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MECHANICAL ENGINEERING
CAD/CAM/CAE
CHAPTER 1. INTRODUCTION
Syllabus
Introduction to CAD, CAM, CIM and CAE,
Product cycle,
Mathematical model for product life cycle.
Introduction
In todays global competition, industries cannot survive unless they introduce
new products or existing ones with:
Better quality
Lower cost
Shorter lead time
Computer aided design (CAD) can be defined as the use of computer systems
to assist in creation, modification, analysis and optimization
Computer aided machining (CAM) can be defined as the use of computer
systems to plan, manage and control a manufacturing plant through either
direct or indirect computer interface with the plants production resources.
CAM
3D CAD data can be read by CAM software which takes 3D data & CNC
machine parameters as inputs and delivers a tool path that cuts metal as per the
part designs.
The tool path so generated can be simulated on the screen to evaluate tool
gauging so that the machining run is perfect.
Computer Integrated manufacturing
Computer-integrated manufacturing (CIM) is manufacturing supported by
computers. It is the total integration of Computer Aided Design /
Manufacturing and also other business operations and databases.
Definition: CIM is the integration of total manufacturing enterprise by using
integrated systems and data communication coupled with new managerial
philosophies that improve organizational and personnel efficiency.
The CIM concept is that all the operations related to the production function in
an integrated computer system to assist, enhance and /or automate the
operations.
The computer system is spread throughout the firm , touching all the activities
that support manufacturing.
In this integrated computer system, the output of one activity serves as the
input to the next activity, through the chain of events that starts with the sales
order and finishes with shipment of the product.
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Customer orders are initial y entered by the companys sales force into a
computerized order-entry system. The orders contain the specifications
describing the product.
The specifications serves as input to the design
New products are designed on a CAD system. The components that comprise
product are designed, the BOM is complied, and assembly dwgs. are prepared.
The output of design serves as input to mfg. engg, where process planning,
tool design and similar activities are accomplished to prepare for production
The output of mfg. engg. Provides input to the PPC, where MRP and
scheduling is performed
Computer-Aided Engineering
1.
2.
3.
4.
5.
6.
7.
8.
T2 be time associated with planning and setting for each batch of production
This include the ordering of raw materials by purchasing department,
time required in production planning to schedule the batch, setup times
for each operation etc.
T3 be the time required for designing the product and for all other activities
that are accomplished once for each different product.
These include process planning, cost estimating and pricing, building
of special tools and fixtures.
B be the number of batches produced throughout the product life cycle.
Q be the number of units produced in each batch.
The aggregate time spent on the product throughout its life cycle can be
The average time spent on each unit of product during its life cycle.
In mass and batch production the T2 and T3 terms can be spread over a large
number of units.
Recognition of need involves the realization by someone that a problem exists for
which some corrective action should be taken e.g. defect in current machine
design
Definition of problem involves a through specifications of the item to be designed.
This specifications includes physical and fundamental characteristics, cost, quality
and operating performance.
Synthesis and analysis are closely related and highly iterative in design process
This iterative process is repeated until the design has been optimized within the
constrained imposed on the designer
The philosophy, functionality and uniqueness are all determined during synthesis.
The major financial commitments to turn conceived product into reality are made
during synthesis.
Information generated during synthesis phase is qualitative and hard to capture by
computer system.
The end goal of synthesis is a conceptual design
Evaluation is concerned with measuring the design against the specifications
established in problem definition phase.
This evaluation often requires fabrication and testing of a prototype model to
assess performance, quality, reliability and other criteria.
Presentation includes documentation of design by means of drawing , material
specifications, assembly list and so on.
Geometric Modeling
It is concerned with the computer compatible mathematical description of the
geometry of the object.
To use geometric modeling, the designer constructs the graphical image of the
object on the CRT screen of the ICG system by inputting three types of
commands
1. The first type of command generates basic geometric elements such as points,
lines and circles.
2. The second command type is used to accomplish scaling, rotation and other
transformations of these elements.
3. The third type of demand causes the various elements to be joined into the
desired shape of the object being created on the ICG system.
During this process , the computer converts the commands into a mathematical
model, stores it in the computer data files, and displays it as an image on CRT
screen.
The model can be called from the data files for review, analysis, or alteration.
There are several different methods of representing the object in geometric
modeling.
The basic form uses wire frames to represent the object. In this form the object
is displayed by interconnecting lines. Wire frame modeling is classified into
three types
1. 2D. Two dimensional representation is used for a flat object
Engineering Analysis
The analysis may involve stress strain calculations, heat transfer computations,
or use of dynamic behaviour of the system being designed.
The computer can be used to aid in this analysis work.
Two important examples of this type are:
1. Analysis of mass properties
2. Finite element analysis
1. Analysis of mass properties:
For solid object: surface area , weight , volume, centre of gravity, and moment
of inertia.
For a plane surface (or c/s of solid object) the corresponding computations
may include the perimeter, area, and inertia properties.
2. Finite element analysis:
With this technique the object is divided into large number of finite elements
(usually triangular or rectangular in shapes) which form an interconnecting
network of concentrated nodes.
By using a computer with significant computer capabilities, the entire object
can be analyzed for stress-strain, heat transfer and other characteristics by
calculating the behaviour of each node.
By determining the interrelating behavior of all the nodes in the system, the
behavior of the entire object can be assessed
Design Review and Analysis
Semi automatic dimensioning and tolerancing routines which assign size
specifications to surfaces indicated by the user help to reduce the possibility of
the dimensioning errors.
The designer can zoom in on part design details and magnify the image on
graphics screen for close scrutiny
A procedure called layering is often helpful in design review. E.g. a good
application of layering involves overlaying the geometric image of the final
shape of the machined part on the top of the image if the rough casting.
This ensures that sufficient material is available on the casting to accomplish
the final machined dimensions.
Another related procedure for design review is interference checking. This
involves the analysis of an assembled structure in which there is a risk that the
components of the assembly may occupy the same space.
MIT (T
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The risk occurs in the design of large chemical plants, cold boxes, and other
complicated piping structures.
One of the feature of CAD systems is kinematics. The available kinematics
packages provide the capability to animate the motion of simple designed
mechanisms such as hinged components and linkages.
Automated Drafting
It involves the creation of hard copy engineering drawings directly from the
CAD database.
CAD systems includes features like automatic dimensioning, generation of
crosshatched areas, scaling of the drawing, and the capability to develop
sectional views and enlarged views of particular part details
Different views like oblique, isometric and perspective views can be of
significant assistance in drafting.
Benefits of CAD
Productivity improvement in Design
Shorter lead times
Reduced engineering personnel requirement
Customer modifications are easier to make
Rapid response of the design analysis
Improved accuracy of design
Avoidance of subcontracting to meet schedules
Provide better functional analysis to reduce prototype testing
Avoidance of subcontracting to meet schedules
Assistance in preparation of documentation
Minimized transcription errors
Designs have more standardization
Fewer errors in NC part programming
Better communication interfaces and greater understanding among engineers,
designers, drafters, management and different project groups.
Principles of Concurrent Engineering
Definition
It is a methodology of restructuring the product development activity in an
organization using a cross functional team and is a technique adopted to
improve efficiency of the product design and reduce product cycle time.
Concurrent engineering brings together a wide spectrum of people from
several functional areas in the design and mfr. of a product.
Representatives
from
R&D,
engineering,
manufacturing,
materials management, quality assurance marketing etc
develop the product as a team.
Traditional Process of Serial Engineering
Functions Separated
Functions Serially Executed
No Interaction
Maintenance Usually an Afterthought
Time Consuming
Costly
By focusing the electron beam , changing its intensity , and controlling its
point of contact against the phosphor coating through the use of deflector
system , the beam can be made to generate picture on the CRT screen
Rasterscan
In this viewing screen is divided into a large number of discrete phosphor
picture elements, called pixels.
The number of pixels in the raster display might be range from 256 X 256 (a
total of 65,000 points) to 1024 X 1024 (a total of 10,00,000 points)
Each pixel on the screen can be made to glow with a different brightness.
Color screens provide for the pixels to have different colors as well as
brightness
Raster scan
Image Generation
Picture quality
Data content
Selective erase
Grey scale
Direct Beam
storage
Stroke writing
Excellent
Limited
Yes
Yes
Stroke writing
Excellent
High
No
No
Raster scan
Moderate to good
Color capability
Moderate
No
Yes
Animation capability
Yes
No
Moderate
Yes
Yes
Picture definition is stored into a refresh buffer, and the firing voltage is
applied to refresh the pixel positions (at the intersection of the conductors) 60
times per second.
Alternating current method are used to provide faster application of the firing
voltages, and thus brighter images.
The disadvantage is that they are strictly monochromatic devices.
Basic design of plasma panel display device
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Application Program
It controls the storage of data into and retrieves data out of application
database
The application program is driven by the user through the graphics package
The application program is implemented by the user to construct the model of
a physical entity whose image to be viewed on the graphics screen.
Application programs are written for particular problem areas.
Problem areas in engineering design would include arch, construction, mech.
Components, ext, chem, aerospace.
Problem areas other than deign include flight simulators, graphical display of
data, mathematical analysis, and even artwork
Graphics Package
The graphics package is the software support between the user and the
graphics terminal.
It manages the graphical interaction between the user and the system
It also serves as a s/w support between the user and the application software
The graphics package consist of input subroutines and output subroutines
The input subroutine accepts the input commands and data from the user and
forward them to the application program
The output subroutines control the display terminal (or other output device)
and converts the application models into 2D or 3D graphics pictures.
Application data base
The database contains mathematical, numerical and logical definitions of the
application models, such as electronic ckts, mechanical components,
automobile bodies, and so forth.
It also contains alphanumeric information associated with the models, such as
BOM, mass properties and other data.
The contents of the data base can be readily displayed on the CRT or plotted
out in hard copy form.
Functions of a Graphics package
Generation of graphics elements
Transformations
Display control and windowing function
Segmenting functions
User input functions
Generation of graphics elements
A graphic element in computer graphics is a basic image entity such as a dot
(or point), line segment, circle, and so forth
The collection of elements in the system could also include alphanumeric
characters and special symbols
There is often a special hardware component in the graphics system associated
with the display of many of the elements.
This speeds up the process of generating the element
The user can construct the application model out of collection of elements
The term primitive is used in reference to the graphics element
E.g. sphere, cube, or cylinder
In 3D wire frame models and solid modelling, primitives are used as building
blocks.
Transformations
Transformations are used to change the image on the display screen
Transformations are applied to graphics elements in order to aid the user in
constructing an application model
Points, lines, arcs , circles can be defined in various ways through interaction
with the ICG system
Transformations
2-D Transformations
3-D Transformations
Two-dimensional Transformations
To locate a point in a two-axis Cartesian system, the x and y coordinates are
specified.
These coordinate can be treated together as a 1 x 2 matrix : (x, y), e.g. the
matrix (1,4) would be interpreted to be point which is 1 unit from the origin in
the x-direction and 4 units from the origin in the y-direction.
This method of representation can be
extended further to define a line as a
2 x 2 matrix by giving x and y coordinates of the two end points of the line.
The notation would be,
Translation
Translation involves moving the element from one location to another
x= x + m, y = y + n
Where,
This would produce an alternation in the size of the element by the factor m in
the x-direction and by the factor n in the y direction
It also repositions the element
If the scaling factor is <1 , it is moved closer to origin
If the scaling factor is >1 , it is moved farther from the origin
Rotation
In this transformation, the points of an object are rotated about the origin by an
angle
For a positive angle, this rotation is in the counter clockwise direction
This accomplishes rotation of the object by the same angle, but it also moves
the object. In matrix notation the procedure will be as follows:
(x, y) = (x, y) R
Where
Example : Translation
Consider the line defined by,
Suppose the line to be translate in space by 2 units in x direction and 3 units in the y
direction.
Example : Scaling
Apply scaling factor of 2 to the line
Example : Rotation
Rotate the line about origin by 30
3 Dimensional Transformation
Transformations by matrix methods can be extended to three dimensional
space.
Translation
The translation matrix for a point defined in three dimensional matrix would
be,
T = (m, n, p)
And would be applied by adding increments m, n and p to the respective
coordinates of each of the points defining the three-dimensional geometry
elements
Scaling
The scaling transformation is given by,
Concatenation
e.g.
1. Rotation of the element about an arbitrary point the element
2. Magnifying the element but maintaining the location of one of its points in the
same location
In the first case transformations would be: translation to the origin, then
rotation about the origin, then translation back to original location
In the second case , the element would be scaled (magnified) followed by a
translation to locate the desired point as needed
The objective of the concatenation is to accomplish a series of image
manipulations as a single transformation
The concatenation is the product of the two transformation matrix
It is important that order of matrix multiplication be the same as the order in
which the transformations are to be carried out.
Example : Concatenation
A point to be scaled by a factor of 2 and rotated by 45. Suppose point under
consideration was (3, 1) . This may be one of the several points defining a
geometric element
First accomplish the transformations sequentially,
First consider the scaling,
(x, y ) = (x, y)S
Examples
A line is defined in 2 D space by its end points (1,2) and (6,4). Express this in
matrix notation and perform the following transformation in succession on this
line
1. Rotate the line by 90 about the origin
2. Scale the line by a factor of 0.5 (Dec/Jan 04/05, 8 Marks)
A square of side 30 units has its coordinates A(10,10), B(40,10), C(40,40) and
D(10,40),
Perform the following transformation in succession and show it on graph
paper
1. Rotate about origin 20 anticlockwise
2. Scale it by factor 1.5
3. Perform the above sequence of transformation by concatenation
(May/June 04, 18 Marks)
Homogeneous representation
In order to concatenate the transformations matrices, all
transformation matrices should be multiplicative type.
However, the translation matrix is vector additive while all other are matrix
multiplications.
It is desirable , to express all geometric transformations in form that ,they can
be concatenated by matrix multiplication only.
In homogeneous representation, an
n-dimensional space
is mapped into (n+1) dimensional space.
Thus a 2 dimensional point [x, y] is represented with the homogeneous
coordinate triple (xh,yh,h)
Where,
Thus , a general homogeneous coordinates can also be written as (h.x, h.y, h).
For two-dimensional geometric transformations, homogeneous parameter h to
be any nonzero value.
Thus , there is an infinite number of equivalent homogeneous representations
for each coordinate point (x, y)
A convenient choice is simply to set h=1.
Each two-dimensional position is then represented with coordinates (x, y, 1)
This facilitates the computer graphics operations where the concatenation of
multiple transformations can be easily carried out.
The translation matrix in multiplication form can be given as,
MECHANICAL ENGINEERING
CAD/CAM/CAE
Primitive Instancing
In primitive instancing modeling approach, primitives are simple 3D solid
shapes, which form the base for creating a solid model
These primitives are parameterized by geometric as well as
physical properties.
The solid model of any object can be created with different combinations of
these primitives.
e.g. one primitive object may be a regular pyramid with a user defined number
of faces meeting at the apex.
A parameterized primitive may be thought of as defining family of parts
whose members vary in few parameters, an important CAD concept known as
group technology.
Primitive instancing is often used for relatively complex objects, such as gears
, bolts, that are tedious to define in terms of Boolean combinations of simpler
objects.
e.g. A gear may be parameterized by its diameter or no. of teeths.
Primitive instancing is based on the concept of families of objects or parts
All parts having same topology but different dimensions are grouped into
family
Each individual part in the family is called a primitive instance.
e.g. a cylinder is represented by diameter(D) and height (h)
Each primitive instancing is defined by specific (D) and (H)
A number of such cylinder primitive instancing creates a family of cylinders
A group of such families can define a solid
Boundary representations (B-rep)
Boundary representations or b-reps describe the solid object in terms of its
boundaries, that is the vertices, edges and faces.
In this model, face is bounded by edges and each edge is bounded by vertices.
The entities which constitute a B-rep model are:
Geometrical Entities Topological entities
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Point
Vertex
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MECHANICAL ENGINEERING
Curve, line
Edge
Surface
CAD/CAM/CAE
Face
B Rep Model
An Edge-Based Model
v
4
e6
e4
e5
e2
e3
v1
v3
e1
v2
Faces:
f1
f2
f3
f4
e1
e2
e3
e3
e4
e6
e5
e2
Edges:
e1
e2
e3
e4
e5
e6
v1
v2
v3
v2
v1
v3
v2
v3
v1
v4
v4
v4
Vertices:
v1
x1
v2
x2
v3
x3
v4
x4
v5
x5
v6
x6
y1
y2
y3
y4
y5
y6
e5
e4
e6
e1
z1
z2
z3
z4
z5
z6
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The building block approach is results in more compact file of the model in
the data base
Unusual shapes can not be formed easily with this representation
This model stores the model by combination of data and logical procedures
(the Boolean model)
This model requires less storage but more computation to reproduce the model
and its image
Because of relative advantages and disadvantages of the two approaches ,
hybrid systems have been developed which combine the CSG and B-rep
approaches.
Construction of a Wrench
MECHANICAL ENGINEERING
CAD/CAM/CAE
Wireframe ambiguity:
Is this object (a), (b) or (c) ?
(c)
(a)
(b)
Solid modeling
An improvement in the wire frame modeling, both in terms of realism to the
user and definition to the computer.
In this models are displayed with less risk of misinterpretation
When color are added the picture becomes realistic one.
The solid modeling has wide range of applications other than CAD and
manufacturing.
These includes color illustrations in magazines and technical publications,
animation in movies and training simulators
Sweeps of solids are useful in modelling the regions swept by a machine tool
or a tool path.
MECHANICAL ENGINEERING
CAD/CAM/CAE
Sweeps whose generating volume or area changes in shape, size or in
orientation as they swept, are known as generalized sweeps.
Sweep representation is useful in generating extruded solids and solids of
revolution.
The sweeping operation is based on sweeping a curve or surface.
Applications involves simulations of material removal due to machining
operations and interference detection of moving objects in space.
1.
2. Non linear
3. Hybrid
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Cell Decomposition
An object can be modelled by decomposing its volume into smaller volume of
cells which are mutually continuous and do not penetrate into each other.
The shape in this need not be a cube nor they should be identical.
It can be seen that some cells are partly outside the boundary, while some of them
are partly inside the boundary
This is approximate representation of an object.
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In such a case , a smaller hole or cavity gets neglected if the size of cavity is
smaller of the cells or other than squares in this scheme.
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This difficulty can be overcome by permitting various shapes of cells other than
squares and rectangles, such as triangles.
The need for portability of the geometric model among different hardware
platforms has led to the development of device independent graphics
Simultaneously standards for exchange of drawing data base among software
packages have been developed to facilitate integration of design and
manufacturing operations
The heart of any CAD model is the component database.
This includes the graphics entities like points, lines, arcs etc. and coordinate
points which define the location of these entities
This geometric data is used in all downstream applications of CAD, which
include finite element modeling and analysis, process planning, estimation,
CNC programming, Robot programming, programming of CMM, MRP
systems
To achieve high level of integration between CAD, analysis
and manufacturing operations, the database must contain:
Shapes of the components ( based on 3-D wire frame or solid model )
Bill of materials (BOM), of the assembly which the components are used.
Materials of the components
The manufacturing, test and assembly procedures to carried out to produce a
component so that it is capable of functioning as per requirements of design
In designing data structure for CAD database the following factors to be
considered:
The data must be neutral
The data structure must be user friendly
The data base must be portable
Features of GKS
The feature of Graphics Kernel system include
1. Device independent: The does not assume that any of the input or output
devices have particular features or restrictions
2. Text/ annotations : All text or clarification are in a neutral languages like
English
3. Display management: A complete set of display management functions, cursor
control and other features are provided.
4. Graphics Functions: Graphics functions are provided in 2D or 3D
GKS Implementation in a CAD W/S
DATA EXCHANGE
The need for exchanging modeling data is directly motivated by the need to
integrate and automate the design and mfg. processes to obtain max. benefits
from CAD/CAM.
The component database can be used in downstream applications like FEA,
Process planning, Robot programming, MRP, C. N. C. programming.
There should be tie between the two or more systems to form an application
that shares common data.
Data exchange files are neutral files. Following are two types of neutral files:
Geometric entities represent the definition of the product shape and include
curves and surfaces.
Non geometric entities provide views and drawings of the model to enrich its
representation and include annotation and structural entities.
Annotation entities include types of dimensions (linear, angular) symbols,
centerlines, cross hatching.
Structure entities include views, drawings, attributes (i.e. line and text fonts,
colors, layers etc.), properties (e.g. mass), symbol (e.g. mechanical and
electrical ) and macros (to define parametric parts)
Flag section
Start section
Global section
Directory entry section
Parameter data section
Terminate section
Start section contains comments that can be used to describe the drawing,
identify its source, comment on its format an so on.
Global section includes information that describes global characteristics of the
IGES file, such as name of the file, the system that created the file, units of
measures, and precision
Directory entry section describes the entities in the drawing. This section
contains attributes such as color, line style. Also provides an index to the
entities in the file
Parameter data section contains data to describe each entity, such as point
coordinates, coefficients of curve and surface equations, text characters and
other attributes.
Terminate section
IGES Limitations
IGES is complex and wordy
These files are about five times larger than an equivalent product file
Several entities required for specialized CAD applications are not available in
IGES file
It does not convey the extensive product information needed in the design and
mfg. cycle.
STEP
Standard for the Exchange of Product Model Data, officially the ISO standard
10303, Product Data Representation and Exchange, is a series of International
Standards with the goal of defining data across the full engineering and mfg.
life cycle.
The ability to share data across applications, across vendor platforms and
between contractors, suppliers and customers, is the main goal of this
standard.
Scope of STEP
The standard method of representing the information necessary for completely
defining a product throughout its entire life, i.e. from the product conception
to the end of useful life.
Standard method for exchanging the data electronically between two different
systems.
It provides worldwide standard for storing, sharing and exchanging product
information among different CAD systems.
It includes methods of representing all critical product specifications such as
shape information, materials, tolerances, finishes and product structure.
It is data exchange that would apply to a wide range of product areas,
including architectural, engineering and construction.
STEP Architecture
It has main four components
1. EXPRESS modelling language
2. Data schemes including attributes such as geometry, topology, features and
tolerances.
3. Application interface called Standard Data Access Interface (SDAI) to enable
applications to access and manipulate STEP data
4. STEP database
MECHANICAL ENGINEERING
CAD/CAM/CAE
CHAPTER 8. ROBOTICS
Definition
A robot is a programmable , multi functio n manipulator deigned to move
material, parts, tools or special devices through variable programmed motion
for the performance of a variety of tasks
An industrial robot is a general purpose , programmable machine processing
certain anthropomorphic characteristics
What are the parts of a robot?
Manipulator
Pedestal
Controller
End Effectors
Power Source
Manipulator (Mimics the human arm)
Base
Appendages
o
Shoulder
o Arm
o Grippers Pedestal
(Human waist)
Supports the manipulator.
Acts as a counterbalance.
Controller (The brain)
Issues instructions to the robot.
Controls peripheral devices.
Interfaces with robot.
Interfaces with humans. End
Effectors (The hand)
Spray paint attachments
Welding attachments
Vacuum heads
Hands
Grippers
Power Source (The food)
Electric
Pneumatic
Hydraulic
ROBOT PHYSICAL CONFIGURATION
1. Cartesian configuration
2. Cylindrical configuration
3. Polar configuration
4. Joint-arm configuration
Cartesian Configuration
Robots with Cartesian configurations consist of links connected by linear
joints (L). Gantry robots are Cartesian robots (LLL).
Cartesian Robots
It consists of three orthogonal slides.
Three slides are parallel to x, y and z axes of the Cartesian coordinate system
Commonly used for:
pick and place work
assembly operations
handling machine tools
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MECHANICAL ENGINEERING
arc welding
CAD/CAM/CAE
Advantages:
ability to do straight line insertions into furnaces.
easy computation and programming.
most rigid structure for given length.
Disadvantages:
requires large operating volume.
exposed guiding surfaces require covering in corrosive or dusty environments.
can only reach front of itself
Cylindrical Configuration
Robots with cylindrical configuration have one rotary ( R) joint at the base and
linear (L) joints succeeded to connect the links.
Cylindrical Robots
In this, the robot body is a vertical column that swivels about vertical axis
The arm consist of several orthogonal slides which allow the arm to be moved
up and down and in or out w.r.t. to body
Commonly used for:
handling at die-casting machines
assembly operations
handling machine tools
spot welding
Advantages:
can reach all around itself
rotational axis easy to seal
relatively easy programming
rigid enough to handle heavy loads through large working space
good access into cavities and machine openings
Disadvantages:
linear axes is hard to seal
wont reach around obstacles
exposed drives are difficult to cover from dust and liquids
Spherical/Polar Robots
A robot with 1 prismatic joint and 2 rotary joints the axes consistent with a polar
coordinate system.
Commonly used for:
handling at die casting or fettling
machines
handling machine tools
arc/spot welding
Advantages:
large working envelope.
two rotary drives are easily sealed against liquids/dust.
Disadvantages:
complex coordinates more difficult to visualize, control, and program.
exposed linear drive.
low accuracy
Joint-arm Configuration
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Pa
Disadvantages
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50
Manual method
It is more like setting machine rather than programming
It involves setting mechanical stops, cams, switches, or relays in the robots
control unit
Used for short work cycles (e.g. pick-and-place operations )
Walkthrough Method
In this programmer manually moves robots arm and hand through the
sequence of the work cycles.
Each movement is recorded into memory for subsequent playback during the
production
Speed is controlled independently
Appropriate for spray painting, arc welding robots
Leadthrough Method
Uses teach pendent to power drive the robot through its motion sequence
Teach pendent is device, consists of switches and dials to control the robots
physical movements
Each motion is recorded into memory for future playback during the
workcycle
Popular because of its ease and convenience
Off-line Programming
It involves the preparation of robot program off-line , in a manner similar to
NC part programming
It is accomplished on computer terminal
After preparation it is entered into the memory of the computer for use during
the work cycle.
The advantage is that production time of robot is not lost to delays in teaching
the robot a new task
Robotic Sensors
Sensors provide feedback to the control systems and give the robots more
flexibility.
Sensors such as visual sensors are useful in the building of more accurate and
intelligent robots.
The sensors can be classified as follows:
Position sensors
Position sensors are used to monitor the position of joints.
Information about the position is fed back to the control systems that are used
to determine the accuracy of positioning
Range sensors
Range sensors measure distances from a reference point to other points of
importance.
Range sensing is accomplished by means of television cameras or sonar
transmitters and receivers.
Velocity Sensors
They are used to estimate the speed with which a manipulator is moved.
The velocity is an important part of the dynamic performance of the
manipulator.
The DC tachometer is one of the most commonly used devices for feedback of
velocity information.
Proximity Sensors
They are used to sense and indicate the presence of an object within a
specified distance without any physical contact.
Grippers
Grippers are generally used to grasp and hold an object and place it at a
desired location.
mechanical grippers
vacuum or suction cups
magnetic grippers
adhesive grippers
hooks, scoops, and so forth
Tools
At times, a robot is required to manipulate a tool to perform an operation on a
workpiece. In such applications the end- effecter is a tool itself
spot-welding tools
arc-welding tools
spray-painting nozzles
rotating spindles for drilling
rotating spindles for grinding
Technical features of Robot
1. Work volume
2. Precision of movement
3. Speed movement
4. Weight carrying capacity
5. Types of drive system
Work Volume
o It refers to the space within which the robot can operate
o It is the spatial region within which the end of the robots wrist can be
manipulated
o The work volume is determined by its physical configuration , size, and limits
of its arms and joint manipulations
o E.g. work volume of Cartesian coordinate robot is rectangular, for polar it is
partial sphere etc.
Precision of movements
1. Spatial resolution:
The spatial resolution of a robot is the smallest increment of movement into
which the robot can divide its work volume.
3. Repeatability:
It is the ability of the robot to position the end effector to the previously
positioned location.
It depends on the stability of the control system and is affected by temperature,
load etc.
Speed of movement
The speed with which the robot can manipulate the end effector ranges up to a
maximum of about 1.5 m/s
The speed is determined depends of factors like weight of the object being
moved, the distance moved, and the precision required.
Heavy objects can not be moved as fast as light objects because of inertia
problem
Objects must be moved slowly when high positional accuracy is required
Weight carrying capacity
It covers wide range
At higher end, there are robots which can lift up to 500 kgs to 1000 kgs.
At lower end, there are robots which can be used for 0.75 to 1.5 kgs.
Types of drive system
1. Hydraulic drive
Provide fast movements
Preferred for moving heavy parts
Preferred to be used in explosive environments
Occupy large space area
There is a danger of oil leak to the shop floor
2. Electric drive
Slower movement compare to the hydraulic robots
Good for small and medium size robots
Better positioning accuracy and repeatability
stepper motor drive: open loop control
DC motor drive: closed loop control
Cleaner environment
The most used type of drive in industry
3. Pneumatic drive
Preferred for smaller robots
Less expensive than electric or hydraulic robots
Suitable for relatively less degrees of freedom design
Suitable for simple pick and place application
Relatively cheaper
Basic components of NC
1. Program of Instructions
The program of instructions is the detailed step by step commands that direct
the processing equipment
Commands refer to position of spindle w. r. t. worktable on which the part
is fixtured
More advanced instructions include selection of spindle speeds, cutting tools
etc.
The common medium used for coding of program is 1- in. wide punched tape.
Some recently used are punched cards, magnetic tape cassettes and floppy
diskettes
2. Machine Control Unit (MOU)
MCU consists of the electronics control and hardware that read and interpret
program of instruction and convert it into mechanical actions of the machine
tool or other processing equipment.
The elements of machine tool are consists of a tape reader, data buffer, signal
input/output channels, feedback channels and sequence control,
The tape reader has an electromechanical device used to read and wind the
tape
The data buffer then interprets the program of instructions and also stores the
instructions in logical blocks of information
From here signals are sent to through the signal output channels which are
connected to the servomotor and other controls in the machine tools.
Feedback signals are provided for ensuring proper execution of the given
instructions
The sequence control coordinates the activities of the other elements of the
control unit
3. Processing Equipment
It is the component that performs useful work
The machine tool consists of worktable and spindle to hold tools, motors and
controls necessary to drive them.
NC Procedure
1. Process planning
2. Part programming
3. Tape preparation
4. Tape verification
5. Production
Process Planning
The engineering drawing of the workpart must be interpreted in terms of the
manufacturing processes to be used
It consists of preparation of route sheet
Part Programming
A part programmer plans for the portions of the job to be accomplished by NC
The part programmers are responsible for planning the sequence of operations
to be performed by NC
There are two ways to program for NC
Manual part programming
Computer-assisted part programming
Manual part programming
In this, the machining instructions are prepared on a form called a part
program manuscript
The manuscript is a listing of the relative cutter/ work piece positions which
must be followed to machine the part.
Computer assisted part programming
In this , much of the tedious computational work required in manual part
programming is transferred to the computer.
This is particularly appropriate for complex work piece geometries and jobs
with many machining steps
It also saves part programming time
Tape Preparation
A punched tape is prepared from the part programmers NC process plan
In manual part programming, the punched tape is prepared from the part
program manuscript or a typewriter like device equipped with tape punching
capability
In Computer assisted part programming, the computer interprets the list of part
programming instructions, performs the necessary calculations to covert this
into detailed set of machine tool commands, and then controls a tape punched
device to prepare tape for specific NC machine
To check the accuracy of punched tape some methods are used
Sometimes the tape is checked by running it through a computer program
which plots the various tool movements (or table movements) on paper. In this
major errors can be discovered
The Acid Test of the tape involves trying it on the machine tool to make the
part.
A foam or plastic material is sometimes used for this purpose.
Production
This involves ordering the raw workparts, specifying and preparing the tooling
and any special fixturing that may be required.
The Operators function is to load the workpart in the machine and establish
the starting position of the cutting tool relative to the workpiece.
The NC system then takes over and machines the part according to the
instructions on tape.
NC coordinate system
In order to plan positions and movement of cutting tool relative to the workpiece,
a standard system is developed to specify relative positions.
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60
2. Floating zero
Fixed zero
In this the origin is always located at the same position on the machine table.
Usually, that position is the southwest (lower left hand corner) of the table and
all tool locations will be defined by positive x and y coordinates.
Floating zero
In this machine operator can set zero point at any point on the machine table.
The part programmer decides the zero point.
The decision based on the part programming convenience
e.g. in case of symmetric part the zero point can be located at the centre of the
symmetry.
The position of the zero point is communicated to the machine operator.
At the start the operator moves the under manual control to some Target
point on the table.
When the tool has been positioned to the target point, the machine operator
pressed a zero button on the machine tool
Absolute and incremental positioning
Absolute positioning means that the tool locations are always defined in
relation to the zero point.
Incremental positioning means that the next tool location must be defined with
reference to the previous tool location.
Absolute and incremental positioning
NC Systems
There are three types of motion control used in Numerical control
1.
2.
3.
Point
Point to point
Straight cut
Contouring
to point NC
Point to point (PTP) is also called a positioning system.
In PTP, the objective of the machine control unit is to move the cutting tool to
a predefined location
The speed or path by which this movements is accomplished is not important
in point to point NC
Once the tool reaches the desired location , the machining operation is
performed at that position
Example of this system is NC drill press.
Positioning system are the simplest machine tool control systems.
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61
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62
Straight-cut NC
Straight cut control systems are capable of moving the cutting tool parallel to
one of the major axis at a controlled rate suitable for machining
It is appropriate for performing milling operations on work pieces
of rectangular shape.
Angular cut would not be possible.
An NC tool capable of straight cur movements is also capable of point to point
movements
Contouring NC
(Continuous path NC )
Contouring is most complex, the most flexible and most expensive type of
machine tool control.
It is capable of performing both PTP and straight cut operations
In addition, it can control more than one axis movement of the machine tool.
The path of the cutter is continuously controlled to generate desired geometry
of the machine tool.
Turing and milling are common examples
This is achieved by breaking the curved path into very short straight line
segments.
Applications
Milling
Drilling and related processes
Boring
Turning
Grinding
Sawing
Other applications
Press working machine tools
Welding machines
Inspection machines
Automatic drafting
Assembly machines
Tube bending
Flame cutting
Plasma arc cutting
Laser beam processes
Cloth cutting
Automatic riveting
NC machines are suitable for
1. Parts are processed frequently and in small lot sizes
2. The part geometry is complex
3. Many operations must be performed on the part in its processing
4. Much metal needs to be removed
X
On
drawing
5
5
55
100
Y
On tape
005
005
055
1
On
drawing
5
45
25
100
On tape
005
045
025
1
2.
3.
4.
5.
6.
MECHANICAL ENGINEERING
CAD/CAM/CAE
G80 Cancel fixed cycle
G83 Milling cycle; the cycle performs rapid traverse to the programmed position in X
and Y coordinates, lowers the cutter to gauge height and stops the machine
G66 Instructs the machine to initiate milling operation to the end of the cut specified
by the programmed point.
Miscellaneous functions used for Programme
M06 Tool change
M13 Spindle start
M05 Spindle stop
M09 Coolant off
M17 No miscellaneous function required for this block
M02 End of program, machine stop, tape rewind
Program
Program
Word address Format
N001
G00 G71 G90 M06 EOB
N002
X50 Y12 EOB
N003
M0
EOB
N004
0
Y35
EOB
X30
N005
M00
EOB
N006
X12 Y55 EOB
N007
M00 EOB
N008
X120 Y120 EOB
N009
M30
M00 Program stop. Program may be initiated by the operator by pushing a
button
Program
MECHANICAL ENGINEERING
Word address Format
CAD/CAM/CAE
Three holes to be drilled
The depth of hole is 10 mm
Z=00 at the surface of the workpiece
The cutting tool is positioned above the workpiece surface
M
IT (T)
Page 70
Spindle speed and feed is to be given in the program . Speed is 1000 rpm, feed
rate is 200 mm/min
Program
N001 G71
G90 G94 EOB
Metric mode, Absolute system and feed in mm/rev
N002 M03 F200 S1000
EOB
Spindle start CW at 1000 rpm and feed rate 200 mm/rev
N003 G00
X10.00
Y10.00EOB
Move in rapid to point P(10,10)
N004 G00 Z2.00 EOB
Move in rapid to a point to point 2 mm above w/p surface
N005 G01 Z-10.00 EOB
Drill hole
N006 G00 Z 2.00 EOB
Move in rapid to a point to point 2 mm above w/p surface
N007
G00 X50.00
EOB
Move in rapid to x=50
N008
G01 Z-10.00
EOB
Drill hole
N009
G00 Z2.00
EOB
Move in rapid to a point to point 2 mm above w/p surface
N010
G00 Y30.00
EOB
Move to point Y30
N011 G01 Z-10.00
EOB
Drill hole
N012 G00
Z20.00 EOB
Move in rapid to a point to point 20 mm above w/p surface
N013 G00 X00 Y00 EOB
Move in rapid to (X0,Y0)
N014 M02 EOB
Programmed end
Program
Machining at AB and BC
Feed 200 mm/rev and speed 2000 r.p.m.
N003 M03
M08
EOB
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72
In the component , it is assumed that the pocket is through and hence only
outside is to be machined as a finish cut of the pocket
The tool to be used is a 20 mm diameter slot drill .
If an end mill is to be used the program should be modified with a hole to be
drilled at B first before the end mill is used
The setting is done with point A as reference (0,0,0)
N001 G92 X0 Y0 Z0 EOB
Absolute presetting at A
N002 G90 G94 EOB
Absolute programming
Part programming for the part shown in the figure using cutter radius
compensation is given below:
Programmed cutter diameter is 0 mm i.e. programming is done as per the part
drawing
Diameter of the cutter available = 28 mm
The difference in radius (0-28)/2 = -14 mm is stored in the memory for cutter
radius compensation under address D 01.
Program
Word address Format
N001 G71 G94 EOB
N002 G00 X-20.00 Y-20.00 Z20.00 EOB
N003 G01 Z-5.00 EOB
N004 G01 G41 D01 X20.00 Y85.00 F400 S1000 M03 EOB
N005 G01 X60.00 Y115.00 EOB
N006 G02 X75.00 Y100.00 I0.00 J-15.00 EOB
N007 G01 X105.00 EOB
N008 G02 X130.00 Y115.00 I15.00 J0.00 EOB
N009 G01 X120.00 Y85.00 EOB
N010 G01 X130.00 Y55.00 EOB
N011 G01 X110.00 EOB
N012 G01 X80.00 Y20.00 EOB
N013 G01 X35.00 Y55.00 EOB
N014 G01 X20.00 Y85.00 EOB
N015 G00 G40 X0.00 Y0.00 EOB
N016 M02 EOB
Program
Word address Format
Program
N001 G71 G90 G94 EOB
N002 G00 X-20.00 EOB
N003 G00 Z-10.00 EOB
N004 G01 G42 D02 X0 Y0 F200 S1000 M03 EOB
N005 G01 X80.00 EOB
N006 G01 X95.00 Y15.00 I0 J15.00 EOB
N007 G01 Y50.00 EOB
N008 G01 X15.00 EOB
N009 G01 X0 Y35.00 EOB
N010 G01 X0 Y0 EOB
N011 G40 EOB
N012 G00 X-20.00 Z20.00 EOB
N013 M02 EOB
Lathe Operations
In case of CNC lathe operations , only two axes (X-axis and Z-axis ) are
involved
The Z-axis is the axis of the spindle and X-axis is the direction of transverse
motion of the tool post.
To develop CNC part programme for lathe operations the following procedure
is adopted.
1. Move the cutting tool to a point near the job in the rapid mode(G00)
2. Set linear interpolation(G01) and move to the required depth of cut in Xdirection
3. Move along Z-axis to the required length of the job as per drawing
4. Set rapid mode (G00) and retract the tool along X-axis.
5. Move to start point in G00 mode.
For the component shown below perform the following operations
Facing operation
To reduce the diameter from 30 mm to 26 mm
The geometry or shape of the component is split into simple elements like
points, lines , arcs, full circles, distances and directions and these elements are
assigned specific numbers to identify their position.
Advantages
1. Part programming is considerably simplified
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80
SPINDL/ON
SPINDL/OFF
TURRET
CYCLE/ is used to execute a particular cycle e.g. drilling, tapping cycle
Page
80
GOTO/P4
CYCLE/DRILL,FEDTO,-15
GODLTA/0,0,20
GOTO/P5
Page
82
CYCLE/DRILL,FEDTO,-15
GODLTA/0,0,20
COOLNT/OFF
SPINDL/OFF
RAPID
GOTO/SETPT
REWIND
FINI
APT MOTION STATEMENTS FOR CONTINUOUS PATH PROGRAMMING
In this the cutter is guided in its path by three planes:
1. Part surface (PS or PSURF): The plane which guides the bottom surface of the
tool is known as the part surface
2. Drive surface (DS or DSURF): The plane guiding the side of the cutting tool.
i.e. the plane along which tool side moves is known as drive surface
3. Check surface (CS or CSURF) :The plane used to stop the cutter or change its
direction is known as check surface.
APT Example
Write a Programme for the following component it is required to write the
Programme for finishing cut
Cutter geometry
APT Example
PARTNO/SAMPLEJOB 1
MACHIN/MILLING 1
CLPRINT
P0 = POINT/0,-20, 0
P1 = POINT/0, 0, 0
P2= POINT/150.0, 0, 0
P3= POINT/150.0, 0, 0
P4 = POINT/ 100.0, 50.0, 0
P5 = POINT/ 100.0, 100.0, 0
P6 = POINT/50, 100.0, 0
P7 = POINT/50.0, 50.0, 0
P8 = POINT/0, 50.0, 0
L1 = LINE/ P1,P2
L2 = LINE/ P2,P3
L3 = LINE/ P3,P4
L4 = LINE/ P4,P5
L5 = LINE/ P5,P6
L6 = LINE/ P6,P7
L7 = LINE/ P7,P8
L8
=
LINE/
P8,P1
PL1= PLANE/P1,P2,P8
CUTTER/10.0
SPINDL/500
FEDRAT/80
COOLNT/ON
FROM/P0
GO/TO, L1,TO, PL1, TO, L8
GORGT/L1,PAST,L2
GOUP/L2,PAST,L3
GOLFT/L3,TO,L4
GOUP/L4,PAST,L5
GOLFT/L5,PAST,L6
GODOWN/L6,TO,L7
GOLFT/L7,PAST,L8
GODWON/L8,PAST,L1
RAPID
GOTO/P0
COOLNT/OFF
FINI
APT Example
PARTNO
MACHIN/ABM,8
UNITS/MM
CLPRINT
SETPT =POINT/0,0,0
P1 = POINT/50,25,0
P2 = POINT/150,25,0
P3 = POINT/150, 40, 0
P4 = POINT/130,50,0
P5 = POINT/50,100,0
L1 = LINE/P1, P2
L2 = LINE/P2, P3
L3 = LINE/P3, P4
C1=CIRCLE/80,100,30
L5 = LINE/P1, LEFT, TANTO.C1
L4 = LINE/P4,RIGHT, TANTO, C1
PL1 = PLANE/P1,P2,P5
CUTTER/10
FEDRAT/0.1, MMPR
REMARK/SET, SPINDL,1000,RPM
INTOL/0.01
OUTTOL/0.01
FROM/SETPT
GO/TO, L1,PL1,TO,L5
SPINDL/ON
COOLNT/ON
GORGT/L1,PAST,L2
GOLFT/L2,PAST,L3
GOLFT/L3,TO,L4
GORGT/L4,TANTO,C1
GOFWD/C1, TANTO,L5
GOFWD/L5,PAST,L1
SPINDL/OFF
COOLNT/OFF
RAPID
GOTO/SETPT
FINI
APT Example
Speed = 700 rpm
Feed = 80 mm/rev
Cutter = 10 mm dia Endmill
APT Example
Post processor ID=MACHIN/NC,1
Feed rate = 100mm/min
Cutter geometry
Function of CNC
The only hardwired elements are those required to interface the computer with
the machine tool and the operators console
Interpolation, tool position feedback, and all other functions are performed by
computer software.
The advantage of this configuration is the additional flexibility.
It is possible to make alternations in the interpolation program whereas the
logic contained in the hard-wired circuits of hybrid CNC cannot be altered.
2. In-Process Compensation
a. This involves dynamic correction of the tool motions for changes
or errors which occur during processing. E.g.
b. Adjustments for errors sensed by in-process inspection probes and
gauges.
c. Recomputation of axis positions when the inspection probe is used to
locate the datum reference on a work part.
d. Offset adjustments for tool radius and length
e. Computations of predicted tool life and selection of alternative tooling
when indicated.
4. Diagnostics
The computer calls the part program instructions from bulk storage and
sends them to the individual machines as the need arises.
It also receives data back from the machines
This two way information flow occurs in real time, which means that
each machines request for instructions must satisfied instantaneously.
Depending upon no. of machines and computational requirements that
are imposed on the computer, it is sometimes necessary to use of
satellites computers.
Each satellite computer controls several machines
Groups of part program instructions are received from the central
computer and stored in buffers.
Feedback data from the machines are also stored in the satel ites
buffer before being collected at the central computer
Two types of DNC
1. Behind The Tape Reader (BTR) System
In this the computer is directly linked to the regular NC controller unit.
In this arrangement the tape reader is replaced by telecommunication lines to
the DNC Computer.
Except for the source of command instructions , the operation of the system is
similar to conventional NC.
The controller unit uses two temporary storage buffers to receive blocks of
instructions from the DNC computer and convert them into machine actions
While one buffer is receiving a block of a data , the other is providing control
instructions to the machine tool.
2. Special Machine Control Unit
In this NC controller is replaced by a special MCU and forms a link between
computer and machine tool.
The special MCU achieves a superior balance between accuracy of machining
and faster material removal rate.
This unit is soft wired so more flexibility can be achieved and alterations can
be made easily.
It is much difficult to make changes in the regular NC controller because
rewiring is required.
Functions of DNC
1. NC without punched tape
One of the original objectives in DNC was to eliminate the use of punched
tape.
Relatively unreliable tape reader
The fragile nature of paper tape
Page
90
2.
Page
91
LLM
L
Drillin
Millin
Lath
M
L
Grindin
Receiving and
Shipping
GG
Assembl
A
A
A
A
Advantage get in the form of reduced workpiece handling, lower setup times,
less in-process inventory, less floor space, and shorter lead times.
Figure 2 GT LAYOUT
Grouping part into part families
Visual inspection
Production flow analysis
Parts classification and coding system.
Visual inspection
It is simplest and cheapest method
It involves classification of parts into families by looking at either the physical
parts or photographs and arranging them into similar grouping.
This method is considered to be least accurate of three.
Production flow analysis
It is a method of identifying part families and associated machine tool
grouping by analyzing the route sheets for parts produced in a given shop.
It groups together the parts that have similar operation sequences and machine
routings.
The major drawback of this system is that it does not consider the actual flow
of material
Parts classification and coding
It involves an examination of the individual design and/or mfg attributes of
actual part.
The attributes of the part are uniquely identified by means of a code no.
This classification and coding may be carried out on the entire list of active
parts in the firm or a sampling process may be used to establish the part
families.
of
three
Major dimensions
Minor dimensions
Tolerances
Surface finish
Operation sequence
Production time
Batch size
Annual production
Fixtures needed
Cutting fluids
3. CODE system
OPTIZ SYSTEM
MICLASS System
(Metal Institute Classification System)
The MICLASS system was developed to help automate and standardize a
number of design, production and management functions. These includes
:
Standardization of engineering drawings
Retrieval of drawing according to classification number.
Standardization of process routings
Automated process planning
Benefits
Product design benefits: 10 % reduction in no. of drawings can be expected
through standardization with GT
Tooling and setup: GT tends to promote standardization of several areas of
mfg.
Material handling: GT machine layout lend themselves to efficient flow of
materials through shop.
Production and inventory control
Employee satisfaction
Process planning procedures.
Benefits of CAPP
Process rationalization
Increased productivity of process planners.
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100
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100
Improved legibility.
Incorporation of other application programs.
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101