANALYSIS EXPERIMENTS 1) Static analysis of beam using ANSYS 2) Static analysis of truss using ANSYS 3) Static analysis of plate using SOLID WORKS

    IV. CAM EXPERIMENTS 1) Manual part programming & Machining using Auto CAD

    for CNC Turning 2) Manual part programming using Auto CAD for CNC

    Milling 3) Robot programming through computer

    V. VIVA QUESTIONS VI. OBJECTIVE TYPE QUESTIONS

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    DRAWING EXPERIMENTS USING AUTO CAD

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    1. Cotter joint with sleeve

    Aim : To draw the cotter joint with sleeve using Auto CAD.

    Procedure

    1. Set limits of Auto CAD screen. Set units Type : Decimal, Insertion scale :

    Millimetres

    2. Insert line types Centre line and Dashed line into the drawing using Linetype

    command.

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    3. Draw the centre line. Draw the two shafts by taking diameter of the shaft as

    30mm and increasing the diameter to 1.3D inside the sleeve as shown in the

    figure. Use line command and spline command for drawing cut sections of the

    rods at the ends.

    4. Draw a sleeve over the rods by taking diameter as 2.5D and length as 8D. using

    trim command remove required portion of the sleeve and rods to insert cotters.

    Cotter length is 4D, width 1.3D and taper is 1:30.

    5. Represent the top half in section by applying hatching using hatch command.

    Represent invisible portion of the rods and cotters in the sleeve with dashed lines.

    6. Drawing the projections from the front view draw the top view using line, arc or

    circle, fillet and trim commands.

    7. Create a new layer using layer command and set color for layer to display

    dimensions. Name this layer as Dim

    8. Create a new dimension style. Draw all dimensions of the drawing in Dim layer.

    Precautions

    1. Use zoom and Pan Commands properly while doing trim and fillet operations at

    very small dimensions.

    2. Use line type scale command(lts) for correct display of dashed and center lines.

    3. Use hatchedit command to adjust the hatching of the sections.

    4. Draw all the dimensions in new layer only.

    Result

    Cotter joint with sleeve has been drawn successfully using Auto CAD software.

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    2. Knuckle Joint

    Aim : To draw the Knuckle using Auto CAD.

    Procedure

    1. Set limits of Auto CAD screen. Set units Type : Decimal, Insertion scale :

    Millimetres

    2. Insert line types Centre line and Dashed line into the drawing using Linetype

    command.

    3. Draw the centre line. Draw the pin in the top view by taking D as diameter 4D as

    length. Draw the Eye end and Forked end using line, circle and arc commands.

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    Draw a octagon and draw the octagonal ends of the rods by drawing projections

    from the octagon drawn in the side view. Erase the octagon after drawing

    projections.

    4. Draw the collar by taking 1.5D diameter and 0.5D as length. Draw the pin inside

    the collar.

    5. Represent partial section by applying hatching using hatch command.

    6. Drawing the projections from the top view draw the front view using line, arc or

    circle, fillet and trim commands.

    7. Create a new layer using layer command and set color for layer to display

    dimensions. Name this layer as Dim

    8. Create a new dimension style. Draw all dimensions of the drawing in Dim layer.

    Precautions

    1. Use zoom and Pan Commands properly while doing trim and fillet operations at

    very small dimensions.

    2. Use line type scale command(lts) for correct display of dashed and center lines.

    3. Use hatchedit command to adjust the hatching of the sections.

    4. Draw all the dimensions in new layer only.

    Result

    Knuckle joint has been drawn successfully using Auto CAD software.

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    3D MODELLING EXPERIMENTS USING SOLID WORKS

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    1. Oldham coupling

    Aim : To make the part model, Assembly and Drawing of the Oldham coupling using

    Solidworks.

    Procedure

    Part modelling

    1. Flange : Select work plane in the side view and create a sketch. Draw a circle of

    100mm dia in the sketch and extrude it to 20mm. Take a new sketch in the top

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    view and draw a rectangle of 10X12mm and create a slot using extruded cut

    feature. Create a hub of 60mm diameter using extrude feature. Create hole with

    key way for the shaft of 30mm diameter.

    2. Central disc : Select the work plane in the side view and create a new sketch.

    Draw a circle of 100mm diameter and extrude it to 20mm. Remove the unwanted

    portion using extruded cut feature and create the projection on both sides of the

    central disc.

    3. Shaft : Select the work plane side view and create a sketch with circle of 30mm

    diameter using extrude feature. Create key way using extruded cut feature.

    4. Key : Select the work plane side view and create a sketch with rectangle D/4 as

    width and length.

    Assembly : Create a sub assembly using shaft and key using coincidence mates. Create a

    main assembly by taking a cental disc as main part. Assemble flanges to the central disc

    and insert sub assembly of shaft and key to flanges.

    Drawing : Create a new drawing file. Insert the assembly into drawing and project the

    side view and front view. Take a sectional view from the side view. Draw the dimensions

    using smart dimensing.

    Precautions

    1. Select the Work plane properly based on the views required in the drawing.

    2. Use the constraineds properly while drawing sketches.

    3. Select the correct mates between the parts.

    Result : Parts, Assembly and Drawing of the Oldham coupling done using Solid Works.

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    2. Screw Jack Aim : To make the part model, Assembly and Drawing of the Screw jack using

    Solidworks.

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    Procedure Part modelling

    1. Body : Select the work plane in the front view. Draw the sketch for the body with

    given dimensions and revolve it using revolve feature to get body of screw jack.

    2. Nut : Select the work plane in the front view. Draw the sketch for the nut with

    given dimensions and revolve it using revolve feature.

    3. Screw : Select the work plane in the front view. Draw the sketch for the screw

    with given dimensions and revolve it using revolve feature. Select the work plane

    in the side view and make a through hole using extruded cut feature. Make a M12

    tapped hole at the top of screw using hole feature.

    4. Cup : Select the work plane in the front view. Draw the sketch for the cup with

    given dimensions and revolve it using revolve feature. Create a work plane in the

    side view and draw a hole and make a semi circular cut using the extruded cut

    option. Repeate the same procedure in the front work plane.

    5. Washer : Select the work plane in the front view. Draw the sketch for the washer

    with given dimensions and revolve it using revolve feature.

    6. Screw : Select the work plane in the front view. Draw the sketch for the washer

    with given dimensions and revolve it using revolve feature.

    7. Tommybar : Select the work plane in the front view. Draw the sketch for the

    tommy bar with given dimensions and revolve it using revolve feature.

    Assembly

    Create a sub assembly with Cup,washer and screw. Insert the Body as main part.

    Use proper mates to assemble remaining parts sub assembly.

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    Drawing

    Insert the assembly into a new drawing file and project the front view and top

    view. Create the sectional front view to get the details of screw and washer in the

    drawing. Mark the dimensions for the entire drawing using smart dimensing.

    Precautions

    1. Select the Work plane properly based on the views required in the drawing.

    2. Use the constraineds properly while drawing sketches.

    3. Select the correct mates between the parts.

    Result : Parts, Assembly and Drawing of the Screw Jack prepared using Solid Works.

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    3. Universal Coupling Aim : To make the part model, Assembly and Drawing of the Universal coupling using

    Solidworks.

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    Procedure

    Part modelling

    1. Fork : Select the front work plane and draw the sketch for the vertical portion of

    the fork. Select the top face and create the sketch for top part of the fork. Use the

    mirror feature to get the bottom part of the fork. Create the hub and shaft for fork

    using extrude feature.

    2. Central block : Select top work plane Draw the sketch with two concentric

    circles and extrude them. Select the front work plane Draw the sketch with two

    concentric circles according to the given dimensions and extrude them.

    3. Shaft : Select the work plane side view and create a sketch with circle of 30mm

    diameter using extrude feature. Create key way using extruded cut feature.

    4. Key : Select the work plane side view and create a sketch with rectangle D/4 as

    width and length.

    Assembly : Create a sub assembly using shaft and key using coincidence mates. Create a

    main assembly by taking a central block as main part. Assemble Forks to the central

    block and insert sub assembly of shaft and key to flanges.

    Drawing : Create a new drawing file. Insert the assembly into drawing and project the

    side view and front view. Take a sectional view from the side view. Draw the dimensions

    using smart dimensing.

    Precautions

    1. Select the Work plane properly based on the views required in the drawing.

    2. Use the constraineds properly while drawing sketches.

    3. Select the correct mates between the parts.

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    Result : Parts, Assembly and Drawing of Universal Coupling prepared using Solid

    Works.

    ANALYSIS EXPERIMENTS

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    1. Static Analysis of a Beam Aim : To find the deflections at the nodes and to draw the shear force and bending moment diagrams of beam shown in figure.

    Data Given : Cross sectional Area of beam = 20.01m Youngs modulus = 7 22 10 /N m Poissons ratio = 0.3 ANSYS Procedure 1. Pre processor : A typical analysis in ANSYS begins with pre processing where data

    such as the geometry, materials and element types are specified.

    i) Set preferences : The preferences dialog box allows to choose the desired engineering discipline for context filtering of menu choices.

    - Turn on structural - Select structural discipline options as h-method

    ii) Define element types and options : Select proper element from this dialog box. Preprocessor Element typeAdd/Edit/DeleteSelect Beam 2DElastic3

    iii) Define real constants : Real constant provide additional geometry information. In this problem cross sectional area and moment of inertia are

    5000N/m

    7000N/m 10000N

    Cross section area=0.01m2

    Moment of Inertia=7.95e-6 m4Young's Modulus=2e7 N/m2

    Poisson ratio=0.3 All dimensions are in metres only

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    the real constants. Moment of inertia is needed to identify the shape of the cross section. Cross section area = 20.01m Moment of inertia = 6 47.95 10 m or 7.95e-6 m4

    iv) Define material properties : Material properties are constitutive properties of a material such as youngs modulus and poissons ratio. In this problem Youngs modulus = 7 22 10 /N m Poissons ratio = 0.3

    v) Modeling : This problem has Discretised into three elements formed from four nodes. In the world co-ordinate system the co-ordinates of the four nodes are as follows. 1(0,0) , 2(7.5,0) , 3(10,0) , 4(12.5,0)

    Preprocessor ModelingCreateNodes InActive CS After entering co-ordinates of each node click on Apply to enter next node

    click on .O K after entering the last node. Elements : In this problem Beam cross section is not varying so no need to set the element attributes. Preprocessor ModelingCreateElementsThruNodes Select two nodes to create an element. Then click on Apply and repeat the same procedure for the complete beam.

    2. Solution : Boundary conditions(Displacement constraints) and loads can be applied in this stage.

    i) Displacement Constraints :

    Solution Loads Apply Structural Displacements On Nodes Select Node-1 as displacement constraint and click on Apply . In this dialog

    box click on All DOF and Click on .O K Select Node-3 and click on Apply . In this dialog box click on UY and click on

    .O K . ii) Applying forces :

    Solution Loads Apply Pressure on Beams Select the element where the continuous varying load is acting. In this dialog box enter pressure at Node I = 5000N/m, Pressure at Node J = 7000N/m. Solution Loads Apply Force/Moment on Nodes Select Node-4 and click on Apply . In this dialog box select UY and enter UY= 10,000N

    iii) Solve : Solution Solve Current L.S

    3. Post processor : Post processor is used to review the results through graphics display and tabular listing.

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    Shear Force and Bending Moment diagrams can be obtained by defining element table. Define sequence numbers 2 and 8 for Shear Force diagram. Define sequence numbers 6 and 12 for Bending Moment diagram General Post processor Element table Define tableAdd In this dialog box scroll down the left text box and select By sequence num Type 2 in the right side down text box. Then click on Apply . Repeat the same procedure for 8,6,12 numbers. Shear force diagram: General Post processor Plot Results Line Element Res In this dialog box select Element table item at Node I =2 select Element table item at Node J =8 Click on .O K . Bending Moment diagram: General Post processor Plot Results Line Element Res In this dialog box select Element table item at Node I =6 select Element table item at Node J =12 Click on .O K .

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    2. Static Analysis of a Truss Aim : To find the deflections at the nodes for the truss configuration shown in figure.

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    Data Given : Cross sectional Area of beam = 20.01m

    At Node-5 Force is acting at an angle 1 2.5tan1

    = 68.11 = Inclined force at Node-5 F1=44480N. Horizontal component of Force F1 = ( )44480 cos 68.11 16525.6N = Vertical component of Force F1 = ( )44480 sin 68.11 41298.64N = Force acting at Node-8 is in vertically downward direction i.e F2=44480N Based on the truss dimensions Co-ordinates of the nodes in World Co-ordinate system are as follows : 1-(0,0) , 2-(12,0) , 3-(2.4,6) , 4-(9.6,6) , 5-(-3,12) , 6-(3,12) , 7-(9,12) , 8-(15,12) , 9-(3,16.5) , 10-(9,16.5). All dimensions are in meters only. ANSYS Procedure 4. Pre processor : A typical analysis in ANSYS begins with pre processing where data

    such as the geometry, materials and element types are specified.

    i) Set preferences : The preferences dialog box allows to choose the desired engineering discipline for context filtering of menu choices.

    - Turn on structural - Select structural discipline options as h-method

    ii) Define element types and options : Select proper element from this dialog box.

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    Preprocessor Element typeAdd/Edit/Delete Select Beam Link-2D spar-1.

    iii) Define real constants : Real constant provide additional geometry information. In this problem links of the entire truss configuration is of same cross sectional area. Cross section area = 20.01m

    iv) Define material properties : Material properties are constitutive properties of a material such as youngs modulus and poissons ratio. Assume the material as isotropic. In this problem Youngs modulus = 7 22 10 /N m Poissons ratio = 0.27

    v) Modeling : This problem has Discretised into 17 elements formed from 10 nodes. In the world co-ordinate system the co-ordinates of the four nodes are as follows. 1-(0,0) , 2-(12,0) , 3-(2.4,6) , 4-(9.6,6) , 5-(-3,12) , 6-(3,12) , 7-(9,12) , 8-(15,12) , 9-(3,16.5) , 10-(9,16.5). All dimensions are in meters only.

    Preprocessor ModelingCreateNodes InActive CS After entering co-ordinates of each node click on Apply to enter next node

    click on .O K after entering the last node. Elements : In this problem link is assumed as isotropic so no need to set the element attributes. Preprocessor ModelingCreateElementsThruNodes Select two nodes to create an element. Then click on Apply and repeat the same procedure for the complete truss.

    5. Solution : Boundary conditions(Displacement constraints) and loads can be applied in this stage.

    i) Displacement Constraints :

    Solution Loads Apply Structural Displacements On Nodes Select Node-1 as displacement constraint and click on Apply . In this dialog

    box click on All DOF and Click on .O K Select Node-2 and click on Apply . In this dialog box click on UY and click on

    .O K . ii) Applying forces :

    Solution Loads Apply Force/Moment on Nodes Select Node-5 and click on Apply . In this dialog box select UX and enter UX= 16525N. Again pick node-5 UY= 41298N Node-8 UY= 44480N

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    iii) Solve : Solution Solve Current L.S

    6. Post processor : Post processor is used to review the results through graphics display and tabular listing. General Post processor Plot Results Nodal Solution In this dialog box select items to be contoured as DOF Solution and translation as USUM. Item to be plotted is Def+Undeformed. Then click on .O K

    3. Static Analysis of a Plate

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    Aim : To find the VonMosses stress distribution and factor of safety for the given plate.

    Procedure

    Part Model

    Prepart model by taking a work plane in the front view. Draw the sketch with

    given dimensions and extrude it to get the given plate.

    Analysis

    1. To start analysis in solid works add the solid works simulations menu in the menu

    bar. To add the menu Select tools ->Options->Solidworks simulation.

    2. Select new study from solid works simulation give a name to that study.

    3. Follow the simulation tool bar. Select the contraints button and select left side

    edge of the plate to fix the plate.

    4. Add material to the model. Select material from the material library. For the given

    plate select steel.

    5. Click on apply force button enter force as 10240N.

    6. Select Mesh and RUN button to solve the problem.

    7. Click on Result button to get the results in the required format.

    Precautions

    1. Select correct edge or face while applying constraints or forces.

    2. Refine the mesh size till the convergence occurs in induced stresses.

    Result : VonMosses stresses and factor of safety are determined for given plate.

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    CAM EXPERIMENTS

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    1. MANUAL PART PROGRAMMING & MACHINING USING AUTO CAD FOR CNC TURNING

    Step Turning Component to be produced in a CNC Turning Machine

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    Table Indicating the End-Point Coordinates

    MANUAL PART PROGRAM O1234;

    G28 U0;

    G28 W0;

    M06 T02;

    M03 S1500;

    G00 X10 Z5;

    G01 X10 Z2;

    G71 U0.3 R1;

    G71 U0.2 W0.2 P10 Q20 F50;

    N10 G01 X10 Z-20;

    G01 X15 Z-20;

    G01 X15 Z-30;

    G01 X20 Z-30;

    G01 X20 Z-40;

    N20 G01 X26 Z-40;

    G70 P10 Q20 F25;

    G28 U0 W0;

    M05;

    M30;

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    2. MANUAL PART PROGRAMMING USING AUTO CAD FOR CNC MILLING

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    MANUAL PART PROGRAM

    MAIN PROGRAM

    O1234;

    G00 G17 G54 G90 G80 G40;

    G00 Z100;

    M03 S2000;

    G00 X-10 Y-10;

    G00 Z10 M09;

    G01 Z0 F300;

    M98 P2000 L20;

    M98 P2001 L1;

    G00 Z10;

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    G00 X100 Y50;

    G01 Z0 F300;

    M98 P2002 L30;

    M98 P2003 L1;

    G00 Z100 M09;

    M30;

    PART SUB-PROGRAM - (ROUGH CONTOUR MILLING)

    O2000;

    G01 G91 Z-0.5 F300;

    G01 G90 X-10 Y9 F300;

    G01 X191 Y9 F300;

    G01 X191 Y91 F300;

    G01 X9 Y91 F300;

    G01 X9 Y-10 F300;

    G01 X-10 Y-10 F300;

    M99;

    PART SUB-PROGRAM (FINISH CONTOUR MILLING)

    O2001;

    G01 G90 G42 D1 X-10 Y10 F300;

    G01 X190 Y10 F300;

    G01 X190 Y90 F300;

    G01 X10 Y90 F300;

    G01 X10 Y-10 F300;

    G01 G40 X-10 Y-10 F300;

    M99;

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    PART SUB-PROGRAM (ROUGH POCKET MILLING)

    O2002;

    G01 G91 Z-0.5 F300;

    G01 G90 G40 X106 Y50 F300;

    G03 X106 Y50 I-6 J0 F300;

    G01 X112 Y50 F300;

    G03 X112 Y50 I-12 J0 F300;

    G01 X118 Y50 F300;

    G03 X118 Y50 I-18 J0 F300;

    G01 X124 Y50 F300;

    G03 X124 Y50 I-24 J0 F300;

    G01 X128 Y50 F300;

    G03 X128 Y50 I-28 J0 F300;

    G01 X100 Y50 F300;

    M99;

    PART SUB-PROGRAM (FINISH CONTOUR MILLING FOR

    POCKET)

    O2003;

    G01 G90 G41 D1 X129 Y50 F300;

    G03 X129 Y50 I-29 J0 F300;

    G03 X100 Y79 I-29 J0 F300;

    G01 X100 Y50 F300;

    M99;

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    3. Robot Programming through computer

    HOME ALL

    SPEED 60

    JOINT A1 22.64 A2 -90.08 A3 90.08 A4 0.00 A5 90.00 A6 0.00

    JOINT A1 22.64 A2 -55.75 A3 59.43 A4 0.00 A5 90.00 A6 0.00

    GRIPPER OPEN

    JOINT A1 22.64 A2 -55.75 A3 69.63 A4 0.00 A5 66.10 A6 0.00

    GRIPPER CLOSE

    JOINT A1 22.64 A2 74.99 A3 84.03 A4 0.00 A5 66.10 A6 0.00

    JOINT A1 -90.97 A2 -74.79 A3 84.03 A4 0.00 A5 66.10 A6 0.00

    JOINT A1 -90.97 A2 -48.99 A3 75.16 A4 0.00 A5 66.10 A6 0.00

    JOINT A1 -90.97 A2 -48.99 A3 76.38 A4 0.00 A5 53.32 A6 0.00

    GRIPPER OPEN

    JOINT A1 -90.97 A2 -71.03 A3 79.89 A4 0.00 A5 53.32 A6 0.00

    JOINT A1 -2.46 A2 -71.03 A3 79.89 A4 0.00 A5 53.32 A6 0.00

    -Run the program

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    VIVA QUESTIONS

    1) DefineAutomation?Answer:Automationmaybedefinedastheprocessofhavingmachinesfollowapredetermined sequence of operations with little or no human labour, usingspecialized equipment and devices that perform and control manufacturingprocesses.

    2) DefineCADandCAM.Answer: CAD may be defined as any design activity that involves the

    effective use if computer to create, modify or documentengineeringdesign.CAM may be defined as an effective use of computers and

    computertechnologyintheplanning, management and control of the manufacturing

    function.

    3) DefineCAD/CAM.Answer:CAD/CAMisatechnologymovinginthedirectionofgreaterintegrationof design & manufacturing & It will provide the technology base for thecomputerintegratedfactoryofthefuture.

    4) DefineCAE?Answer: It becomes a comprehensive tool to form a link throughout atengineeringindustry.Thus,CAEisacombinationoftechniquesinwhichmanandmachineareblended intoaproblemsolvingteam, intimatelycouplingthebestcharacteristicsofeach.

    5) WhatarethebasicstepsinvolvedinShigleyDesignProcess.Answer: 1)RecognitionofNeed 2)DefinitionofProblem 3)Synthesis 4)AnalysisandOptimization 5)Evaluation 6)Presentation

    6) ExplainthetermProductlifecycle.

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    Answer:AManufacturedproducthasalife.Thedemandforaproductdoesnotlast long.The lifecycle isdrivenbycustomersandmarkets,whichdemand theproduct.Theproductcyclebeginswithaconcept,and idea foraproduct.Thisconcept is cultivated, refined, analyzed, improved upon and translated into aplanfortheproductthroughthedesignengineeringprocess.

    7) WhatdoyoumeanbyIslandsofautomation?Answer:Theindividuallyautomatedworkstationsorprocessesarecalledislandsofautomation. Inotherwords the term islandsofautomation represents thevarious technologies that facilitate manufacturing automation in isolation,withouthavingintegratedwithothermanufacturingtechnologies.

    8) ExplainGeometricModelling?Answer:GeometricModellingreferstocomputercompatibleandmathematicalrepresentationof geometry.Onlymathematical representationof geometry isnotenough.Onlyvisualrepresentationofgeometryisnotenough.

    9) Whatarethe3basictypesofGeometricModelling?Answer:1)Wireframemodelling,2)surfacemodelling,3)SolidModelling

    10) WhatismeantbyRapidPrototyping?Answer: It is developed as an alternative to subtractive processes. Thesemethods are unique in that they add and bond materials in layers to formobjects&alsoforproducingcomplexpartgeometries.

    11) Whatisproductionplanningandproductioncontrol?Answer: Production planning is a preproduction activity. It is the predetermination of manufacturing requirements such as manpower, materials,machines,andmanufacturingprocess.Productioncontrol, throughcontrolmechanism, tries to takecorrectiveactiontotakecorrectiveactiontomatchtheplannedandactualproduction.

    12) Whatisgrouptechnology(GT)?Answer: Group technology (GT) is a manufacturing philosophy to increaseproductionefficiencybygroupingavarietyofpartshavingsimilaritiesofshape,dimension,and/orprocessroute.

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    13) Whatisapartfamily?Answer:Apartfamilyisacollectionofpartswhicharesimilareitherbecauseofgeometric shape and size or because similar processing steps are required intheirmanufacture.

    14) Listthegeneralmethodsusedforgroupingpartsintopartfamilies.Answer: 1.Visualinspection, 2.Partsclassificationandcodingsystem,and 3.Productionflowanalysis

    15) Listanysixcodingsystemsthatarewidelyrecognizedinindustries.Answer: 1.Opitzclassificationsystem, 2.MICLASSsystem, 2.DCLASSsystem, 4.CODEsystem, 5.KK3system,and 6.CUTPLANsystem.

    16) WhatismeantbyCAPP?Answer: CAPP refers to Computer Aided Process Planning. CAPP is used toovercomethedrawbacksofmanualprocessplanning.Withtheuseofcomputerson the process planning one can reduce the routine electrical work ofmanufacturingengineers.Also itprovidestheopportunitytogeneraterational,consistentandoptimalplans.

    17) Writetheactivitiesofproductioncontrol.Answer: 1.Shopfloorcontrol; 2.Inventorycontrol; 3.ManufacturingResourceplanning(MRPII) 4.Justintimemanufacturingsystems.

    18) WhatisBOM?Answer: Thebillofmaterials (BOM)designateswhat items andhowmanyofeachareusedtomakeupaspecifiedfinalproduct.

    19) DefineCIM.Answer:CIMistheintegrationofthetotalmanufacturingenterprisethroughtheuse of integrated systems and data communication coupled with newmanagerialphilosophiesthatimproveorganizationalandpersonnelefficiency.

    20) WhatarethebasicapproachesofCAPP?Answer: 1.Retrieval(orVariant)CAPPsystem

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    2.GenerativeCAPPsystem.21) DefineFMS?

    Answer: A Flexible Manufacturing System (FMS) is an individual machine orgroup of machines served by an automated material handling system that iscomputercontrolledandhasatoolhandlingcapability.

    22) WhatarethecomponentsofFMS?Answer: 1.Processingstationsorworkstations 2. Material handlingandstorage 3.Computercontrolsystem 4.Humanlabour

    23) WhatismeantbyNC?Answer:NCcanbedefinedasaformofprogrammableautomationinwhichtheprocessiscontrolledbynos,lettersandsymbols.

    24) WhatarethebasicelementsofNCMachinesystem?Answer: 1.Programofinstructions 2)MachineControlUnit 3.NCMachinetool 4)NCcuttingtools

    25) Whatarethetoolpositioningmethods?Answer: 1)Absolutepositioningmethod 2) Incremental PositioningMethod

    26) DifferenttypesofNCmotioncontrolsystems.Answer: 1)Pointtopointcutmode 2)Straightcutmode 3)Contouringcutmode

    27) Explaintheterms,Fixedzero&Floatingzero.Answer: Fixed zero: The origin is always located at the same position on themachinetableFloatingZero:Toset thezeropointatanypositionon themachine table.Thisfeatureiscalledfloatingzero.

    28) Whatisthecodeusedforspindlerotation,clockwiseandcounterclockwise.Answer:M03forspindleCW,M05forspindleCCW

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    29) FunctionofM33code.Answer:Threadcuttingconstantlead

    30) FunctionofG90,G91.Answer:AbsoluteInput,IncrementalInput.

    31) FunctionofG81G89.Answer:Canneddrillingandboringcycle.

    32) FunctionofAdaptivecontrol.Answer:Machinecontrolunitsforwhichfixedspeedsandfeedsaredeterminedbyfeedsaredeterminedbyfeedbacksensorsratherthanbybeingprogrammed.

    33) DatabaseManagementsystem(DBMS),explain.Answer: A software system formanaging data andmaking such features asinterrogation,maintenance,andanalysisofdataavailabletousers.

    34) WhatistheuseofF3keyinAutoCAD?Answer:OSNAPON\OFF

    35) WhatistheuseofXPLODEcommand?Answer: This command is used to convert a polyline object into individualobjects.

    36) UseofPEDITcommandinAutoCAD.Answer: This command is used to edit the existing polyline object on thedrawingscreen.

    37) FunctionofWBLOCKcommandinAutoCAD.Answer:Thiscommand isusedtocreateblockswithselectedobjects fromthedrawingscreenwhichcanberecalledatanytimeinanyotherdrawingfile.

    38) WhatistheuseofCommand,REVSURF?Answer:Itcreatesrevolvedsurfacealongthegivenaxistogivenangle.

    39) WhatisthefunctionofEXTRUDEcommand?

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    Answer:Thiscommandisusedtoaddmaterialtoaclosed2dpolylineobjectinzdirectiontothegivendepthandtaperangle.

    40) WhataretheBooleanoperationsinAutoCAD?Answer:UNION,SUBTRACT,INTERSECT,INTERFERE.

    OBJECTIVE TYPE QUESTIONS

    1) CAD/CAMistheinterrelationshipbetween

    A) Marketinganddesign B)ManufacturingandmarketingC) Engineeringandmarketing D)EngineeringandManufacturing

    2) Twodiscipline,whichareusuallytiedbyacommondatabaseareA) Marketinganddesign B)ManufacturingandmarketingC) Engineering and marketing D) Engineering and Manufacturing

    3) CAEandCAMarelinkedthroughA) A common data base and communications system B) NC tape programming and automated design C) Assembly automation and tool production D) Parts production and testing

    4) CAD/CAMishardwareoriented,A)Numericalcontrol B)DocumentationC)Software D)Communications

    5) KeyhardwareitemswhichtiesaCAD/CAMsystemtogetherisA)Keyboard B)GraphicsworkstationC)Digitizer D)Plotter

    6) Item,whichbestdescribesaCAMtechnologyisA)Numericalcontrol B)DocumentationC)Drafting D)GeometricModelling

    7) GrouptechnologybringstogetherandorganizesA)Partsandsimulationanalysis B)DocumentationandanalysisC)Automationandtoolproduction D) Common parts, problems, andtasks

    8) Fourbasicelementsarerequiredforanautomatedmachinetoolorproductionprocessareinputinterface,memory,outputinterfacesandA)Logic B)NCtapeprogramming

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    B)Software D)Computergraphicsworkstation9) Automationmeans

    A)Increasedproductivity B)WorkerscontrollingmachinesC)AssistingandreplacinghumansbymachinesD)Allofthese

    10) UseofmoderncontroltechnologyinautomationsystemsA)Reducedcost B)IncreasesyieldC)Improvereliability D)Allofthese

    11) AflexiblemanufacturingsystemmaybeA)Anautomatedassemblyline B)ExpensivetoalterC)VerydifficulttochangewhennewproductsareintroducedD)Allofthese

    12) NumericcontrolA)Appliesonlytomillingmachine B)IsamethodforproducingexactnumberofpartsperhourC)IsamethodforcontrollingbymeansofsetofinstructionsD)Allofthese

    13) WhatarethecomponentstypicalNCsystems?A)Tapeinput B)ControllerC)Machinetool D)Allofthese

    14) FlexiblemanufacturingallowsforA)Factorymanagement B)AutomatedDesignC)ToolDesign D) quick and in expensive productdesign

    15) AprogrammablecontrollerA)Allowsfastermachinecheckout B) Is easier to repair than standardrelaylogicC)Hasallthelogicstatusmaintainedinmemory D)Allofthese

    16) ThebenefitisofnumericalcontrolonmachinesareA)Reducedfixturing B)reducednonproductivetimeB)Improvedqualitycontrol D)Allofthese

    17) ThebenefitsofCADareA)Improveddesignaccuracy B)ShorterleadtimesC)Minimumtranscriptionerrors D)Allofthese

    18) IntegrationofCADandCAMiscalledA)CIM B)CAEC)CAMalone D)CADalone

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    19) RobotsarespecifiedbyA)Controlsystem B)AxisofmovementC)Payload D)Allofthese

    20) AdvantageofNCisA)Reducedmanufacturingtime B)ReducedfixturingC)Reducednonproductivetime D)Allofthese

    21) ThemainfunctionsofCADareA)Drafting B)GeometricmodellingC)Documentation D)Allofthese

    22) CADdisplayconfigurability,whichallowsworkwithoutanyhostsupportisA)Highlyintelligence B)LowintelligenceC)mediumintelligence D) one with no secondary storagecapacity

    23) WhichofthefollowingitemsbestdescribesaCAMtechnologyA)Drafting B)Numericalcontrol C)Documentation D)GeometricModelling

    24) ANCmachinetoolsystemhasreplacedA)Handactionoftheoperator B)brainoftheoperationC)Handandbrainoftheoperator D)noneofthese

    25) NCmachineiseconomicaltouseespeciallywhenonehastomanufactureA)Smallquantityofpartsproducts B)NewproductC)Largevarietywithsmallnumberofproducts D)Noneofthese

    26) InpointtopointNCmachine toolsystem themovementof tool to thenextpointA)Isofmostsignificance B)isofnosignificanceC)NextpositionoftheworkisachievedbymovingthehobD)AandC

    27) Whichofthe following isnotconsideredamethodof inputcontrol inaCADsystem?A)Programmablefunctionbox B)JoystickC)Plotter D)Touchterminal

    28) OperatorinteractiondirectlywithCRTisaccomplishedviaA)VectorScanning B)AdigitizingtabletC)AStylus D)ATouchterminal

    29) Thetermthat isusedforgeometricmodeling likesolidmodeling,wireframemodelinganddraftingisknownas:A) Softwarepackage B)OperatingsystemC) Application software D) None of these

    30) Thenervecenterorbrainofanycomputersystemisknownas

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    A)CPU B)StoragedevicesC)ALU D)Monitor

    31) FollowingisnotaoperatingsystemsoftwareA)Windows B)UNIXC)VAX/VMS D)IDEAS

    32) 2 DCADmodelwillhave

    A)Zerothickness B)ConstantthicknessC)Variablethickness D)None

    33) No.oftangentsrequiredtodescribecubicsplinesA)1 B)2C)3 D)4

    34) FurgusoncurvesarealsocalledasA)BSplines B)CubicsplineC)RationalBsplines D)Beziercurve

    35) ComputerwillperformthedataprocessingfunctionsinA)N.C B)C.N.CC)D.N.C D)BothAandB

    36) APTstandsforA)AutomaticallyProgrammedTool B)AutomatedPartToolC)AutomatedPalletTool D)Noneoftheabove

    37) CNCdrillingmachineisconsideredtobeA)PTPcontrolledmachine B) Continuous path controlledmachineC)Servocontrolledmachine D)Adaptivecontrolledmachine

    38) Thefollowingcodeisusedtospecifyfeedrateinmm/minisA)G28 B)G40 C)G94 D)G90

    39) LinearinterpolationisaccomplishedbyA)G00 B)G01 C)G02 D)G03

    40) EIAStandardpunchtapehasA)Eightregularcolumnofholes B)SevenregularcolumnofholesC)Nineregularcolumnofholes D)Tenregularcolumnofholes

    41) InOPITZcode,plainsurfacearerepresentedinA)1digit B)2nddigitC)3rddigit D)4thdigit

    42) CellularmanufacturingsystemisdesignedonthebasisofA)JIT B)MRPC)GT D)Layout

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    43) KK3systemconsistsofA)21digits B)22digitsC)23digits D)25digits

    44) Fordevelopmentofaprocessplanfornewparts,thebestisA)Variantprocessplan B)GenerativeprocessplanningC)GTplanning D)Noneoftheabove

    45) Capacityplanningisconcernedwith A)Howmanymachinesrequired B)howmuchlabourrequiredC)BothA&B D)None

    ANSWERS

    1) D 2) B 3) A 4) C 5) B 6) A 7) D 8) A 9) D 10) D 11) A 12) D 13) B

    14) D 15) C 16) D 17) D 18) A 19) C 20) D 21) C 22) D 23) D 24) A 25) A 26) B

    27) C 28) A 29) A 30) A 31) D 32) B 33) B 34) B 35) B 36) A 37) A 38) C 39) B

    40) A 41) D 42) C 43) A 44) B 45) C