UNIT-I

1. What is meant by DFMA?

It involves the systematic consideration of manufacturability and assemblability in the

development of a new product design.

2. What are the coding systems?

a. Opitz classification systems
b. MICLASS system
c. Multiclass
d. CODE
e. DCLASS
f. CUTPLAN
g. RNC

3. Compare the Part design and Manufacturing attributes

Part design attributes Part Manufacturing

attributes
Shape( basic external, basic internal) Production processes
Rotational or rectangular Operational sequence
Dimensions (major or minor) Production time
Material type Tools required
Part function Fixtures required
Length to diameter ratio(rotational parts) Batch size
Aspect ratio (rectangular parts) Machine tool
Surface finish Annual production
Tolerances Surface finish

4. Define the objectives of DFM

a. To identify product concepts that are inherently easy to manufacture.
b. To focus on component design for ease of manufacture and assembly
c. To integrate manufacturing process design and product design to ensure the best
matching of needs and requirements.

5. Define the objectives of DFA

a. To reduce the number of parts in an assembly
b. To optimize the assemblability of the parts
c. To optimize the handlability of parts and assemblies
d. To improve quality, increase efficiency and reduce assembly costs.

6. Give few guidelines for DFA.

a. Minimize the number of parts
b. Minimize assembly surfaces
c. Design for top-down assembly
d. Improve assemble access
e. Maximize part compliance
f. Maximize part symmetry
 g. Optimize part handling
h. Avoid separate fasteners
i. Standardize fasteners
j. Drive toward modular design
k. Design for ease of handling
l. Design for ease of testing.

7. What is Concurrent engineering?

It is a systematic approach to the integrated, concurrent design of products and their
related processes, including manufacture and support. This approach is intended to cause the
developers, from the outset, to consider all elements of the product life cycle from concept
through disposal, including quality, cost, schedule, and user requirements.

8. Define QFD.
Quality function deployment (QFD) is an important tool to facilitate multi functional
planning and communication in a concurrent engineering product development environment. It is
achieved by cross- functional teams, which collect, interpret, document, and prioritize customer
requirements.

9. What is Failure mode effective analysis (FMEA)?

Failure mode effective analysis is a systematic technique for the identification of the
possible modes of failure of a product or process, and of the likely consequences of such failure.

10. What is Poka- Yoke?

It is a device that permanently prevents the recurrence of the defect it is designed to
eliminate.

11. What is Rapid prototyping?

It is a term used to describe a number of techniques which rapidly produce solid physical
models of components ( ie, prototypes) and products using 3D computer data. The other names
for rapid prototyping include. Solid object modeling, tool-less manufacturing and desktop
manufacturing.

12. what are the different rapid prototyping techniques?

a. Stereolithography.
b. Selective laser sintering
c. laminated object manufacturing
d. Fused deposition modeling
e. Solider.
13. List few CAD/CAM software packages.
a. Auto-cad
b. Catia V5
c. Master cam
d. Pro/Engineer
e. Unigraphics
f. Edgecam
g. Solidworks

14. Define Group Technology (GT).

Group Technology (GT) is a manufacturing methodology in which identical or
similar components grouped processed together during design, process planning and
manufacturing so that a wide variety of components can be manufactured, at the least expense of
time, inventory, man hours and material handling.

15. List out the stages in Group Technology.

a) Production planners to setup the GT database.
b) Grouping the parts or components into part-families with some similar characteristics.
c) Re-design the shop-floor arrangement according to common shape, function or
manufacturing process and tooling.

16. Define Part families.

Part-family is defined as" collection of parts which are similar in terms of
geometric shape, size, and similar processing steps required in manufacturing, so flow of
materials through the plant improves".

17. Explain the two categories of attributes of parts.

1) Design attributes, which are concerned with part characteristics such as geometry, size, and
material.
2) Manufacturing attributes, which consider the sequence of processing steps required to make a
part.

18. List out the premises for the developed of DCLASS code.
i) A part may be best characterized bytes basic shape, usually is most apartment attribute.
ii) A Each basic shape may have several features, such as holes, slots, threads and grooves.
iii) A part can be completely characterized by basic shape; size; precision and material type, from
and condition.
iv) Several short code segments can be linked to from classification code that is
human recognizable and adequate for human monitoring.
v) Each of these code segments can point to more detailed information.

19. What is PFA?

Production flow analysis is a technique for pre-planning the division of the whole
factory into groups or departmental groups. When the knowledge of division is available,
then it is possible to plan the layout.

20. What is the weakness of PFA?

The weakness of production flow analysis (PFA) that the data used are derived
from production route-sheets. But the process-sequences have been prepared by different
process lanners and the difference is reflected on to these route-sheets.

21. What are the applications of GT?

1. Design: In a firm many components have similar shape. They can be grouped
in to design families and a design can be created by simply modifying an existing
component design from the same family.

2. In Manufacturing: For this purpose GT gives a great importance than simply a design
philosophy. Parts that are not similar in shape may still need similar manufacturing processes.
Parts of this type are called production family. (All parts may need same operation like drilling,
milling thread cutting etc.)

3. Process Planning: Process planning work can be facilitated as similar processes are needed
for all components of a particular family.
This helps production planning and control much easier because only similar parts are
considered for each cell. Such a cell-oriented layout is called a group technology layout or cellular
layout.

UNIT-2

1. What is a CNC system?

Computer numerical control (CNC) is the numerical control system in which a dedicated computer
is built into the control to perform basic and advanced NC functions. CNC controls are also
referred to as soft-wired NC systems because most of their control functions are implemented by
the control software programs.
2. List out any eight important Features of machine control unit in CNC.
a, Storage of more than one part program
b, Use of diskettes
c, Program editing at the machine tool site
d, Fixed cycles and programming subroutines
e, Interpolation
f, Positioning features for setup
g, Cutter length compensation
h, Diagnostics

3.What are the advantages of CNC over N.C?

a, The part program tape and tape reader are used only once to enter the program in to memory
b, Tape editing at machine site.
c, Greater flexibility.
d, Metric conversion.
e, Total manufacturing system

4.List out any four advantages of DNC system

a, Time sharing- the control of more than one machine by the computer.
b, Greater computational capability for such functions as circular interpolation.
c, Remote computer location- the computer is located in a computer-type environment.
d, elimination of tapes and tape reader at the machine for improved reliability.
e, elimination of hardwired controller unit on some systems.

5. List out any four CNC interpolation methods.

i. Linear Interpolator.
ii. Circular interpolator.
iii. Helical Interpolator.
iv. Parabolic Interpolator.
6. Classify the CNC Machine tool systems.
The classification of CNC machine tool systems can be done in four ways:
1. According to the type of machine: Point-to-point versus contouring
(Continuous path)
2. According to the structure of the controller: hardware-based NC versus CNC
3. According to the programming method: incremental versus absolute
4. According to the type of control loops: open-loop versus closed-loop
7. Distinguish Point to Point and continuous path CNC control.
S.No Point to point CNC control Continuous path CNC control

1 In a PTP system, the path of the In contouring, or continuous-path, systems,

cutting tool and its feed rate while the tool is cutting while the axes of motion
traveling from one point to the next are are moving.
without any significance

2 The simplest example of a point-to- The simplest example of a Continuous path

point (PTP) NC machine tool is a NC machine tool is a Milling machine.
drilling machine.

3 The path from the starting point to the All axes of motion might move
final position is not controlled. simultaneously, each at a different velocity

7. Distinguish between incremental and absolute systems.

S.No Incremental system Absolute system

1. An incremental system is one in which An absolute NC system is one in which all

the reference point to the next moving commands are referred to one
instruction is the endpoint of the reference point, which is the origin and is
preceding operation called the zero point

2. Each piece of dimensional data is A zero floating point allows the operator, by
applied to the system as a distance pushing a button, to select arbitrarily any
increment, measured from the point within the limits of the machine tool
preceding point at which the axis of table as the zero reference point
motion was present.

3. A further advantage of the absolute In the case of the incremental system, the
system is the possibility of easily part must be reprogrammed from the point at
changing the dimensional data in the which the original program has been
part program whenever required modified.

8. Distinguish between open loop control and closed loop control in the context of CNC control
system.
S.no Open loop control CNC system Closed loop control CNC system

1 The term open-loop control means that The closed-loop control measures the actual
there is no feedback, and the action of position and velocity of the axis and compares
the controller has no information about them with the desired references.
the effect of the signals that it Produces.

2. The open-loop NC systems are of digital
type and use stepping motors for driving
the slides.
The digital comparator correlates the two
sequences and gives, by means of a digital-to
analog converter (DAC), a signal representing
the position error of the system, which is used
to drive the dc servomotor.
9. What are all the feedback devices used in CNC system?
1. Resolver
2. Encoder
3. Feedback transducer
4. Linear scale or Tacho generator.

10. Draw the Basic block diagram of CNC System.

11. List out few Applications of NC/CNC machine tools.

CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch
presses etc and now expanded to robotics, grinders, welding machinery, EDM's, flame cutters
and also for inspection equipment etc. The machines controlled by CNC can be classified into the
following categories: CNC mills and machining centers.

CNC lathes and turning centers

CNC EDM
CNC grinding machines
CNC cutting machines (laser, plasma, electron, or flame)
CNC fabrication machines (sheet metal punch press, bending machine, or press brake)
CNC welding machines
CNC coordinate measuring machines.

12. What is MCU?

The Machine Control Unit (MCU) is the brain of the CNC System. The term MCU can be
interpreted broadly to encompass all electronics associated with the machine servo system.
Depending upon the number of microprocessors used the CNC systems are classified into single
processor or multiprocessor systems.

13. List out the functions of Microprocessor used in CNC system.

I) Overall system control.

ii) Input /output (I/O) control.

iii) Servo control of slide movements and main spindle rotation.

iv) Computations required for interpolation, spline fitting etc.

14. What are the advantages of using circular interpolation?

i, Better surface finish

ii, Greater accuracy.

iii. Less total machining time.

iv. Lower working costs.

15. List out four components used in DNC systems.

 1. central computer
2. bulk memory, which stores the NC part programs
3. Telecommunication lines
4. Machine tools

UNIT-III
1. What are the advantages of ball screws over conventional type screws used in CNC
system?
i, Ball screws have a longer life.
ii, Higher accuracy can be maintained.
iii, Two frictional resistance hence used for carrying heavier loads at faster rate.
iv, Low power requirement for driving.
2. Classify the feed back devices used in CNC system?
i, Velocity feed back device
a, analog type
b, Digital type
Digital type classified in to two types.
a, Photo electric type
b, Inductive type
ii, position feedback device.
a, Rotary transducers
b, Linear transducers
3. What is Ferranti system?
Ferranti system uses the Moir fringe effect for measuring the displacement of machine
slide/table. This set up consists of fixed and movable gratings etched on glass. The displacement
is measured by using the relation np= w tan
Where w= Width of the fixed grating.
P= Thickness of the fixed grating
= Angle of in inclination of grating, and
n= number of horizontal block areas in the moving grating.

4. Write the design criteria used in designing CNC Machine tools.

a, Machine structure
b, Guideways
c, Feed drives
d, Spindle and spindle bearings
e, Measuring systems and control, and
f, Gauging and tool monitoring
5. Explain the characteristics of sideways system.
-Good wear and friction resistance
-Good rigidity and damping capability
-Very close geometric and kinematic accuracy
-Ensure higher velocity of slide
-protect the machine structure against damage and swarf
-provision for adjusting the play, and
-Position in relation to work area.
6. List out few advantages of using Linear Motion Guide ways.
a, To reduce the friction.
b, To reduce the amount of wear.
 c, To reduce the heat generation
d, To improve the smoothness
e, Zero stick slip.
7. List out the few important types of spindles.
a. Collet and chucks with extensions
b. Face mill adaptor
c. End mill adaptor
d. Screwed end mill holder
e. Tapping head
f. Boring heads
g. Shell mill adaptor.
8. Define ATC.
An Automatic tool changer (ATC) is an important part of a machining centre. An
ATC picks up a tool from the magazine and keeps it ready for swapping with the tool in
the spindle which is presently cutting. The time for tool change varies between 3 to 7
seconds. The ATC plays a significant role in reducing idle time during tool change
operations. There are a number of different designs for automatic changers.
9. What are all important points to consider Ball screws arrangement.
- general arrangement of ball screws
- nut configurations
- mounting methods
- materials and heat treatment
- preloading
- preloading methods
- life and basic load capacity
- relation of life to load
- Selection of ball screws.
10. List out few requirements of selection of spindles in CNC Machines.
- High stiffness both static and dynamic
- Running accuracy
- Axial load carrying capacity
- Thermal stability
- Axial freedom for thermal expansion
- High speeds of operation.
11. What is a machining centre and classify?
The centre which consists of multifunction CNC machines equipped with ATCs, which are
capable of carrying out milling, drilling, reaming, tapping, boring, counter boring and allied
operations without operator intervention is called as machining centres.
Classification of machining centres.
a, Horizontal machining centre
b, Vertical machining centre
c, Universal machining centre
12. What is a rotary type encoder?
Rotary encoder is a device, which converts rotary motion into a sequence of digital
pulses. Encoder working based on photo- electric principle. There are two types of encoders
a, Absolute encoder
b, Incremental encoder
13. What are stepper motors?
 Stepper motors are also called as stepping motors or step motors. The name stepper is
given because this motor rotates through a fixed angular step in response to each input electrical
pulse received by its controller.
These motors are used for precise positioning and precise speed control in automation
system.
This motor is well suited for open loop control system because no feedback is required.
14. What are the types of work holding devices?
- V Blocks
- Step blocks
- Clamps
- Swivel base vice
- Angle plate
- Support jacks
15. Define qualified tools?
The tool which fits in to a location on the machine, where its cutting edge is accurately
positioned within close limits relative to a specified datum on the tool holder or slide.
16. What are the types of motors used in CNC systems?
For spindle drive motors
- Separately excited DC shunt motor, and
- Three phase AC induction motor.
For Feed drives
- servo motors
(a) AC servo motor
(b) DC servo motor
(c) Brushless DC servo motor
- stepper motors
(a) Variable reluctance motor
(b) Permanent magnet stepper motor
(c) Hybrid stepper motor
- Linear motors
17. Define Moir fringes
The moir fringe effect is produced when an optical granting slides in a direction at right
angles to its lines over another similar optical grating with its lines inclined at a slight angle to
those on the other grating. This interference fringe effect manifests itself as a pattern of light and
dark alternating bands, and progressive movement one grating relative the other causes the
pattern to go through a cycle.

UNIT- 4

1. What are the types of part programs prominent today?

APT- Automatically programmed tools
ADAPT Adaptation of APT
EXAPT- Extended subset of APT
UNIAPT- UNIted APT
SPLIT- Surdstrand processing Language Internally Translated
COMPACT II
CINTURN II
PROMPT
ELAN GNC
2. What is the difference between canned cycles and subroutines?

S.No Canned cycle Subroutines

1 A canned cycle is a cycle in which A Subroutine is a portion of a part

series of machine movements to
perform a particular machining
function such as drilling, milling,
boring and tapping.
program complete in itself, which is
stored in the computer, after
programming once. It is called again
and again in a main program with
required data whenever needed.

It is usually placed at the end of

The corresponding instructions of a main program. We can perform the
canned cycle are already stored in following functions.
2. the system memory. The following 1. Turning Subroutine
examples are some basic and 2. Milling Subroutine. etc
canned cycles codes available with
a number of machines, assigned by
EIA.
1. Drill cycle.
2. Dwell cycle
3. Basic Mill cycle
4. Peck drill cycle
5. Bore cycle
6. Cancel cycle

3. Distinguish between absolute and incremental positional methods.

S.No Absolute dimensional system Incremental dimensional

1 All the measurements are taken
from a fixed origin (0,0)
system.
It is one, which all the
measurements for the next
position are calculated from
the point at which the slide
was resting previously.

4. Explain the function of codes G28 and M30 (FANUC)

G28 Goto Reference point

A G28 causes a fast traverse to the specified position and then to the machine datum.
Examples G28 X34.0 Z5.0
G28 U0.0 W0.0

M30- Program end

Stops the spindle. Turns the coolant off. Terminates and resets the CNC program.

Example. M30

5. What are the four statements in APT language?

a) Geometric statements
b) Motion statements
c) Postprocessor statements
d) Auxiliary statements

6. State the function of a post processor in computer aided part programming.

The post processor is a separate computer program, written to prepare the
punched tape for a specific machine tool.

7. List the differences between modal and non-modal G codes.

Modal codes remain active until it is cancelled by a contradictory G code of same class.
For example, G70 which defines the dimensional units are metric will remain active until it is
cancelled by G71, but non-modal codes are active within the block. For example G04.
 8. What is the coordinate system for Lathe operations?

For Lathe operations only X and Z axes are used to represent the axis of the movement of the
tool and the axis of spindle respectively.

9. Write the procedure for developing Manual part programme.

The part programming requires an NC programmer to know some basic elements for
writing the programming steps of a part take place. The elements to be considered for manual
part programming are as follows.

- Type of dimensioning system

- Axis designation
- NC words
- Standard G and M codes
- Tape programming format
- Machine tool zero point setting

10. What is meant by Code and Redundant code?

Code is the series of combination of 1,s and 0,s. It represents a number or an alphabet or
any symbol. Redundant codes are necessary to reduce the possibility of incorrect reading of
tape by the tape reader.

11. Write the functions of the following codes:

(a) G00, G01, G02, G03 (b) M03, M05, M02.
G00- Point to point positioning
G01- Linear interpolation
G02- Arc clockwise
G03- Arc counter clockwise
M03- spindle clockwise
M05- Spindle
M02- End of program.

12. Write the advantages and limitations of fixed block format.

The main advantage of this format is that the whole instruction block can be read at the
same instant, instead of reading character by character. Hence best suitable for pneumatic, hole
sensing, series of tape reading.

13. What is Do-loop? Give the general structure of it.

Do-loop is a number of steps or operations repeated over a number of equal steps for a
previously fixed number of times.
The general format of Do-loop is as follows: Nm/n

Where n= Number of times to execute a loop, and

M= Block number up to which the loop is repeated.

14. List any four-post processor statements.

-COOLANT/ON, OFF, MIST
-RAPID
-TURRET
-MACHIN
15. List the motion command words used in achieving path commands.
GOLFT
GORGT
GOFWD
GOBACK
GOUP
GODOWN
 UNIT-5
1. What are the components of shop floor control system?
a. Master schedule
b. Engineering database
c. Manufacturing database
d. MRP
e. Capacity planning

2. What is JIT Logic?

a. zero defects
b. zero set up time
c. zero inventory
d. zero handling
e. zero breakdowns
f. zero leadtime
g. batch size of one

3. What is aggregate production planning?

Aggregate planning is an operational activity which does an aggregate plan for the
production process, in advance of 2 to 18 months, to give an idea to management as to what
quantity of materials and other resources are to be procured and when, so that the total cost
of operations of the organization is kept to the minimum over that period.The quantity of
outsourcing, subcontracting of items, overtime of labor, numbers to be hired and fired in each
period and the amount of inventory to be held in stock and to be backlogged for each period
are decided. All of these activities are done within the framework of the company ethics,
policies, and long term commitment to the society, community and the country of operation.

Aggregate planning has certain prerequired inputs which are inevitable. They include:

Information about the resources and the facilities available.

Demand forecast for the period for which the planning has to be done.
Cost of various alternatives and resources. This includes cost of holding inventory,
ordering cost, cost of production through various production alternatives like
subcontracting, backordering and overtime.
Organizational policies regarding the usage of above alternatives.

4. What is a digital mock up?

Digital MockUp or DMU is a concept that allows the description of a product, usually
in 3D, for its entire life cycle. Digital Mockup is enriched by all the activities that contribute to
describing the product. The product design engineers, the manufacturing engineers, and the
support engineers work together to create and manage the DMU.

5. what are the activities of process planning?

a. analyzing finished part requirements
b. determining operating sequence
c. selecting machines
d. selecting material parameters
e. calculating processing times
f. documenting process planning
g.
6. what are the objectives of product data management system?
A product data management or PDM system should be in place to manage all of
this product related data across the various functions and through the lifetime of the
product , irrespective of where in the company the data is located.
PDM Functions
A. User functions
- data vault and document management
- process and workflow management
- product structure management
- data classification and retrieval
- project management
B. Utility functions
- data communication and notification
- data transport
- data translation
- image services
- system administration
 7. what is meant by CAPP?
CAPP refers computer aided- process planning . CAPP is used to overcome the
drawbacks of manual process planning. With the use of computers in the process
planning, one can reduce the routine clerical work of manufacturing engineers. Also it
provides the opportunity to generate rational, consistent and optimal plans.

8. Differentiate the underlying concepts of variant and generative CAPP systems.

In variant CAPP system, a process plan for a new part is created by
recalling, identifying and retrieving an existing plan for a similar part, and making the
necessary modifications for the new part.
Whereas the generative CAPP system automatically generates the process plan
based on decision logics and pre-cooled algorithms.

8. List some commercial variant and generative CAPP software systems.

Some of the commercial variant CAPP systems include CUTPLAN,
COMCAPP,V,DCLASS, and INTELLICAP
Some of the commercial generative CAPP systems include AUTAP,CMPP,GENPLAN
and LOCAM.

9. Define the terms Schema and DBMS

The schema is a diagrammatic representation of the database structure.
A database management system is the collection of software which generates, runs and
maintains a database.

10. Classify the data models.

1. Record- based models
- Hierarchical data models
- Network data models
- Relational data models
2. object-0riented data models.

11. List various relational database operators.

- union
- intersection
- difference
- product
- select
- project
- join
- divide
12. list some important features of DBMS
- Data dictionary
- Utilities
- Query language
- Report generator
- Access security
- Data recovery
13. Why companies need databases?
According to date, companies need databases due to the following
seven reasons
1. the data can be shared
2. redundancy can be reduced
3. inconsistency can be avoided/ reduced
4. standards can be enforced
5. security restrictions can be applied
6. integrity can be maintained
7. Conflicting requirements can be balanced.
14. what is meant by bilateral tolerance
it is specified as plus or minus deviation from the basic size, for example , 3,850 +or
0.0003 mm.

15. what are the four important aspects of computer aided tolerancing
- tolerance representation
- tolerance specification
- tolerance analysis
- tolerance synthesis