Soly(4,5,12) Abdullah(15,16,18)

4- Detail the different stages in the production of a component on CNC machines.

First stage The shape of the component has to be converted from the
pictorial representation (the drawing) into a numerical format, and a part
program created. The part program contains the sequence of operations
and the numerical format which represent the movements that the cutter or
work has to follow to produce the component.
Second stage It is necessary to enter the details of the part program on to a
suitable medium such as punched tape which can be 'read' electronically.
Third stage After the information has been input to the control unit the
component is produced by controlling the movements of the cutter. There
are two systems used for controlling the movement of the carriages on
numerically controlled machine tools: closed loop and open loop.
5- Describe the principle of operation of CNC machines using (a) Closed loop systems and (b) Open loop
systems
With open loop systems special electrical
motors are used, and there are no output transducers for positional
control. Consequently there is no monitoring of the work size while it is
being machined. The actual size of the component is not known until it is measured after it is completed ;
that is, the loop is not complete and is said
to be 'open'.
With these systems, components of correct size and shape are produced by
continuously monitoring (measuring) the movement and position of the
carriages (work tables) on which the tools or work are mounted, while the
component is being machined. The amount of movement is controlled to
specified requirements; this ensures that the actual size of the work is the

desired (designed) size. Any difference between actual and desired size is
corrected while the component is being machined, that is the machining
'loop' is closed.
12- Detail all the words that can appear in a block.
Following is a list of the different types of words in the formation of a block.
SEQUENCE NUMBER (n-words): This is used to identify the block.

PREPARATORY WORD (g-words): This word is used to prepare the

controller for instructions that are to follow. For example, the word g02 is
used to prepare the NC controller unit for circular interpolation along an
arc in the clockwise direction. The preparatory word is needed so 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/or b-words would
specify the angular positions

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, t05 might be the

designation of a '/2-in. drill bit in turret position 5 on an NC turret drill.

MISCELLANEOUS FUNCTION (m-word): The m-word is used to specify

certain miscellaneous or auxiliary functions which may be available on
the machine tool. Of course, the machine must possess the function that
is being called. An example would be m03 to start the spindle rotation.
The miscellaneous function is the last word in the block. To identify the
end of the instruction, an end-of-block (EOB) symbol is punched on the
tape.
15- Define repeatability as applied to CNC machine tools.
The ability of the machine to produce continually accurate slide movement is called repeatability
16- List five qualities which need to be incorporated in a machine design if repeatability is to be
maintained.
Repeatability is dependent on the following features being incorporated in
the design of the machine;
(a) Adequate strength;
(b) Rigidity;
(c) Minimum of vibration;
(d) Dimensional stability;
(e) Accurate control of the slide movements.
18- List the advantages of using recirculating ball screws to facilitate slide movement.
The advantages of recirculating ball screws over Acme screws are:
(a) Longer life;
(h) Less wear:
(c) Low frictional resistance;

(d) Less drive power required due to reduced friction;

(e) Higher traversing speeds can be used;
(f) No stick slips effect;
(g) More precise positioning over the total life of the machine.