MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)

(ISO/IEC - 27001 - 2005 Certified)

WINTER 13 EXAMINATION Subject Code: 12154

Model Answer

_____________________________________________________________________________________________

Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in the
model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try
to assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more
Importance (Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give credit for
any
equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidates answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidates understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.
1. A) Attempt any three of the following :

12 marks

a) Compare traditional and non traditional machining process ( any four points)
Sr.
Parameter
Traditional machining process
Non Traditional machining process
no
1

Tool Geometry

It s uses a cutting tool of fixed

geometry

Its uses some sort of energy along with

tool which doesnt have a fixed
geometry.

Tool Hardness

Tool material should be harder than

the metal to be cut.

Hardness of tool is independent of

material hardness.

Cutting ability

Hard metals are difficult to cut and

some time impossible

Almost any known hard material can be

cut.

Complex profile

Difficult to produce complex

surface

Complex profiles can easily be obtained.

Metal Removal
Rate

Metal removal rate is comparatively

high.

Metal remove rate is low

Metal Removal
method

Metal removed in the form of chips.

Metal is removed by melting,

vaporization , electrochemical reaction
etc.

Tool force

Higher tool forces are required to cut

harder material.

Tool force is independent of the

material hardness.

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Application

Very minute holes cannot be

produced

Very fine or minute holes can be easily

drilled.

Example

Turning , milling shaping , drilling

etc.

EDM, LBM, USM, EBM,PAM,ECM,

etc..
Different forms of energy is used for
machining such as Kinetic Energy,Heat
Energy, Chemical, Electrochemical etc.

10

[Any Four point 4 Marks ]

b) Draw the block diagram of open loop control system and explain

Block diagram of open loop control system

[Block diagram 1 mark]

1. There is no feedback system

2. Simple to design , less expensive , less accurate as compared to closed loop system.
3. It consists of an input device which loads the program in the machine. The program is decoded in
the machine understandable format and the required signals are send to the machine control unit.
The machine control unit send the series of electrical pulses to the drive unit this result in the
motion of the slides through a desired motion.
[ Explanation 03 marks]

c) What are the transfers machines ? What are its type?

Transfer Machining:
It consists of several individual machine tool arranged in a sequence and connected
together by means of suitable material handling equipment or units.
Each machine in this series is called a station and performs operation repeatedly on every
work piece.
Work pieces are loaded at the first machining center.
All the stations operate simultaneously on the different work piece and the work piece are
automatically transferred to the next station along with its fixture.

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The number of work piece being machined at one time is equal to number of
workstations.
As the numbers of machining head are arranged in sequence. They are called as transfer
machines.
In every cycle of the transfer machine one complete part is produced.
For example: Automobile assembly air craft industry.
[Explanation 03 marks ]
Types of transfer machining:
1. In-line transfer machining
2. Rotary transfer machining
3. Drum type transfer machine

[Types 1 mark ]

d) What is the requirement of tool material in ECM? Give applications of ECM

Requirement of tool material are as follows
i)
It should be good conductor of electricity
ii)
It should have good machinability.
iii)
It should be chemically inert to the electrolyte.
iv)
It should have high thermal conductivity.
v)
It should be anti corrosive in nature.
[Any two requirement 2 marks]
Application of ECM
i)
ii)
iii)
iv)
v)
vi)
vii)

Die sinking
Profiling and contouring
Trepanning
Grinding
Drilling
Micro-machining
Turbine Blade Machining

Q.1B) Attempt any one of the following:

[Any two application 2 marks ]

6 marks

a) Explain the principle of EDM with neat sketch. Give two application of EDM .
Principles of EDM
- Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used
to remove metal by means of electric spark erosion.
- In this process an electric spark is used as the cutting tool to cut the workpiece to produce the
finished part to the desired shape.
- The tool (Cathode ) and work piece (Anode) are separated by a small gap(0.01 to 0.5) called as
spark gap
- The workpiece and tool both are immersed in the dielectric fluid.
- When the supply is made ON thousand of spark are produced per second. The duration of each
spark is very short.
- When spark come in contact with the dielectric fluid in the spark gap, the fluid get ionized. It
allows current to flow between the tool and work piece as shown in fig.
- A very high temperature of around 10000C is generated in the spark region. As a result, the
material gets melted and is removed from the work piece.

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Model Answer

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These metal particles of the metal are then driven away by the forced dielectric fluid circulated.
[Principle Explanation 03 marks]

Principles of EDM
[Sketch 01 marks]
Application of EDM
Dies and moulds like extrusion dies; wire drawing dies, plastic moulds.
Dies for producing jewelry and badges
Stamping tools like stamping Die.
Small hole drilling, curve hole drilling .
Machining delicate work piece like copper parts are used for fitting in vacuum tubes.
In resharpening of cutting tools and broaches.
Machining complicated profiles.
Thin electronics parts.
Aero space parts.
Refractory materials, carbides hardened steel production components.

[Any Two Application 02 M]

b) List the controlling parameters in WEDM . State advantages and disadvantages of WEDM.
Controlling parameter of WEDM
1. Discharge current
2. Pulse duration
3. Pulse frequency
4. Wire speed
5. Wire tension
6. Dielectric flow
[ 2 Marks]
Advantages of WEDM
1. Forming Electrode adapted to product shape is not required.
2. Electrode Wear is Negligible.
3. High degree of accuracy and surface finish
4. Geometrical and Dimensional Tolerances are tight.
5. Relative tolerance between punch and die is extremely high and die life is extended.
6. Straight holes can be produced to closed tolerance.
7. As a NC unit is used , the machine can be operated unattended for longer period of time.

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8. Very sharp angle can be produces with almost no radius.

9. The part produced are burr- free.
[Any 4 Advantages 2 marks ]
Disadvantages of WEDM
1.
2.
3.
4.
5.
6.

Wire cannot be reused, because due to sparking the wire no longer remains round.
If proper tension in wire is not maintained, the surface finish will be poor
Only electrically conductive material can be machined.
Residual stresses are induced in the work piece during machining.
The maximum depth o work piece which can be machined is around 90mm.
A hole is necessary in the work piece for machining of surface which are not at the edge.
[Any 4 Disdvantages 2 marks ]

Q2 Attempt any two of the following

16 marks

a) Define part programming. Explain the principle of computer aided part programming.
Part programming Part program defined as the way in which the blocks of instructions are
planned and written such that after its execution on the CNC machine the required shape is
obtained on the work piece in minimum possible time.
OR
Part program is a set of instructions the machine tool about the processing steps to be performed
the manufacture of component.
The process of generating part programmes with use of computer languages like APT and COMPACT II with help of part programmer is called computer aided part programming.
[Definition 2 Marks]
The computer job consists of following steps.
a) Input translation The program entered by programmer is converted into the computer
understandable form by the input translation component.
b) Arithmetic calculations This component helps in solving the mathematics required to
generate the part surface.
c) Cutter offset compensation The program is written for component outline. But the actual
cutter path depending on the cutter diameter is determined by the computer.
d) Post processor This unit prepares the separate computer program used for a specific
machine tool.
Part programmers job
a) Defining the component geometry Any part composed of the basic geometric shape of line
and circle. The programmer job is to identify each entity and dimension it.
b) Specifying the operation sequence and the tool path The next job of the programmer is to
construct the path that should by followed by cutter. The tool path involves details steps
involved in cutter movement.
[Explanation 6 marks]

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WINTER 13 EXAMINATION Subject Code: 12154

Model Answer

_____________________________________________________________________________________________

(b) Explain programmable logic controller as applied to control system.

The programmable controllers are also called as programmable logic controllers because its
operation requires many logic functions to be performed.
The basic elements or components of a PLC are:
I. Power supply unit
II. Programming unit
III. Processor
IV. Input /Output section
V. Housing

Power supply unit The power supply unit provides voltage that is necessary to operate the
circuit throughout the controller. Some sections of the PLC such as input and output unit require
an AC voltage. Other sections like internal circuit of processing unit require a low level DC
voltage.
Programming unit The programming unit is an external electronic device that is connected to
the PLC when programming occurs. It allows the user to enter data and to edit and monitor
programs stored in the processor unit. The unit communicates with the processor unit by using a
data communication link. The first is the CRT terminal. The second type of unit is a small key
board with this data is entered
Processor - The processor is a computer that executes a program to perform the specific
operations. It controls the operation of the entire system. The processor is composed of three
main units.
Central Processing Unit (CPU)
Arithmetic Logic Unit (ALU)

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Model Answer

_____________________________________________________________________________________________

Memory
CPU: It is the brain of the PLC. The main function of the CPU is to interpret & execute computer
base programs that are permanently stored in the processors memory.
ALU: Performs mathematical calculations & make logic calculations.
Memory: The program & other data required by the CPU is stored in the memory unit. The
memory can be RAM or ROM.
Input Output section The input interface is designed to receive process and machine signals
and convert them into an acceptable form for the PLC. The output interface converts PLC control
signals into a form which can be used by the process equipment. Inputs are defined as the signals
given to the controller. Outputs are defined as signals given from the controller to the industrial
equipment.
Housing The elements of PLC are installed in a suitable housing to withstand the shop
environment.
[Block diagram 2 M + Explanation 6 M]
(c) What is a servo control system? Explain servo control system with a block diagram.
Servo control system
- It is also called as position control system.
- It is also known as servomechanism as it uses a servo motor
- The objective of servo mechanism is to force some parameter to vary in a specific manner.
- A servo mechanism is an automatic device for control of large power output by means of a small
power input or for maintaining correct operating conditions in a mechanism. It is a type of
feedback system
- It is also known as a device used to correct the performance of a mechanism automatically, by
means of error sensing feedback.
- But the servomechanism force the controlled variable value ( output value) to follow the
reference value (input value)
- A servo control system is used to control a physical variable such as position or motion (velocity
and acceleration)
- For example
1. The movement of robot arm
2. Power steering used in an automobile , machine tool position control, missile launcher ,
constant tension control of sheet rolls in a paper mill.
[4marks ]

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Model Answer

_____________________________________________________________________________________________

[Block diagram 2 marks ]

The above figure shows block diagram of servo control system. In servo control system, a
command signal is issued from the users interface panel, which comes in to the servos
positioning controller. Positioning controller stores information about various jobs or functions. It
has been programmed to activate the motor or load e.g. change in speed or position. Then signal
passes in to the servo control or amplifier section. In the section low power level signals are
amplified to higher speeds to provide torque for moving the heavy loads.
The servomechanism consists several devices. As load moves, tachometer or encoder providing
feedback signal to the positioning controller whether the motor is doing the proper job positioning
controller checks this feedback signal and determine whether the load is being moved properly by
the

servo

motor.

If

not

then

the

controller

makes

appropriate

corrections.

[Explanation 2 marks]

Que. 3 Attempt any four of the following: 4X4

a) Describe LBM with a sketch.
Ans:- Laser beam machining utilizes the narrow beam of intense monochromatic light which melts and
vaporize the material of the work piece. The setup of the process is shown in the figure. It mainly consists
of:
1.Laser Generation Unit: In this unit ruby rod, flash lamp, power supply, mirrors are used for production
of laser beams. The solid state laser i.e ruby rod is used in the form of cylindrical crystal with 10 mm
diameter and 150 mm long. The ends are finished to close optical tolerances. The flash lamp is wounded
around the ruby rod and it is connected to the electric power supply. The inner surface of the container
wall is made highly reflective to reflect all the light on the ruby rod. The electrical power supply is
designed to give 250 to 1000 watts energy to the flash lamp.
2.Cooling Arrangement: The ruby rod becomes less efficient at higher temperatures and gives maximum
efficiency when kept at a very low temperature. Hence cooling system is provided in which liquid
nitrogen is used, sometimes air or water cooled provision is also made, but it has less effectiveness
compared to liquid nitrogen.
3.Collimating Lens: The highly amplified beam of laser light is focused on the work piece through a lens,
it gives high energy density which melts and vaporizes the metal.
4.Workpiece Tables: The workpiece to be cut is places on the aluminium work table which is resistant to
the laser beam. The laser head is traverse over the workpiece and table can be moves as per requirement.
For machining powerful short pulses of say 100 Joules energy are required. The laser can, therefore,
provide enough heat of melt and vaporize any of the known materials.
The mechanism by which a
laser beam removes material from the surface being worked involves a combination of melting and
evaporation process. However, with some materials, mechanism is purely of evaporation. 2 MARKS

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Model Answer

_____________________________________________________________________________________________

2 MARKS
b)Enlist the functions of dielectric fluid.
Ans:- 1. Remain electrically nonconducting until the required break down voltage has been reached.
2. It breakdowns electrically in the shortest possible time once the breakdown voltage has been reached.
3.It rapidly quenches the spark or deionize the spark or spark gap after the discharges have occurred.
4.It provides an effective cooling medium.
5. It carries away the swarf particles, in suspension away from the working gap.

Any four functions. Each carry 1 mark

4X 1

c) Give the need of machining center. State its advantages.

Ans:- Need of machining centre.
1. To increase the productivity.
2. To increase the production rate. 3. To reduce the non-productive
time. 4. To reduce setup time. 5. To reduce in process inventory. 4. To reduce the floor space area.

Any four points. Each carry 1/2 mark 4X = 2mark

Advantagesof machining centre.
1. They are capable of versatile operations. It can also perform milling operation as well as
other operations like drilling, boring, reaming, profile cutting.
2. They are provided with multiple tool in single setup hence reduces tool change over time.
3. They have high production rate due to less cycle time of manufacturing.
4. Less floor space is required for installation.
5. More accuracy and more flexibility.
6. Less numbers of operators are needed.

Any four points. Each carry 1/2 mark 4X = 2mark

d) What is tool magazine? Explain the methods of selecting tool from tool magazine.

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Ans.: Tool Magazine: It is required to perform various operations on CNC machine, then large number
of cutting tools are mounted in a compact unit with facility to mount the tool, it is called tool magazine.
The turret has limited capacity to hold 8, 12 tools but tool magazine can hold more than 200 tools in a
large machining centre. The tool magazine may be indexed to select the correct tool. There are three types
tool magazine: 1.Circular or drum type 2. Chain type 3. Egg box type.
Methods of selecting tool from tool magazine: The tool can be arranged in the tool magazine in two ways.

1. Random tool selection.

2. Sequential tool selection

2 marks
Random tool selection: In this type of tool selection method, the tools are not loaded in to the
magazine, in order in which they are called in the programme. The tools are loaded in the tool
magazine in their regular locations.
Sequential tool selection:In this type the tool selection method,the tools are loaded in sequential
manner as in they are written part programme.

2.

2 marks

e)Describe Ultrasonic machining with block diagram.

Ans:- The term ultrasonic is used to describe a vibratory wave of frequency above that of the upper
frequency limit of the human ear,i.e.,generally above 16 kHz.The device for converting any type of
energy into ultrasonic waves is ultrasonic transducer.The electrical energy is converted into mechanical
vibrations,and for this piezo-electric effect in natural or electric crystals or magnetostriction effect
exhibited by some metals is utilized. Magne-tostriction means a change in the dimension occurring in
ferromagnetic materials subjected to an alternating magnetic field.
In ultrasonic machining, a tool vibrating longitudinally at 20 to 30 kHz with amplitude between 0.01 to
0.06 mm is pressed on to the work surface with a light force.As the tool vibrates with a specific
frequency, an abrasive slurry,usually a mixture of abrasive grains and water of definite proportion(20-30
per cent), is made to flow under pressure through the tool-workpiece interface.The impact force arising
out of vibration of the tool end and the flow of slurry through the work tool interface actually causes
thousands of microscopic grains to remove the work material by abrasion.The tool has the same shape as
the cavity to be machined.The method is chiefly employed to machine hard and brittle materials (which
are either electrically conducting or non-conducting). Explanation 2 marks

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Neat diagram 2 marks

Q.4 Attempt any three of the following:
a) What are the causes of machine breakdown?
Ans: Causes of machine breakdown:
1.Insufficient lubrication: Sliding, rotary (moving) components like gears, pulley and slide ways may be
subjected to friction and wear occurs hence proper lubrication is necessary by using correct lubricating
oil. Improper & negligence to cooling system
2.Overloading:When machine is operated beyond its specified speed, feed, depth of cut it may cause
undue excessive stresses of machine parts and causes breakdown.
3.Misalignment of parts: The machine components are mounted in the form of subassemblies and
alignment between them should be correct. Loose parts, bent shafts, etc. may cause breakdown.
4.Vibrations: If machine tools not properly balanced, then more vibrations are produced. Excessive
vibration leads to more friction and wear and tear. Rigid foundations are necessary.
5. By rough & careless use of machine tools by operator.
6. Failure to replace machine part which is not working properly in time.

Four points each carry 1 mark, 4 X 1= 4 Marks

b) How will you classify special purpose machines? Give examples in each category.
Ans: Classification of SPM: They are classified according to the positioning of the work piece :
1. Job remains fixed in one position: In this case the job is mounted on the machine table and the
machine may perform either one or more operations. E.g. multi spindle machine, Capstan and
turret lathe, etc.
Example: Multispindle heads machine tools: They are used to perform parallel
operation of similar size and depth. They consists of drilling unit to guide tools and other
attachments.

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2. Job moves from one station to other: The Job moves continuously or intermittently the operations
are performed one after another in a sequence from one location to another. E.g. rotary
intermittent motion transfer machine.
Example:Rotary index type machine tools:
i)
They are suitable for smaller size of component. They are provided with
hydraulic clamping/declamping mechanism.The unmachining movements are
made faster and feed during machining operation is carried out through indexing.
ii)
In line transfer machines:
It consists of series of machining units with their respective work-holding fixtures linked
with workpiece. Machining operations are carried out at tool changing and maintenance.

Four points each carry 2 marks, 2 X 2= 4 Marks

c)
Explain what is meant by preventive maintenance. Give its advantages.
Ans: Preventive maintenance is on the basis of principle prevention is better than cure. Instead
of doing breakdown maintenance it is better to prevent/ avoid the breakdown before it occurs. It
is naturally undertaken before the interruption of production and major break down. It is most
popular maintenance system adopted by many industries. It is planned maintenance of machine
tools carried out on schedule decided already. It is similar to regularly body check up for
maintaining of our health for blood pressure, sugar, etc. by the doctor. The machine tool also
checked for repair, lubrication, abnormal noise and vibrations, oil change, belt, bearing
replacement, etc. regularly. The machine tool is regularly checked and after repairs in preventive
maintenance, it is again used nearly to the original condition of equipment.

Explanation 2 marks
Advantages:
1. Less production down time, because of zero or minimum breakdowns.
2. Major repairs and repetitive repairs can be avoided.
3. Less standby equipments are needed, it helps to reduce capital investment.
4. Faulty products, product rejection comes to minimum level by minimizing chances of spoilage.
5. Life of components, machine tools increases and better conservation of assets and equipments.
6.Better control on quality of product.
7.Provide greater safety and protection to the operators.
8.Spare parts control is better, less inventory is needed.

Four poits each carry 1/2 mark, 4 X 1/2= 2 Marks

d)

Differentiate between breakdown and corrective maintenance.

Breakdown maintenance
Corrective maintenance
Is carried out only after breakdown of machine
tool.

Is maintenance work that consists of

replacement or repair of components which are
failed or going to fail or warn out.

Machine is not in working condition.

Machine is in working condition after

immediate replacing the component .It gives
proper service throughout its lifetime.

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No initial investment for maintenance.

Initial investments high due to different sensing

elements are connected to each machine to
detect any changes in the various parameters.

Delay in production if maintenance is carried

out for long time.

It is the pre-maintenance before breakdown

hence no delay in production i. e. less down
time

Due to emergency in maintenance, more cost

needed and always pressure on maintenance
people.

Regular inspection to identify faults in time

reduces the chances of breakdown hence no
emergency in maintenance and no pressure on
maintenance people.

The basic concept of this maintenance is not to

do anything until and unless the machine stops
its function

It is continuous process even fault is eliminated

e.g. maintenance of loose bolts, packing,
leakages, V belts etc.

Four points each carry 1 mark, 4 X 1= 4 Marks

B) a)What is total productive maintenance? State its benefits.
Ans:
TPM is defined as it is participative type maintenance technique in which responsibility of routine
maintenance is shared by the operator himself rather than separate maintenance staff.
Explaination:
The new concept of preventive maintenance modified by Japanese industry is known as total
productive maintenance. In our nation, the maintenance activity is separated to special team and it
is responsible for all the activities related to the maintenance while the user of the equipment or
machine is not involved.
In TPM, preventive maintenance is carried out through participation of the operator for routine
maintenance activity by imparting training, improving skills etc. It is the new approach of
maintenance which not only maintains the effectiveness of machine but also increases the
flexibility to reduce the material handling and promote smooth flow of production.

Explanation 3 marks
Benefits of TPM.
1. Increases effectiveness and overall efficiency of machines/equipments.
2. Improve operator skills including maintenance.
3. Minimise maintenance cost.
4. Minimise breakdowns.
5. Improve the quality of product.
6. Improve safety.
7. Improve reputation of company in the market.

Any six points each carry mark, 3 X 1/2= 3 Marks

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b)

Explain the principles of SPM design.

Ans: Some common principle which are to be kept in mind while designing of SPM are:
1. Specialazation of operation: This is the basic factor to design SPM. As per job requirement the
SPM is designed for dedicated machining operation e.g. multiple role drilling. Machining of
complex profile etc.
2. Multiple tooling: It is necessary to operate number of cutting tools simultaneously to reduce the
cycle time of the product. Hence the multispindle tooling is to be considered while designing the
SPM.
3. Combined operation: It means more than one operation is carried out at one station to reduce the
movement of the workpiece from one station to another. Complex shaped parts require large
number of operations and more time is necessary for setup and material handling hence similar
nature of operations can be combined which can be performed in less number of setups at a one
station e.g. drilling and boring can combined on a single station.
4. Integration of operations: It is nothing but linking of number of operation by using compact
arrangement of several machines using automated material movement. It is the formation of
group of machines for processing identical parts. While SPM designing, it is to be considered for
easy integration of operation.
5. Automation: In SPM design, automation is to be considered for:
(i) Material handling (ii) Indexing of various cutting tools
(iii)Setup time reduction
(iv)Idle/ Non-productive operation
6. Higher range of cutting parameters: The SPM are designed for higher range of cutting parameters
like cutting speeds, feed and depth of cut. The drive required is of high capacity than
conventional machines. It should have high rigidity to withstand higher cutting forces with
minimum deflection.

Six poits each carry 1 mark 6 X 1= 6 Marks

Q.5 Attempt any four of the following.
a) Explain the parameters which control the EDM process .
[any four Parameters 4 mark]
1) Spark gap: It is very small gap between tool and work piece about 0.0125-0.125 mm.
2) Current: The D.C. power supply with a current of 0.5-400A is used in this process.
3) V0ltage(DC) : The voltage supplied in the range of 40-300 volts.
4) Pulse duration: It is the duration between successive pulses for producing sparks. It is about 22000s.Pulse duration has effect on tool wear rate.
5) Dielectric pressure: It is the pressure under which the dielectric fluid is forced or circulated. It is less
than 0.2 MPa.

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6) Surface finish: It is the finish obtained after machining. It is about 3-10m for rough machining and
0.8-3m for finishing.
7) Material removal rate : It is the volume of metal removed per unit time. It depends of the material to
be cut and spark frequency
b)What are canned cycles? Differentiate between canned cycle and subroutine.
Canned cycles:- Canned cycle is defined as a set of instructions, inbuilt or stored in the system memory,
to perform a fixed sequence of operations. The canned cycles can by brought into action with a single
command and as such reduce the programming time and effort. Canned cycles are used for repetitive and
commonly used machining operations. The canned cycles are stored under G code address.G81 to G89
are reserved for fixed canned cycles and G80 is used to cancel the canned cycle.-[2 Marks]
Canned Cycle

Subroutine

1.It consist of some very common(general) moves

of different machines coded.

1. These are, repeating some moves(operations)on

a component for a variable number of times.

2. They dont allow optimization of program in

their movements fixed for operation.

2.They allow to make their own cycle with

different parametric dimensions at different
locations i.e. user defined canned cycles

[2 marks]

c) What is maintenance manual? What are its contents?

Maintenance Manual:- Whenever we purchase any machine, vehicle then service or maintenance booklet
is provided by the manufacturer which is called as maintenance manual. This booklet in the printed
format gives the user of the equipment about the preventive maintenance to be done with respect to time
scale/service period of that machine tool. The maintenance manual is prepared based on the vast
experience of the manufacture and the feedback collected from the customers who had used that type of
machine tool already. This document helps for systematically maintenance of machine tool in a right
manner without trial and error method. In this manual standardized maintenance procedure is given with
respect to standards designed by the manufacturer e.g. if oil grade is 40,then it is compulsory to use oil of
specific grade only.
[2 marks]
Contents:- In general, the maintenance manual contains following data.
1. maintenance procedure 2. Maintenance requirement 3. Safety precautions 4. Handling
procedure , troubleshooting, abbreviations
[2 marks]

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d) How linear axes are designated on a machining centre?

[4 marks]
It is important feature of the information supplied to the control system is slide displacement. Most
machines have two or more slides and they can be moved in one of two directions. It is therefore essential
that the control system knows which slide is to be actuated, which direction the slide is to move in, how
far the slide is to move. The axis and motion is intended to simplify programming and to standardize
machine movements. Each slide can be fitted with a control system and for the purpose of giving
commands to the control system the axis have to be identified. As usually in the real world space every
point is designated by 3-Dimensions,there are three linear axes of movement identified as X,Y and Z.
Certain rules are followed for designating these axes for applying it to different types of machines having
different relative motions of tool and work piece.
X-axis: It should be horizontal and perpendicular to Z-axis. It is generally longest axis of movement of
work piece or tool and always parallel to surface of the holding device.
Y-axis: It should be perpendicular to X and Z axes.
Z-axis: It is always parallel to the spindle. It should be perpendicular to the X and Y axis.
e) What are proximity switches? List its types.
Proximity Switches : It is the detector which measures or indicates the presence of an object without
making physical contact. They are used in automatic door opening, robotics object sensor system, CNC
machines, packing industries, washing machines etc
[2 marks]
Types:[2 marks]
Inductive , acoustic, capacitive , infrared
f) Differentiate between horizontal machining centre and vertical machining centre
[4 points 4 marks]
Horizontal machining centre

Vertical machining centre

1.When the position of the spindle is horizontal in

direction in the machining centre.

1.When the position of the spindle is vertical in

direction in the machining centre.

2.The rotating cutter is mounted in the cylindrical

shaft known as arbor and rotates along a horizontal
axis

2.The rotating cutter is mounted on vertical spindle

and rotates along a vertical axis

3.High material removal rate

3.Low material removal rate

4.It has tool magazine for mounting cutting tools

which has capacity limited to 8,12 and 16.

4.It has tool magazine for mounting cutting tools

which has large capacity to 80,120 etc.

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5.It is useful for the operations like flat surface

machining, angular operations, straddle, gang
milling etc.

5. It is useful for the operations like slot cutting,

drilling, profile machining, facing etc.

Q.6:-Attempt any four of the following:

a) Explain the principle of Electron Beam Machining. State one application of EBM
Principle of Electron Beam Machining: A stream of high-velocity electrons is emitted from the
tungsten cathode as shown in fig. The apparatus consists of a tungsten cathode that emits electrons and an
anode through which the electrons pass. A lens is used to focus the electrons at a point, reducing the
electron beam up to cross-sectional area of 0.0-0.02 mm diameter. The apparatus works at 50150kV,1100-1000A,with a power output of 100-150 W. The EBM process is very suitable for cutting
narrow slots and drilling holes of small diameter. [1 mark]

Fig. [2 marks]
Applications:- [any two 1 mark]
1.
2.
3.
4.
5.
6.

Drilling of holes in pressure differential devices used in nuclear reactors, air craft engines etc
Manufacture of wire drawing dies having small cross-sectional area
Scribing of thin films
Removing small broken taps from holes
Micro welding and drilling
Drilling of apparatus for electron microscopes.

b) What are the characteristics of a machining centre?

[any eight 4 marks]
Characteristics of machining center:1. Versatile NC machine tool
2. Tool magazine and ATC facility

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3. Elimination of non-productive activities

4. Less space needed
5. High rate of production
6. High manufacturing accuracy
7. Complex jobs
8. Less manpower.
c) Explain the meaning of scheduled maintenance.
[4 marks]
Scheduled Maintenance:When maintenance is carried out as per the time table prepared in advance for the machine tool, it is
known as scheduled maintenance. A schedule is framed for an instrument/machine showing the due dates
for inspection, lubrication, repair and overhaul.
The frequency or schedule is prepared by the experienced maintenance person and as per guidelines or
instructions given the manufacturer of machine tool. It is purely planned maintenance which is time scale
based and routine for the maintenance activity e.g. cleaning of water tanks, checking of pressure vessel,
refilling of CO2 in fire extinguisher, calibration of measuring instruments etc.
d)What is automation of a machine tool? Give its types.
Automation of machine tool: It is the technology concerned with application of mechanical, electronic
and computer based system to enhance operation and control of production activity. Automation is useful
for medium to large scale industries to increase productivity, it also helps to carry out unsafe operations
like welding, handling chemicals and acids.
[2 marks]
Types:- Fixed, Programmable, Flexible and Integrated
[2 marks]
e) What do you mean by axis identification? Explain thumb rule for axis identification
Axis Identification: It is the three dimensional Cartesian co-ordinate system and the three axis of
movement are identified as X,Y and Z axis. The possible linear and rotary movements of machine
slides/work piece are shown in fig below. Rotary movements about X,Y and Z axis are designated as A,B
and C respectively.

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[1 mark]
Thumb Rule:

[3 marks]

The main axis of movement and the direction of movement along these axis is
identified as follows:

Z-axis: The Z-axis of motion is always the axis of the main spindle of the machine. It does not matter
whether the spindle carries the workpiece or the cutting tool. If there are several spindles on a machine,
one spindle is selected as a principal spindle and its axis is then considered to be Z-axis. On vertical
machining centres, the Z-axis is vertical and on horizontal machining centres and turning centres the Zaxis is horizontal. Positive Z movement (+Z) is in the direction that increases the distance between the
workpiece and the tool. Convention of designating the Z-axis on milling, drilling and turning machines is
shown in figs.
X-axis: The X-axis is always horizontal and is always parallel to work holding surface. If the Z-axis is
vertical, as in vertical milling machine, positive X-axis(+x) movement is identified as being to the right,
when looking from the spindle towards its supporting column. If Z-axis is also horizontal as in turning
centres, positive X-axis motions is to the right, when looking from the spindle towards the work piece.

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Y-axis: The Y-axis is always at right angles to both the X-axis and Z-axis. Positive Y-axis movement
(+Y) is always such as to complete the standard 3-dimensional co-ordinate system.
Rotary axis : The rotary motion about the X,Y and Z-axis are identified by A,B,C respectively. Clockwise
rotation is designated positive movement and counter-clockwise rotation as negative movement. Positive
rotation is identified looking in +X,+Y and +Z directions respectively.

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