ADVANCED MANUFACTURING TECHNOLOGY

2- MARKS QUESTION AND

ANSWER
UNIT-I
1. What is the need for unconventional machining processes?
High production rate
Low cost of production
Better surface integrity,
High surface
finish
2.
What are the characteristics of UCM processes?
Performance is independent of strength barrier
Use different kinds of energy in direct form
In general, low MRR but better quality products
Comparatively high initial investment cost
3.
Differentiate the conventional and unconventional machining processes
in terms of principles.
In conventional processes, the material is removed in the form of chips
by the advancing cutting tool that plastically deforms (shearing) the material
ahead.
In the case of the UCM processes,energy (Electrical, Chemical, ThermoElectric, Mechanical) in its direct form is utilized for the material removal and
so there is no physical contact between the workpiece and tool.
What are the various types of energy
traditional machining
techniques? Give examples for each
.
-Pneumatic pressure- AJM
-Hydraulic pressure- WJM, USM, AWJM
-Corrosion- CHM, CHB, PCM
-High current density in electrolytes- ECM
-High voltage- EDM (for sparking);
-IBM, EBM (ionizing);
-LBM(creating avalanche in lazing medium);
-PAM (for ionizing the plasma gases)
4.

sources

used

in

non-

5. Classify the different types of unconventional machining processes

based on the mechanical energy.
Abrasive Jet Machining (AJM)
Water Jet Machining (WJM)
Ultrasonic Machining (USM)
Abrasive Water Jet Machining (AWJM)
6. Identify the mechanism of material removal, transfer media and energy
source for EDM.
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Removal- Fusion of materials by arcs

Transfer media

- Electron stream

Energy source

- High voltage

7. Identify the mechanism of material removal, transfer media and

energy source for ECM. Mechanism of material removal- Ion
displacement
Transfer media

- Electrolyte

Energy source

- High current

8. Identify the mechanism of material removal, transfer media and

energy source for EBM. Mechanism of material removalVaporization
Transfer media

- Electron stream

Energy source

- High voltage

9. Identify the mechanism of material removal, transfer media and

energy source for LBM. Mechanism of material removalVaporization
Transfer media

- Amplified coherent light radiation

Energy source

- High voltage

10. Identify the mechanism of material removal, transfer media and

energy source for PAM. Mechanism of material removalVaporization
Transfer media

- Ionised gas stream

Energy source

- High voltage

11. Identify the mechanism of material removal, transfer media and

energy source for USM. Mechanism of material removalErosion
Transfer media

- High velocity particles

Energy source

- Hydraulic pressure

12. Identify the mechanism of material removal, transfer media and

energy source for AJM. Mechanism of material removalErosion
Transfer media

- High velocity particles

Energy source
- Pneumatic pressure
13. Identify the mechanism of material removal, transfer media and
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energy source for WJM. Mechanism of material removalErosion

Transfer media

- High velocity water jet

Energy source

- Hydraulic pressure

14. What is the principle behind abrasive jet machining?

A jet of inert gas consisting of very fine abrasive particles strikes the
work piece at high velocity (usually between 200-400 m/sec)
resulting in material removal through chipping / erosive action.
15. What is the mechanism of material removal in AJM?
Erosion. Abrasive jet machining removes material through the action
of a focused stream of abrasive-laden gas
3. What are the major subsystems of
AJM? AJM system consists of four
major subsystems:
Gas propulsion system
Metering system
Delivery system
Abrasive collection system
4. Why the abrasive particles not reused in the AJM?
During the process, abrasive particles get contaminated with different
gases used in the process, affecting their cutting efficiency; Also the
cutting capacity decreases after the first application. Further, cost of the
abrasive is also low.

5. Why is AJM not suitable for soft materials?

Abrasive particles used in AJM can penetrate and embed with soft
materials.
6. Name the abrasive materials that are used for the AJM.
The common abrasives used for the AJM process are:

Dolomite
Sodium Bicarbonate
Glass beads
Silicon carbide
Silicon Nitride
Alumina

7. Mention the abrasives used for different applications

3

Abrasive

Application

Aluminium oxide

Cleaning, cutting and

deburring

Silicon carbide

As above but for harder

materials

Glass beads

Matt polishing, cleaning

Crushed glass

Peening, cleaning

Sodium bicarbonate

Cleaning, cutting for soft

materials

8. Name different gases used in AJM. Which of this is most widely used?
Dry air
Carbon-di-oxide
Nitrogen
Helium
Air is most widely used owing to easy availability and little cost.

9. What is the effect of the grain size on the material removal rate (MRR)
in the AJM?
Finer grain sizes are less irregular in shape, and hence, posses lesser
cutting ability. Moreover, finer grains tend to stick together and choke
the nozzle. The most favourable grain sizes range from 10 to 50 m.
Larger particle sizes remove the material faster.
10. What is the effect of jet velocity on the MRR in AJM?
The kinetic energy of the abrasive jet is utilised for metal removal by
erosion. The jet velocity is a function of the nozzle pressure, nozzle
design, abrasive grain size and the mean number of abrasives per unit
volume of the carrier gas. In general with increase in the jet velocity,
the MRR increases.
12. What is the effect of the abrasive powder flow rate on the MRR in
4

AJM?
Increasing the flow rate increases the removal rate because more
abrasive particles are available for cutting. However as the powder
flow rate is increased, the mass fraction of abrasive in the jet is also
increasing. As the mass fraction increases, the abrasive velocity
decreases, thus reducing the removal rate.
13. What are common materials used for the nozzle in AJM?
Sapphire and tungsten carbide are the common materials for the
nozzle.
14. Why are masks used in AJM? Which material is used for fabrication of
masks?
Masks are used to control over spray or to produce large holes and
intricate detail without having to move the nozzle and trace the
shape. Masks can be fabricated from rubber or metal, each having
its advantage and disadvantage. While the rubber masks are easy to
fabricate, they give poor edge definition. The metal masks give
much better definition but erode faster
15. Mention the process capabilities (process characteristics) of AJM
Low MRR
Intricate details can be produced
Narrow slots
Low tolerances
Minimization of taper
Thin-sectioned, brittle material, inaccessible areas
Almost no surface damage
16. What are the advantages and limitations of AJM?
Advantages:
Machining of very hard materials
Heat sensitive materials can be machined the gas stream
dissipates generated heat when cutting heat-sensitive
materials
Fragile materials can be machined the small loads
transmitted to the workpiece allow the cutting of fragile
pieces
Very low capital cost and low power consumption
No part shatter or vibration
The nozzle can be directed towards small, difficult-to-reach
areas
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Limitations:
Low material removal rate
Stray cutting can occur and hence accuracy is not good
Excessive taper on deep cuts may also be a disadvantage,
although the amount of taper can be reduced by tilting the
nozzle
Short nozzle standoff when used for cutting
Possibility of abrasive particles becoming embedded in the
workpiece
Nozzle wear rate is high
Process tends to pollute the environment
17. Mention some typical applications of AJM in engineering.
Removing flash and parting lines from injection moulded parts
Deburring and polishing plastic, nylon and teflon components
Cleaning metallic mould cavities which otherwise may
inaccessible
Cleaning oxides from metal surfaces
Cleaning metallic smears from ceramics

be

13. Please identify the principle of ECM. How does it differ from
electroplating?
Principle of ECM - electrolysis. When a D.C potential is applied across two
electrodes separated by a small gap and an electrolyte is pumped through
the small gap, the constituents of the anode work piece material goes into
the solution and not plate on the cathode tool. Electroplating is the
reverse of ECM where the cathode is plated by the depleted metal from
the anode.

14. What is Faradays first law?

The amount of chemical changes produced by an electric current (or the
amount of substance deposited or dissolved) is proportional to the
quantity of electricity passed.
15. What is Faradays second law?
The amount of different substances deposited or dissolved by the same
quantity of electricity are proportional to their chemical equivalent
weights.
16. Explain the parameters controlling the MRR in ECM. (Ref. P.N.Rao and
Benedict)
MRR in ECM is primarily controlled by current density. When all other
6

variables are held constant, the tool penetration rate is directly

proportional to the current density. Current density is not only controlled
by the amount of current but also by the size of the gap between the tool
and the workpiece.
Feed rate: a high feed rate results in a higher MRR. It also decreases
the equilibrium machining gap resulting in improvement of the surface
finish and tolerance control
The velocity and the electrolyte flow through the gap is also an
important parameter affecting the surface finish and removal rate
17. What are the various process parameters of ECM?
The process parameters that have a control on the performance of the
ECM process is: Feed rate, current density, voltage, electrolyte
concentration (low concentration of the electrolyte decreases the
machining gap and results in a better surface finish and finer tolerance
control) and electrolyte temperature (low temperature of the electrolyte is
conducive to a better surface finish and tolerances), velocity and flow of
electrolyte.
18. What are the various process characteristics of the ECM?
Material Removal Rate the MRRs with ECM are sufficiently large3 and
comparable with that of the conventional methods. MRR of 16m /min
for 10,000 A is generally obtained in ECM
Surface finish under certain conditions, ECM can produce surface
finishes of the order of 0.4m
Accuracy under ideal conditions and with properly designed tooling,
ECM is capable of holding tolerance of the order of 0.02mm and
less.
Economy
19. What are the various tool materials that can be used effectively with
ECM?
Generally aluminium, copper, brass, titanium, cupro-nickel and stainless
steel are used as tool materials.
20. What factors should be considered in selecting the tool materials in
ECM?
High thermal and electrical conductivity
Good stiffness- Rigidity of the tool construction and material is
important because the high pressure can cause deflection of the tool
Easy machinability- particularly important if complex shaped tools are
required
High corrosion resistance- to protect itself from the highly corrosive
electrolyte solution

21. What are the different types ECM operations?

Electro Chemical Milling (ECM)

Electro Chemical
Grinding
(ECG)

Electro ChemicalHoning(ECH)

ElectroChemicalDeburingCD)
Electrochemical
turning
(ECT)

Electro chemical trepanning (ECTr) etc.,

22. Enumerate some typical examples where ECM process can be
effectively adopted.
Deep hole drilling having L/D>20
Contouring operations in the
die blocks
Through cutting
and through cavities
23. What are the different applications of ECM?
Aerospace industries: machining gas turbine blades, airframe
component fabrication, honey-comb aircraft panels, jet engine blade
airfoils
Manufacture of general machine parts: thin wall mechanical slotting,
difficult to machine hollow shafts, chain pinions, internal profile of
internal cams, driving joints, pump glands and impellers, connecting
rod, hydraulic spools, gear wheels
Facing and turning complex 3D surfaces
Cutting off
24. What are the advantages of the ECM process?
Long tool life
Machines complicated shapes in single pass
Machines any material hardness independent of physical and
mechanical properties
No burrs
No stress
Good surface finish
Good accuracy
25. What are the limitations of the ECM process?
Work must be electrically conductive
High maintenance
Can cause intergranular attack (IGA)
High tooling and set-up costs
26. For which type of work, ECM is useful?
ECM is suitable for hard and difficult to machine materials and when
complex shapes are required which are not machinable by
conventional methods.
27. What is ECG? Identify its applications.
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ECG is a process that combines the ECM with the mechanical grinding
operation to remove material. It uses a grinding wheel with an electrically
conductive abrasive bonding agent.
Applications:

Single largest use for ECG is in the manufacturing and

remanufacturing of turbine blades and vanes for aircraft turbine
engines

Grinding of tungsten carbide tool inserts

Re-profiling worn locomotive traction motor gears

sharpening
of hypodermic
comb,Burr-free
Machining
fragile
very hard needles
and tough material honey
thin walledoftubes
andorskins

High MRRs when grinding hard, tough, stringy, work-hardenable

or heat sensitive materials
28. Explain the difference between the ECG and conventional grinding?
In ECG, there is a grinding wheel similar to a conventional grinding wheel
except that the bonding material is electrically conductive.
Conventional grinding produces components with good surface finish
and dimensional tolerances but such components are also associated with
burrs, comparatively large heat affected zone (HAZ), and thermal residual
stresses. These defects are not found in electrochemically ground
workpieces.

29. What are the advantages of ECG over conventional grinding?

Higher MRR
Reduce cost of grinding (higher cost of equipment compensated by
higher MRR, reduced consumption of expensive diamond wheels)
Reduced heating of workpiece resulting in less thermal damage
Absence of burrs on the finished surface
Improved surface finish with no grinding scratches
Reduced pressure of work against the wheel and so delicate parts
can be manufactured without distortion
30. Identify any two advantages and limitations of electrochemical
grinding (ECG)
Advantages
No thermal damage to workpiece
Elimination of grinding burn
Absence of work hardening
Long-lasting wheels less truing
Higher MRR;
Single pass grinding - reduced cost of grinding;
Absence of burrs on the finished surface;
Improved surface finish with no grinding scratches;
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 Reduced pressure of work against the wheel no distortion;

In ECG, the ECM action is efficient
Limitations
High capital cost / Higher cost of grinding wheel;
Corrosive environment
High preventive maintenance cost
Tolerance achieved are low;
Difficult to optimize due to the complexity of the process;
Non-conductive materials cannot be machined
Not economical for soft materials noncompetitive removal rates
compared to
conventional methods for readily machinable metals
Requires disposal and filtering of electrolytes
Applications: the process is easily adaptable to cylindrical parts for
trueing the inside surfaces.
35. What are the functions served by the electrolyte in the ECM process?
Medium for current to flow
Takes away heat generated
Removes reaction products
36. What is the principle of EDM?
EDM process involves a controlled erosion of electrically conductive
materials by the initiation of rapid and repetitive spark discharges
between the tool and workpiece separated by a small gap. The controlled
pulsing of the direct current between the tool and the workpiece produces
the spark discharge. Heat transfer from the spark to both the tool and
workpiece makes the latter to melt and partially vaporise and partially
ionize the metal in a thin surface layer.
37. What causes the material to be removed from the work piece surface?
(Or) How does the dielectric assist in removing the material from the
work piece?
Due to the inertia of the surrounding fluid, the pressure within the spark
becomes quite large and may possibly assist in blasting the molten
material from the surface leaving a fairly flat and shallow crater.
38. What are the principle components of EDM process?
Power supply, Dielectric system, electrodes: workpiece and tool and servo
system (tool feed)
39. What is the use of dielectric in EDM process?
spark conductor that must ionize under an applied voltage
deionize the spark gap after the discharge has occurred
effective cooling medium (coolant)
carry the swarf particles away from the working gap (flushing
10

medium)
40.

What the dielectric fluids commonly used in EDM?

Petrolium based hydrocarbon fluids.
Parafin, white sprite, transformer oil.
Kerosine, mineral oil.
Ethylene glycol and water miscible compounds.

41. List the desirable characteristics of a dielectric.

The following are the desirable characteristics of a dielectric:
It should have sufficient and stable dielectric strength to serve as an
insulation between the tool and work till the breakdown voltage is
reached
It should deionise rapidly after the spark discharge has taken place
It should have low viscosity and good wetting capacity to provide an
effective cooling mechanism and remove the swarf particles from
machining
gap
the
It
should
be
chemically
neutral so as not to attack the electrode,
workpiece,
table
or the tank.
It should not emit any toxic vapours or have any unpleasant odour.
It should have high flash point so as to avoid any fire hazards.
It should maintain its properties over a wide range of temperature,
contamination by debris and products of decomposition.
It should be economical and easily available.
42. What is tool wear in the EDM process?
Partial removal of the tool material form the tool surface while machining
the workpiece due to the discharge spark produced between the tool and
the workpiece.
43. How does tool wear occur in the EDM?
Due to the sparking action, the intense heat generated near the zone
melts and evaporates the materials in the sparking zone. Since the tool
is also within this zone, it also gets eroded.
44. How to minimise tool wear in EDM?
Tool wear can be minimized by using a tool material that has a high
melting point and high thermal conductivity. Also by properly configuring
the tool design, tool wear can be minimized.
45. Please identify the characteristics of an electrode material in order to
serve as a good tool.
It should be a good conductor of electricity and heat
It should be easily machinable to any shape at a reasonable cost
It should produce efficient material removal rates from the
workpieces
It should resist the deformation during the erosion process
It should exhibit low electrode (tool) wear rates
It should be easily available in a variety of shapes
46. Name some of the tool material used in EDM?
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Copper, brass, alloys of Zinc &tin.

Hardend plain carbon steel
Copper tungsten, silver tungsten, tungsten
Copper graphite and graphite.

47. Why is graphite the most preferred electrode material in EDM?

Graphite has very high melting point (3727C). It does not melt rather
vaporizes. At the same time, the tool wear is minimum.
48. How does the melting temperature of work material affect the MRR in
EDM?
Work materials having higher melting temperature have lower MRRs.
49. What is the effect of capacitance in EDM?
Increasing the capacitance causes the discharge to increase and increase
both the peak current and discharge time.
50. Define wear ratio
It is the ratio of volume of work removed to the volume of tool removed.
51. Define over cut
It is the distance by which the machined hole in the work piece exceeds
the electrode size and is determined by both the initiating voltage and the
discharge energy.
52. . Name the best electrode material for finish operations on a small die
made of WC by the EDM process.
Best electrode material for finish machining a small die made of WC
steel. Steel is used because 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 workpiece.
53. Explain why tool shape in the EDM process should be complementary
to the final form? Since the arc is always struck at a point
between the workpiece that is closest from the tool (electrode),
the complementary tool surface will be reproduced in the workpiece.
54. What are the factors upon which the material removal rate and surface
roughness depends?
Increase in current or spark voltage increases MRR and produces
higher surface roughness
Increase
in spark
frequency results in improved surface finish but
the MRR can
be maintained
Low inter electrode gap (IEG) results in lower MRR, higher surface
finish and better accuracy

12

55. What are the design factors to be considered while selecting the
machine tool?

Number of parts to be produced.

Accuracy.
Size of work piece.
Size of electrode.
Depth of cavity.

56. . Why is a servo-controlled system required in EDM?

EDM requires that a constant arc gap be maintained between the
electrode and the work piece to obtain maximum machining efficiency.
Therefore EDM tool incorporates some form of servo control.
57. What are the various applications of EDM?
Mould making industry manufacture moulds for plastics
Tool and die industry- manufacture extruding, heading, drawing,
forging and die lasting dies.
Aerospace and electronic industry to make prototypes and production
parts- made of difficult to machine material
Small or odd shaped holes
Miniature parts and parts made from thin or fragile materials (delicate)
58. What is meant by Wire cut EDM?
The principle and working of an WEDM is similar to the EDM but instead of
using a solid electrode, a wire (about 0.05-0.30mm diameter) is used as
an electrode in EDM.
59. What are salient features of WEDM?
WEDM uses a small diameter wire as tool electrode, which produces a
very narrow kerf in the work. Because of this reason, very sharp corners
can be easily produced.
60. Please identify various applications of Wire cut EDM.
Wire cut EDM is used for the manufacture
of:
Dies
Press tools
Electrodes
61. What are the different types of the electrical circuits that are used for
electro spark machining?
R.C. Circuits
Rotary impulse generator
Pulse controlled circuits
Hybrid circuits
62. What is an arc gap?
Optimum distance between the tool and the workpiece so that spark can
run and cause useful erosion.
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63. How is the arc gap controlled in EDM?

Servo mechanism is used to control the arc gap average voltage is
measured and as long as it is within a certain limit, no correction signal is
fed to the feed drive.
64. What are the limitations of EDM process?
Low material removal rate
Only electrically conductive materials can be
machined
Tool electrode wear is very high
More time in the fabrication of the electrodes.
High cost involved.

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UNIT-2
CNC MACHINES
1. Name any two mechanisms that are available to provide the rotational
indexing motion for transferring work parts.
(i)
Geneva mechanism
(ii)
Cam mechanism
2. What is the use of Part feeding devices ?
This is a mechanism that removes the components from the hopper one
at a time for delivery to the assembly work head. The hopper and parts
feeder are often combined into one operating mechanism.
3. What is Adaptive control ?

It is basically a feed back system in which the operating parameters

automatically adopt themselves to the actual conditions of the process.
4. What are the features of CAD based NC programming ?
5. What are the different types of Workpart Transfer mechanisms?

Walking beam transfer mechanism

6.

Define NC system?
NC is defined as a form of programmable automation in which the
process is controlled by alphanumeric data.

7. What is MCU?
MCU is a hardware system which reads, interprets and translates the
program of instructions into mechanical action of machine tool.
8.

List out any four advantage of using NC?

Increased flexibility.
Reduced setup time.
Production of complex part.
Elimination of special jigs and fixtures.
Less scrap

9.

What are the limitations of using NC?

Relatively high price.
More complicated maintenance, a special crew is desirable.
Highly skilled and properly trained programmers are needed.

10. What are all the problems encountered with NC system?

15

Part programming mistakes.

Non-optional speeds and feeds.
Problem with punched tape and tape reader.
Problem with controller and management information.
11. Define CNC?
CNC is defined as a NC system that utilizes a dedicated, stored
computer program to perform some or the entire basic NC functions.
12. Write the main functions of CNC?
Machine tool control.
In-process compensation.
Improved programming and operating features.
Diagnostics
13. What are the functions of diagnostic system in NC machine
tools?
To identify the reason for a down time occurrence so that maintenance
personal should make repairs fast.
To alert to signs that indicate the imminent failure of certain
component which are considered unreliable
14. List the differences between NC and CNC system?
NC system

CNC system
Only one time the tape is
1. Programming and punched tape read and stored.
is read every time
Less manual work.

2. Moderate manual work.

More flexible

3. Medium flexible.

Reprogramming is easy

4. Part programming is used

16

15. List the differences between open loop and closed loop control
system?
Open loop control system
1. Feedback device is not used
2. Low accuracy.
3. Low maintenance is required.
4. Less expensive.

Closed loop control system

Feedback device is used
Higher accuracy can be
achieved.
More maintenance is needed
Cost of the equipment is high

16. List any two advantages and disadvantages of open loop control
system?
Advantages:
Low cost and less manual work.
Disadvantages:
Low accuracy.
Periodically adjustments are required to compensate backlash errors.
17. What is the function of a transducer?
Transducer is a device in which one form of physical quantity like
speed, velocity is converted into another form of physical quantity.
18. What are all the basic elements of closed loop control system?
a. Input parameter
b. Output variable
c. Controller
d. Process.
e. Sensor.
f. Actuator
18. Write the various types of MCU used in CNC machines?
Three types of MCU are
17

a. Housed MCU
b. Swing around MCU
c. Stand alone MCU.
19. di Define DNC?
Direct numerical control system is defined as a manufacturing system
in which a number of machine tools are controlled by a computer
through direct connection and in real time.
19. List the main component of DNC?
Main component are
a. Central computer.
b. Bulk memory.
c. Telecommunications lines.
d. Machine tools.
20. Write the functions of DNC?
It will take some of the burden of the main computer.
Each satellite computer.
21. List out the types of CNC machine?
CNC machine can be classified as:
i.
Machining centers
ii.

Lathe machines

iii.

Drilling machine

iv.

Turning centers

v.

Milling machines

vi.

Gear shaping

vii.

CNC gear hobbling

22. Define the term Basic unit length?

The minimum possible incremental movement is called the Basic unit
length (BLU). The BLU might be on the order of 0.01 mm in typical
machine tool system.
23. Write the functions of guideways.
The functions of sideways:
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a. To control the line of action of the carriage/table on which the

tool/work piece is held.
b. To absorb static and dynamic forces.
24. List out the characteristics of guideways used in CNC.
The sideways should have the following characteristics.
a. Good rigidity and damping capability.
b. Good wear and friction resistance.
c. Geometric and kinematic accuracy.
d. Ensure higher velocity of slide.
e. Protect against damage and sward.
f. Provision for adjusting the play
g. Position in relation to work area.
25. What are the different types of friction guide ways?
The different types of friction guide ways are:
a. Flat guide
b. Vee guide
c. Dovetail guide and
d. Cylindrical guide.
24. List the limitations of friction guide ways?
The limitations of friction guide ways ARE:
a. Surface to surface contact between the sliding members, which
leads to more
amount of wear.
b. Large amount of friction and heat developed in the sliding parts.
25. Write the advantages of LM guide ways?
The following are the advantages:
a. To reduce the amount of wear
b. To reduce the friction.
c. To reduce heat generation
19

d. To improve smoothness.
e. Zero stick slip
27. What is actuating system? Write the various types of actuating system
used in CNC?
Actuation systems are used to convert the rotational movement into
translation movement. The two types of actuation systems used in CNC
are:
a. Screw and nut, and
b. Rack and pinion.
28. What are the advantages of ball screws sideways over conventional
sideways.
a. Ball screws have longer life.
b. Higher accuracy can be maintained.
c. Low frictional resistance and hence used for carrying heavier loads
at faster rate.
d. Low power requirement for driving.
29. What is meant by feed drive? List the different types of feed drives.
Feed drive is used to provide motion to the slide as per the motion
commands. Feed drives are classified as follows:
I. Servo motors,
a. AC servo motor,
b. DC servo motor,
c. Brushless DC servo motor
II. Stepper motors, and
III. Linear motors.
30. What is the function of ATC?
The function of ATC is to change the tool once the particular operation
is over and the next tool is automatically changed and positioned for
machining based on the tool sequence given in part program.
31. What is machining center? Write the different types of machining centre.
How it differs from conventional CNC milling machines?
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The centers which consists of multi function CNC machines equipped

with ATC which are capable of carrying out milling, reaming, tapping,
boring, counter boring and allied operations without operator
intervention is called machining centre.
Different types of machining centers are:
a. Horizontal machining centre,
b. Vertical machining centre,
c. Universal machining centre.
32. What are the functions of feedback drives?
The functions of feedback drives are:
a. To convert one form of physical quantity like speed, displacement,
etc., into
electrical signals.
b. This electrical signal is then compared with the reference signal to
check whether
the desired motion of tool/worktable is achieved or not.
33. Enumerate the various feedback devices used in CNC system?
There are two types of feedback devices used in CNC system.
a. Position feedback devices (Example : Linear transducers, encoders)
b. Velocity feedback devices (Example : Tachogenerator)
34. What is the use of position feedback circuits and classify it.
Position feedback circuits are used to measure the position of the tool
edge with reference to the machine slide. They may be classified as:
Rotary transducers

Linear transducers

a. Rotary encoder
b. Resolver

a. Glass scales with line

grating.
b. Ferranti system.
c. Binary coded system

35. What are the different forms of Inductosyn? Where it is used and why?
Inductosyn are classified into:
Rotary encoder and Linear encoder.
Rotary form is used in precision servo systems on machine tools
whereas linear forma are used in automatic machine tool slide controls.

21

Reason: Inductosyn is a precision feedback device for the accurate

measurement and control of angles or distances with inductive
coupling between conductors separated by a small space
36. What is a rotary type encoder? Where it is used?
An encoder is a rotary transducer that provides continuous or discrete
signal value of an angular or linear movement. It is used in the CNC at
the end of the slide screw directly or through gearing timer belt.
37. What is the role of optical grating in CNC drive?
An optical grating is a glass strip marked with series of equally spaced
transparent opaque lines. They are used as transducers on machine
tools. This is used to measure the position of the table.
38. What is Inductosyn?
Inductosyn is a analogue type position back device which is used for
the, measurement of control angle and/or linear distance.
39. Write the various measures employed in CNC machine to minimize the
structural deformation.
To avoid the structural deformation, following precautions have to be
considered.
a. Providing a proper design mild steel structure having higher
stiffness.
b. Use of ribs, braces and plates to increase the stiffness of machine.
c. Providing large heat removing surfaces.
d. Use of excellent coolants.
e. Reduction of ambient temperature by using air conditioning units
40. Write the salient features of tooling system?
The following features should be considered before the selection of
tooling.
a. Rigidity to withstand higher cutting forces
b. Rigidity to transmit the spindle power at higher speed.
c. Perform variety of cutting operations.
d. To keep down time

22

UNIT-3
1.

Define numerical control.

Numerical control is a form of programmable automation in which the
mechanical action of machine tool or other processing equipment are
controlled by a program containing alphanumeric data numbers, letters
and symbols.

2. What are the different types of dimensioning system used?

a. Absolute dimensioning or baseline dimensioning system.
b. Incremental dimensioning or delta dimensioning system.
3. What is BIT? What is the use of it?
a. Bit is an abbreviation of Binary digit which can be 1 or 0.Uses
in binary coded decimal system.
4. What is block? Write the significance of it?

5.

a. Block is the basic unit of a part program input to the control. It

contains adequate information for the machine to perform a
movement and for functions.
What Is G code? How G codes are represented?

6.

a. It is the series of combination of 1s and 0s.It represents a

number or an alphabet or any symbol.
Write the different types of tape programming format?
a. The following are the types of tape programming format.
b. Word address format,
c. Table sequential format,
d. Fined block format.

7.

Explain the functions of codes G28 and M30.

a. G28 = Mirroring

8.

b. M30 = End of data.

State the function of post processor in CAPP.

9.

a. Post processor is separate computer program which has been

used to prepare the punched tape for a specific machine tool.
List out some of the important NC languages.
a. APT
23

b. ADAPT
c. EXAPT
d. Compact II
e. PROMPT
f. CINTURNII
10. What are the four statements used in APT language?
a. Geometric statements
b. Motion statements
c. Post processor statements
d. Auxiliary statements.
11. How can you represent an APT geometric statement?
a. Symbol = Geometry/Descriptive data
b. Example: point, line, circle, plane
12. What are the different types of surfaces used for achieving continuous
path commands?
a. Drive surface, which guides the tool.
b. Part surface, on which the bottom of the tool rides.
c. Check surface, which stops the movement of the tool.
13. List the motion command words used in achieving path commands.
a. GOLFT
b. GORGT
c. GOFWD
d. GOBACK
e. GOUP
f. GODOWN
14. What are the modifiers used with motion command words?
a. TO
b. ON
c. PAST
d. TANTO
24

15. List any four post processor statements.

a. COOLANT/ON,OFF,MIST
b. RAPID
c. TURRET
d. MACHIN
16. Write any four auxiliary statements.
a. INTOL
b. OUTTOL
c. CLPRNT
d. PARTNO
e. FINI
17. What are the identifications needed to store a tool library?
a. Tool dimension details and
b. Tool assembly details.
18. Difference between 21/2 and 3 axes machine.
a. 21/2 axis machining implies that the machine movements are in
planes parallel to the X-Y plane.
b. 3 axes machining implies that machine movements are in all the
3 axes (X, Y and Z)
19. What is the role of computer aided part programming?
a. The role of computers in CAPP is as follows:
b. Input translation
c. Arithmetic calculations
d. Cutter offset compensators
e. Post processor.

UNIT-4
25

1. Name

the FOUR basic robot configurations.

Cartesian coordinate system
Cylindrical coordinate system
Polar or spherical coordinate system
Revolute coordinate system

4. List out the types of joint Notation.

i.
Linear joint,
ii.
Rotational joint,
iii.
Twisting joint,
iv.
Revolving joint.
3. What is meant by a work envelope?
The work envelope is described by the surface of the work space. It
depends upon the number of types of joints, physical types of joints and links
and the range of various joints.
4. Sketch a robot and name its parts.
1. Manipulator (Robot arm)
2. End effector
3. Controller
4. Gripper
5. Actuator
5. What is meant by workspace?
The space in which the end point of the robot arm is capable of
operating is called as workspace in other words, reach ability of robot arm
is known as workspace.
6. List the various types of robot drive system for industrial robots
1. Electric drive:
(a)DC motor; (b) Servomotor; (c) Stepper motor
2. Pneumatic drive
3. Hydraulic drive
8. Sketch and indicate the type of any rotating joints used in
robots. (or) Sketch a twisting joint. Rotational (R):

of hydraulic actuators used

in robotics?

9. What are the types

26

(i)
(ii)
(iii)

Piston
Swing motor,
Hydraulic motor

cylinder,

9. What is meant by robot anatomy?

The robot anatomy is the study of structure of robot that is physical
construction of the manipulator's structure.
The mechanical structure of manipulator that consists of rigid bodies
(links) connected by means of joints, is segmented into arm that
ensures mobility and reachability, a wrist that confers orientation, and
an end effectors that performs the required task
10.What are the three degrees of freedom associated with the arm and body
motion?
Three degrees of freedom associated with the arm and
body motion are:
Right (or) Left movement (X-axis motion)
In and out movement (Y -axis motion)
Vertical movement (Z-axis motion)

12.Define the term work envelope.

Work envelop is defined as the envelope (or) space
within which the robot can manipulate the end of
the wrist.
A robot's work envelope is the range of movement
13.Give some application of robots in industries.
(a)Material Handling Application
(i) Material transfer application
(ii)
Machine loading /unloading application.
(b)Process Application
(i)
Welding
(ii) Painting
(iii) Assembly
(iv) Machining
(v) Inspection
14. How do you specify a robot?
(i) Speed;
(ii) Actuator
(iii) Payload;
(iv) Repeatability
(v) Accuracy;
(vi) Reliability
(vii) Manipulator; (viii) End effectors
27

1. State any two techniques used for object recognition.

a) Template matching
b)Structural Technique
2. Write about Hall Effect sensors.
When a beam of charged particles passes through a magnetic field
forces act on the particles and the beam is deflected from the straight line
path a current flowing in a conductor is like a beam of moving charges and
thus can be defined by magnetic field
3. Classify the robots according to the drive system.
1. Pneumatic drive
2. Hydraulic drive
3. Electric drive
(a)DC Motor
(b)Servo motor
(c)Stepper motor
4. List any two important advantages and disadvantages of a pneumatic
gripper.
Advantages of pneumatic gripper:
1. Its light weight design.
2. It is possible to distribute the pressure uniformly the entire
area.
3. Control is simple
4. Pick up time is very fast.
Disadvantages:
1. It is not suitable for heavy loads.
2. Sometime is required to build the pressure.
6. Name any four proximity sensors used in robotics
Sensor, which senses the presence or absence of the object without
having physical contact between the objects
I) Inductive Sensor
2)Capacitive Sensor
3)Ultrasonic Sensor
4)Magnetic Sensor
7. Sketch the screw-actuated mechanical gripper.

28

What are the limitations of adhesive grippers?

0 Adhesive substances losses his tackiness on repeated usage.
1 Reliability is diminished with successive operations

10. Differentiate between touch and force sensors.

Touch sensor: It senses the presence or absence of the object by
having physical contact between the objects.
Force sensors: Force sensors are used primarily for measuring the
reaction forces developed at the interface between
mechanical assemblies
11. List the

types of drives used in robots.

Electric drives
Hydraulic drives
Pneumatic drives

12.What is a RCC device? For what purpose is it used in a robot?

RCC device means Remote. Center Compliance devices.
Uses: (i) RCC device are commonly used in automated assembly
applications to provide Compliance for
misalignment during assembly.
(ii)
The compensator is a .compliance device that enhances
the flexibility and reliability of a robot
13.What is a mechanical gripper?
A mechanical gripper is an end effector that uses mechanical finger
actuated by mechanism to grasp an object.
Mechanical grippers are used to transfer parts from one location to
another or to assemble parts.
14.What is the properties 0f stepper motor?
Stator wiring (number of coils and wire loads).
Number of steps in a complete rotation.
Operating voltage and current.
Amount of force generated (torque).
Maximum rotation speed (steps per second).
15.State the advantage and limitation of hydraulic drive.
29

Advantage:
i. Robust
ii. Self lubrication
iii. It can also provide precise control at low speeds.
iv. High efficiency and high power to size ratio.
v. Hydraulic robots are more capable of withstanding shock
loads.
Disadvantage:
1. Expensive
2. High maintenance

3. Not energy efficient

4. Noisy
5. Not suited for clean air environments
Write the basic principle of servo motor.
0 A servomotor is used within position control (or) speed control
feedback control system.
1 An electrostatic motor is based on the attraction and repulsion of
electrical charge.
Give some examples of robot end effector.
0 Gripper
1 Tools
2 Welding equipment
3 End of arm tooling
What are the types of grippers?'
0 Mechanical finger grippers.
1 Pneumatic grippers.
2 Hydraulic grippers.
3 Collect gripper.
4 Magnetic gripper.
5 Vacuum gripper.
1. Define a tactile sensor and list the types.
Tactile sensor is device that indicates the contact between themselves
and some other solid objects.
0 Digital (Touch) Sensor
1 Analogue (Force) Sensor
2. List the two basic types of robot
programming method.
30

a. Lead through methods

b. Textual robot languages
c. Mechanical Programming
3. State the working principle of a touch sensor.
Touch sensors in sensors, which senses the presence or absence of the
object by having physical contact between the objects. When the button is
pressed, an electrical circuit is closed inside the sensors. This lets electricity
flow. When the button is released, the circuit is broken and no electricity
flows. Touch sensors send a signal when physical contact is made.
65.

What is the function of a frame grabber?

A frame grabber is an electronic device that captures individual,
digital still frames from an analog video signal or a digital video
stream.
It is hardware device used to capture and store the digital image.

66.

What are the limitations of hydraulic drive systems?

0 Expensive
1 High maintenance
2 Not energy efficient
3 Noisy
4 Not suited for clean-air environments.

67.

What is the purpose of thresholding in analysis?

Thresholding is a binary conversion technique in which each pixel is
converted into a binary value either black or white.

7. Mention use of machine vision system.

(i)This can be used to replace, machining for applications like
welding, machining to maintain relationship between tool and
work.
(ii) Machine vision systems are used for printed circuit board.
(iii) This is for the recognition of object from its image.
(iv) Achieve 100% accuracy.
8. Enumerate the difference between open loop and closed loop control
system

Open loop control system

31

Closed loop control

system

It is being relatively simple

More complex

Low cost

More cost
Greater chance of breakdowns as a
consequence of the greater
number of
components

Good reliability
The disadvantage is that they are
often
inaccurate since there are no
correction for

Relatively accurate in matching the

actual to
the required values

error

9. What is meant by template matching?

Templates of the parts to be recognized are stored in the vision system
memory. The images recorded by the vision camera are compared with the
templates stored in memory to determine if a matching part is present.
10. What is a teach pendant?
The teach pendant is usually a small handheld control box with
combinations of toggle switches, dials and buttons to regulate the robot's
physical movement's and program capabilities
11.Classify the position sensors.
Main types of position sensors are:
Incremental
Absolute
Some other devices which are used as position sensors.
Resistive position sensors.
Linear variable differential transformer (LVDT)
Encoders.
Potentiometer.
Resolver
12.Brief on the working of inductive type proximity sensor.
Inductive proximity sensors operate under the electrical principle of
inductance.
Inductance is the phenomenon where fluctuating current, which by
definition has a magnetic component induces an electromotive force
is a target
object.
(emf)
To
amplify
a devices
inductance
effect,through
a sensor
wire
into a tight
coil and
runs a current
it. manufacturer twists
13.What is triangulation?
Triangulation is a process by which the location of radio transmitter
can be determined by measuring either the radial distance, or the
of the
received
signal from
two (or) three different points.
direction
Triangulation
is position
sometimes
the geographic
of aused
user.in cellular communication to pin point
32

14.What is smoothing in vision system?

Smoothing in vision system is often used to reduce noise within
an image (or) to produce a less pixelated image.
Most smoothing methods are based on low pass filter
15.What are the desirable features of sensor?
Ease of
1. Cost
2. operation
Operating
3. range
4. Accuracy
5. Precision
6. Reliability'
7. Speed of response
8. Calibration
16.List the different types of tactile sensor.
Digital (Touch) Sensor
Analogue (Force) Sensor
17.What are the applications of Machine Vision System?

Inspection
Identification
Visual serving and navigation
18.What are the various techniques in image processing and analysis?
Image data reduction
Segmentation
Feature extraction
Object recognition
1. What are Actuators?
Actuators are the devices used for converting hydraulic energy (or)
electrical energy into mechanical energy.
In other words, actuators perform a function just opposite to that of the
pumps.
The pressurized hydraulic fluid delivered by the hydraulic pump is
supplied to the actuators, which converts the energy of the fluid into
mechanical energy.
This mechanical energy is used to get the work done. The hydraulic
actuators produce linear, rotary, or oscillating motion.
2. What is transformation?
Transformations of frames introduced to make modeling the relocation
of objects easier.An object is described with respect to a frame located
in the object, and this frame is relocated with a transformation.
The transformation is the result of a sequence of rotations and
translations, which are recorded with a transformation equation
3. What is meant by a teach pendent?
The teach pendent is usually a small hand held control box with
combination of toggle switches, dials and buttons to regulate the robot's
physical movements and program capabilities.
33

5. Define the term 'feature extraction

Transforming the input data into the set of feature is called
feature extraction. A feature area, diameter, perimeter, is a single
parameter that permits ease of comparison and identification.
6. State any two techniques used for object recognition.
a) Template matching
b)Structural Technique
7. What the

benefits of this off line programming?

Reduced down time for programming.
Programming tools make programming easier.
Enables concurrent engineering and reduces product lead time.
Assists cell design and allows process optimization.

8. Explain the reasons for defining points in a program.

To define a working position for the end-effector
To avoid obstacles
9. What is AGV?
Automated guided vehicle (AGV) is an independently operated selfpropelled vehicle guided along defined pathways in the floor. It is normally
powered with batteries. It is mainly used for handling material from one
place to other place.
2. List out different types of image compression technique.
Discrete image transforms in image data compression
Hierarchical and progressive compression techniques
Comparison of compression methods
16. Define degrees of freedom
It is defined as one of the variables required to define the motion of
a body in space. Each joint in a robotic system gives the robot one
degrees of freedom.
18. What is teach pendant?
The teach pendant is usually a small handheld control box with
combination of toggle switches, dials and buttons to regulate the robot's
physical movements and program capabilities.
1. What is continuous path programming?
It is the types of programming were the motion cycle involves smooth
complex
Curvilinear movements of robot arm.
2. What is teach pendant?
34

The teach pendant is usually a small handheld control box with

combinations of toggle switches, dials and buttons to regulate the
robot's physical movements and program capabilities.
3.List

any two important considerations for robot safety.

Environmental condition.
Location and installation requirement. ,
Human errors.
Mode of operation

5. What is the purpose of structured lighting?

The intersection of the sheet with objects in the work space
yields a light stripe which is viewed through 'a television camera
displaced a distance from the light source. The stripe pattern is easily
analyzed by a computer to obtain range information.
6. What are the general characteristics that make potential robot application
technically
practical and economically feasible?
Hazardous or uncomfortable working conditions
Repetitive operations
Difficult handling jobs
Multicast operation
Selection of the application.
Selection of the robot.
Detailed economic analysis and capital authorization.
Planning and engineering the installation.
Installation.
8. What is meant by image analysis?
Image analysis ids the collection of processes in which a captured
image that is prepared by image processing is analyzed in order to extract
information about the image and to identify objects or facts about the object
or its environment.
10.Give two applications of robot in machining.
Drilling;
Grinding;
Reaming;
Tapping
Deburring
15.List out types of A GV vehicles.
1. To wing vehicles
3. Unit load vehicles Pallet truck vehicles
4. Fork truck vehicles
5. Light load vehicles
35

17.Assemblyline vehicles What are types of robots commonly used for

machine loading and unloading operation?
1. Servo control robot (point to point)
2. Non-servo robot (pick and place robot)
18.Write two aspects of the safety issue in robotics.
1. Redundancy
2. Back up system

UNIT-5
1. What is meant by Cellular manufacturing?
Grouping the production equipment in to Machine cells ,where each
cell specializes in the production of a particular family is called Cellular
manufacturing
36

2. What is Group technology?

It is a manufacturing philosophy in which similar parts are identified
and grouped together to take advantage of their similarities in design
and production.
3. What is a Part family?
A part family is a collection of parts that are similar because of
geometric shape and size or because similar processing steps are
required in their manufacture.
4. What are the different types of FMS layouts?
i.
In-line
ii.
Loop
iii.
Ladder
iv.
Open field
v.
Robot centered cell
5. Comment on the benefits that are expected from an FMS.
i.
Higher machine utilization
ii.
Reduced manufacturing lead time
iii.
Reduced work in progress
iv.
Greater flexibility in production scheduling
v.
Higher labour productivity
vi.
Quicker response to market changes
vii.
Reduced space requirements
viii.
Expandability for additional processes or added capacity
ix.
Reduced number of tools and machines required.

What are the various components of

6. What is FMS ?
A flexible manufacturing system is a highly automated GT machine cell
, consisting of group of processing workstations (Usually CNC machine tools) ,
interconnected by an automated material handling and storage system , and
controlled by a distributed computer system.
7. What are the benefits of FMS?
i.
Increased machine utilization
ii.
Fewer machines required
iii.
Greater responsiveness to change
iv.
Reduced inventory requirements
v.
Lower manufacturing lead times
vi.
Reduced direct labor requirements and higher labor productivity
vii.
Opportunity for unattended production
8. What make FMS flexible?
i.
The ability to identify and distinguish among the different part or
product styles processed by the system.
ii.
Quick changeover of operating instructions
37

iii.
Quick change over of physical setup.
9. What are the various types of FMS?
i.
Flexible manufacturing module
ii.
Flexible manufacturing cell
iii.
Flexible manufacturing group
iv.
Flexible fabrication- machining assembly system
10. What are the various components of an FMS?
i.
Work stations
ii.
Material handling and storage systems
iii.
Computer control system. In addition even through an FMS is highly
automated
iv.
People are required to manage and operate the system.
11. What is meant by a Dedicated FMS, Random order FMS ?
A dedicated FMS is designed to produce a limited variety
of part styles, and the complete universe of parts to be made
on the system is known in advance.
A random order FMS is more appropriate when the part
family is large, there are substantial variations in part
configurations, there will be new part designs introduced into
the system and engineering changes in parts currently
produced.
12. What are the different types of FMS layout?
i.
In line layout
ii.
Loop layout
iii.
Ladder layout
iv.
Open field layout
v.
Robot centered cell
13. What is meant by a machining center?
CNC machining centers posses features that make them
compatible with the FMS, including automatic tool changing and tool
storage, use of palletized work parts CNC and capacity for
distributed numerical control.
14. What is meant by an ATC?

A variety of machining operations means that a variety of

cutting tools is required. The tools are contained in a tool storage
unit that is integrated with the machine tool. When a cutter needs to
be changed, the tool drum rotates to the proper position and an
automatic tool changer ( ATC) operating under part program control
exchanges the tool in the spindle for the tool in the tool storage
unit. Capacities of the tool storage unit commonly range from 16 to
80 cutting tools
15. What is meant by Lean production?
38

Lean production can be defined as an adaptation of mass

production in which workers and work cells are made more flexible
and efficient by adopting methods that reduce waste in all forms.
16. What is meant by Agile manufacturing?
Agile manufacturing can be defined as :
An enterprise level manufacturing strategy of introducing new
products into rapidly changing markets.
(ii)
An organizational ability to thrive in a competitive
environment characterized by continuous and sometimes
unforeseen change.
17. Compare Lean production and Agile manufacturing
(i)

Lean production
1.
2.
3.
4.

Agile manufacturing

Minimize waste

1.

Enrich the customer

Perfect first time quality

2.

Cooperate to enhance
competitiveness

Flexible production lines

3.

Organize to master change

Continuous improvement

4.

Leverage the impact of people

and information

18. Compare Mass production and Agile manufacturing.

Mass production

Agile manufacturing

1.

Standardized products

1.

Customized products

2.

Long markets life expected

2.

Short market life expected

3.

Produce to forecast

3.

Produce to order

4.

Low information content

4.

5.

Single time sales

5.

Continuing relationship

6.

Pricing by production cost

6.

Pricing by customer value

High information content

19. What is Group technology?

Group technology is a manufacturing philosophy in which
similar parts are identified and grouped together to take advantage
of their similarities in design and production. Similar parts are
arranged into part families
39

20. Define the term Part family.

A part family is a collection of parts that are similar either because
of geometric shape and size or because similar processing steps are
required in their manufacture.
21. What is the advantage of FMS over the other types of manufacturing
systems?
Flexible manufacturing systems are designed to fill the gap between
high production transfer line and low production NC machines.

ADVANCED MANUFACTURING TECHNOLOGY

2-MARKS

(UNIVERSITY QUESTIONS)

PART A
1. The automated elements of the productions system can be

separated into two categories. What are they ?

The automated elements of the production system can be separated
into two categories
Automation of the manufacturing systems in the factory
Computerization of the manufacturing support systems.
2. Define : Flexible Automation.
(i)
(ii)

Flexible Automation is an extension of programmable automation. A

flexible automated system is capable of producing a variety of parts (or
products) with virtually no time lost for changeovers from one part
style to the next. There is no lost production time while reprogramming
the system and altering the physical setup tooling, fixtures, machine
settings.
3. What are the goals of automation in manufacturing industry ?
i.

To increase labour productivity,

ii.

To reduce labour cost,

iii.

To mitigate the effects of labour shortages.

iv.

To reduce or eliminate routine manual and clerical tasks.

v.

To improve worker safety

40

vi.

To improve product quality.

vii.

To reduce manufacturing lead lime.

4. Give the classification of automation .

i.
ii.
iii.
iv.

Fixed automation
Programmable automation
Flexible automation
Integrated automation

5. What do you understand from the term Automated Production

Line ?
An automated production line consists of several machines or
workstations which are linked together by work handling
devices that transfer parts between stations .
6. Define : Automation .

Automation can be defined as a technology concerned with the

application of mechanical, electronic and computer based
systems to operate and control production
7. Differentiate between fixed automation and programmable

automation .
8. What do you understand from the term USA Principle ?
(i)
Understand the existing process
(ii)
Simplify the process
(iii)
Automate the process
9. What is the use of Part feeding devices ?

This is a mechanism that removes the components from the

hopper one at a time for delivery to the assembly work head. The
hopper and parts feeder are often combined into one operating
mechanism.
10. Name any two mechanisms that are available to provide the

rotational indexing motion for transferring work parts.

(iii)
Geneva mechanism
(iv)
Cam mechanism
11. What is Adaptive control ?

41

It is basically a feed back system in which the operating

parameters automatically adopt themselves to the actual
conditions of the process.
12. What are the features of CAD based NC programming ?
13. What is a DNC system ?

14. Write the function that is represented by the code GO3 .

Circular interpolation, counterclockwise.

15. Differentiate between Direct Numerical Control and Distributed

Numerical Control units.

16. Differentiate between Absolute and Incremental Positioning .
17. Write the function that is represented by the code M04.

Spindle rotation (Counter clockwise)

18. How does an orthogonal joint function in a robot ?

It provides a translational sliding motion, but the input and

output links are perpendicular to each other during the move.
19. Enlist the different types (any four) of Automated Storage and

Retrieval Systems.
(i)
Unit load AS/RS
(ii)
Deep-lane AS/RS
(iii)
Miniload AS/RS
(iv)
Man on board AS/RS
(v)
Automated item retrieval system
(vi)
Vertical lift storage modules
20. What do you mean by the term Cellular Manufacturing ?
Grouping the production equipment into machine cells , where
each cell specializes in the production of a part family, is called
cellular manufacturing.
21. Compare Machine flexibility with production flexibility ?

22. Sketch the screw actuated mechanical gripper.

23. What is machine vision ?

Machine vision can be defined as the acquisition of image

data , followed by the processing and interpretation of these
data by computer for some useful application.
42

24. Define Part families .

A part family is a collection of parts that are similar either

because of geometric shape and size or because similar
processing steps are required in their manufacture.
25. What are the applications of GT ?
26. Define : Automation .

Automation can be defined as a technology concerned with the

application of mechanical, electronic and computer based
systems to operate and control production
27. The term ------------ is sometimes used to identify a transfer line

that uses pallet fixtures or similar work holding devices.

Palletized transfer line
28. Mention any two reasons for the commercial and technological

importance of industrial robots.

29. How does an optical sensor functions ?
30. What do you mean by the term Part family ?
31. Comment on the benefits that are expected from an FMS.
x.
Higher machine utilization
xi.
Reduced manufacturing lead time
xii.
Reduced work in progress
xiii.
Greater flexibility in production scheduling
xiv.
Higher labour productivity
xv.
Quicker response to market changes
xvi.
Reduced space requirements
xvii.
Expandability for additional processes or added capacity
xviii.
Reduced number of tools and machines required.

What are the various components of

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