22563 22563

2.
[2]

Attempt any THREE of the following:

Marks
12
23124 a) Explain working principle of Abrasive Jet Machine (AJM) with
3 Hours / 70 Marks Seat No. neat sketch.

b) Compare between up milling and down milling process.

(four points)
Instructions – (1) All Questions are Compulsory.
(2) Answer each next main Question on a new page. c) Describe the concept of cutter radius compensation for CNC
machine with suitable example.
(3) Illustrate your answers with neat sketches wherever
necessary. d) Justify need of tool length compensation of CNC machine.
(4) Figures to the right indicate full marks.
3. Attempt any THREE of the following: 12
(5) Assume suitable data, if necessary.
(6) Use of Non-programmable Electronic Pocket a) Classify the different method of gear manufacturing.
Calculator is permissible. b) Explain absolute and incremental co-ordinate system in CNC
(7) Mobile Phone, Pager and any other Electronic machines with suitable example.
Communication devices are not permissible in
c) Explain the term preparatory function and miscellaneous function
Examination Hall.
in the context of CNC Part programming.
Marks d) Describe fixed and programmable automation.

1. Attempt any FIVE of the following: 10

a) State any four needs of non-conventional machining processes.
b) Enlist different milling operations (Any four).
c) List various gear finishing method (Any four).
d) State two advantages of CNC machines over conventional
machines.
e) Write meaning of following G and M-codes.
i) G 03
ii) M 08
f) State the meaning of subroutine and canned cycle in CNC part
programming.
g) Define robotics. State two application of robot.

P.T.O.
22563 [3] 22563 [4]
Marks Marks
4. Attempt any THREE of the following: 12 5. Attempt any TWO of the following: 12
a) Differentiate between gear hobbing process and gear shaping a) Draw set up diagram of EDM process showing all the elements.
process (four points). State function of dielectric fluid with example.
b) Explain work holding devices used in CNC lathes. b) Draw internal mechanism of universal dividing head and lable
c) Prepare process sheet and calculate cutting parameters for turning the parts.
on CNC lathe for the component shown in Figure No. 1. Neglect c) Illustrate axes nomenclature of CNC lathe and milling with
tool compensation. Assume suitable data if necessary. sign conventions.
Given – Raw material stock : φ35 × 50 mm
6. Attempt any TWO of the following: 12
Stock : Aluminium
a) Draw the setup diagram of Laser Beam Machining (LBM).
Feed (f) : 0.2 mm/rev. Explain the function of elements in setup.
Cutting velocity (ν) = 90 m/min. b) Apply compounding indexing method for indexing 69 divisions.
c) Justify the need of gear finishing. Demonstrate any one gear
finishing process with important process parameters.

Fig. No. 1
d) Develop full G and M - code manual part program of CNC
lathe for component given in Figure No. 1 in Word Address
Formate (WAF).
e) Justify the need of group technology in today’s manufacturing
system.

P.T.O.
 22563 22563

2.
[2]

Attempt any THREE of the following:

Marks
12
a) Describe the basic mechanism of material removal in AJM
22223 with neat sketch.
3 Hours / 70 Marks Seat No. b) Explain the construction of planomiller with neat sketch.
c) Explain linear and circular interpolations used in turning with
Instructions – (1) All Questions are Compulsory.
suitable examples.
(2) Illustrate your answers with neat sketches wherever
d) Explain the term cutter tool compensation and state it's
necessary.
importance in CNC machine part programming.
(3) Figures to the right indicate full marks.
(4) Assume suitable data, if necessary. 3. Attempt any THREE of the following: 12

(5) Mobile Phone, Pager and any other Electronic a) Explain the principle of operation of gear hobbing process
with neat sketch.
Communication devices are not permissible in
Examination Hall. b) Describe with sketch the working and construction of
recirculating ball screw used in CNC machine.
(6) Preferably, write the answers in sequential order.
c) Describe the various formats used for manual part
Marks programming and write word address format.
d) State the objectives of cellular manufacturing? List the different
1. Attempt any FIVE of the following: 10 types of machine cell design.
a) List down the various mechanical energy based unconventional
machining processes. 4. Attempt any THREE of the following: 12
b) Define angle milling cutter. a) Differentiate between gear hobbing process and gear shaping
process.
c) List the gear generating processes.
b) List the requirements to operate the automatic tool changer (ATC).
d) Enlist the main functions of CNC.
c) Construct a part programme for the following component
e) State the function of G01 and M12 codes in CNC Programming.
using do-loops shown in Fig. No. 1 (All dimensions are in mm)
f) Explain the term canned cycle.
g) Enlist the benefits of automation

Fig. No. 1
P.T.O.
22563 [3]

d) Develop a CNC program using appropriate G and M code

Marks 22563
to turn component as shown in Fig. No. 2.
21222
3 Hours / 70 Marks Seat No.
15 minutes extra for each hour

Instructions – (1) All Questions are Compulsory.

(2) Illustrate your answers with neat sketches wherever
necessary.
(3) Figures to the right indicate full marks.
(4) Assume suitable data, if necessary.
(5) Preferably, write the answers in sequential order.
(6) Mobile Phone, Pager and any other Electronic
Fig. No. 2 Communication devices are not permissible in
Examination Hall.
Raw material : MSφ57 × 70 mm, cutting speed V = 40 m/min
and Feed = 0.1 mm/rev. Assume suitable data for depth of cut.
Marks
e) Define the term FMS? Explain basic components of FMS.

5. Attempt any TWO of the following: 12 1. Attempt any FIVE of the following : 10
a) Explain the working principle of PAM with neat sketch and a) Enlist the different types of non-conventional machining
list the applications of PAM. processes.
b) Explain the cutting parameters in milling machine. How is the
b) Name the various types of cutters used in milling operations.
machining time calculated on a milling machines.
c) Explain : Open loop control and closed loop control in CNC c) Enlist the different types of gear manufacturing methods.
with suitable example. d) State the advantages of CNC machines over conventional
machines.
6. Attempt any TWO of the following: 12
e) State the meaning of subroutine and canned cycles in CNC
a) Describe the working principle of EDM with neat sketch and part programming.
list the applications of EDM.
f) State the function of Automatic tool changer (ATC) in CNC
b) With suitable example, explain the steps for compound indexing.
machines.
c) Explain with neat sketch pinion cutter gear shaping process.
g) Define Robotics. State the components of Robotics
manipulator.

P.T.O.
22563 [2] 22563 [3]
Marks Marks
2. Attempt any THREE of the following : 12 c) Develop a part program for turning on CNC lathe for the
component shown in Fig. 1 using ISO format. Use the tool
a) Explain working principle of Electro Discharge Machining
path co-ordinates shown in Fig. 1. Neglect tool compensation.
(EDM) with sketch.
Assume suitable data if necessary. Speed of spindle 1000 rpm
b) Explain Face milling and side milling operations with neat and feed 100 mm/min.
sketch.
c) Explain the concept of tool presetting in CNC tooling.
d) Explain the use of following codes in CNC part programme.
(i) G00
(ii) G03
(iii) M03
(iv) M30

3. Attempt any THREE of the following : 12 Fig. No. 1

a) Explain the working principle of gear hobbing with suitable d) Develop a part program for CNC milling for the part shown
sketch. in Fig. 2 using ISO format. Take spindle speed 800 rpm,
feed 80 mm/min. Depth of slot 5 mm. Assume suitable data
b) Explain absolute and incremental co-ordinate system in CNC
if necessary. Neglect cutter compensation.
machines with simple suitable example.
c) Explain the Do loops programming format with simple
example.
d) Compare hard automation and soft automation stating one
application of each.

4. Attempt any THREE of the following : 12

a) Classify gear finishing methods stating one application of
each.
b) Explain Re-circulating ball screw arrangement in CNC
machines with neat sketch.
Fig. No. 2
e) Select a engineering product manufactured by applying group
technology principles. Write its part classification and coding.

P.T.O.
22563

5.
[4]

Attempt any TWO of the following :

Marks
12
22563
a) Draw Abrasive Jet Machining (AJM) setup diagram showing 11920
all the elements. State the function of each elements.
3 Hours / 70 Marks Seat No.
b) Find cutting speed for milling operation to machine two
parallel vertical surfaces of a workpiece simultaneously by
using pair of side milling cutters, when cutter rpm is 600 rpm Instructions – (1) All Questions are Compulsory.
and diameter of cutter is 200 mm. (2) Answer each next main Question on a new page.
Draw the cutter and work arrangement diagram for above
(3) Illustrate your answers with neat sketches wherever
operation.
necessary.
c) Sketch the Axes nomenclature for CNC lathe and CNC
milling. Show major axes with sign conventions. (4) Figures to the right indicate full marks.
(5) Assume suitable data, if necessary.
6. Attempt any TWO of the following : 12 (6) Use of Non-programmable Electronic Pocket
a) Draw the setup diagram of ultrasonic machining (USM). Calculator is permissible.
Explain the function of elements in setup. State the process
parameters in it. Marks
b) Compare simple indexing and compound indexing methods
with suitable example.
1. Attempt any FIVE of the following: 10
c) Draw the setup of Gear shaping by pinion cutter or rotary
gear cutter and explain its working. a) Enlist any four process parameters in EDM.
b) State the equation of cutting speed for milling operation.
c) List the various gear finishing methods.
d) Name the basic components of an CNC machine.
e) Write only classification of CNC machine.
f) Write meaning of following G and M-codes.
(i) G02
(ii) M30
g) State any two examples of fixed automation.

P.T.O.
22563 [2] 22563 [3]
Marks Marks
2. Attempt any THREE of the following: 12 d) Develop full G and M code manual part program of CNC
a) Explain the purpose of electrolyte in ECM. lathe for component shown in Fig. No.1. using word address
format (WAF).
b) Compare between vertical and horizontal milling machine.
e) Justify the need of Group Technology in today’s manufacturing
c) Describe automatic tool changer (ATC) of CNC machine. situation.
d) Justify need of tool length compensation of CNC machine.
5. Attempt any TWO of the following: 12
3. Attempt any THREE of the following: 12 a) Draw set-up diagram of ECM processes showing all the
a) Differentiate between gear hobbing and gear honing. elements. State the function of each elements.
b) Compare “Point to Point” and continuous path CNC machine. b) Draw internal mechanism of universal dividing head and
label the parts.
c) Explain the meaning of following block format of CNC.
c) Explain need of virtual CNC machine simulators.
N020 G03 X12 Y14 Z-0.5 I0 J12 F90 E0B
d) Describe fixed and programmable automation. 6. Attempt any TWO of the following: 12
a) Draw set-up diagram of wire cut EDM and label the
4. Attempt any THREE of the following: 12
parts, also suggest approximate range of following process
a) Classify the different methods of gear manufacturing. parameters with it’s measuring unit.
b) Apply right hand rule of axes identification to CNC vertical (i) Discharge current OR Pulse frequency.
milling with neat diagram.
(ii) Wire speed OR Wire tension.
c) Calculate the cutting parameters and prepare process sheet for
b) Apply compound indexing method to divide 51 divisions on
the component shown in Fig. No.1. with neat diagram. All
circular blank.
dimensions are in mm.
c) Use the different milling cutter to cut ‘T’ slot on rectangular
Given: Raw material - Aluminium, stock size φ14 X42
block with neat diagram, also mention the sequence of
length, feed (f) = 0.2 mm/rev, cutting speed (V) = 90 m/min.
operations and types of milling cutter used.
Consider work zero (W) as per the Fig. No.1.

Q. No. 4c & 4d Fig. No. 1

 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
WINTER – 2022 EXAMINATION b Types of Milling Machines: 1/2 mark
Model Answer each any
Knee and Column type four
Subject Name: Advanced Manufacturing Process Subject Code: 22563
a. Horizontal.
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. b. Vertical
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. c. Universal
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
d. Turret Type
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures Production Type
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 a. Simplex
there may be some difference in the candidate’s 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 b. Duplex
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept. c. Triplex
8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual (English +
Marathi) medium is introduced at first year of AICTE diploma Programme from academic year 2021-2022. Hence if Special Type
the students in first year (first and second semesters) write answers in Marathi or bilingual language (English
a. Rotary table
+Marathi), the Examiner shall consider the same and assess the answer based on matching of concepts with
model answer. b. Drum type
Q. Sub Answer Marking c. Copy milling
No. Q. N. Scheme
d. Planetary milling machine.
1 a Advantages of Electro- Discharge Machining process 01 mark
each any Planner Type milling
1) Process can be applied to all electrically conductive metals and alloys. two
c Gear Manufacturing Methods: 01 mark
2) Any complicated shape that can be made on the tool can be reproduces on the each any
workpiece. Casting two
3) Can be employed to extremely hardened material. Forging
4) No mechanical stress is present in the process. Extrusion and cold-drawing
5) Hard and corrosion resistant surfaces essentially needed for die making can be Powder metallurgy
developed.
Blanking
6) The process leaves a non-directional surface finish. The surface consists of tiny craters
with no definite pattern or lay. (craters accommodate lubricants causing the die life to Gear Machining
improve)
- Hobbing

- Shaping

- Milling

- Broaching

1 2
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
d Functions of CNC machine components: 01 mark g Automation generally is defined as the process of enabling machines to follow a 01 mark
each any predetermined sequence of operations with little or no human intervention and using for
1) Machine Control Panel – A machine Control Panel is a flat area where controlling, two specialized equipment and devices that perform and control manufacturing processes and definitio
monitoring, or managing instruments are displayed, serving as the direct interface between operations. n, 01
the operator and the NC system. Example: mark for
In hard automation, or fixed-position automation, the machines are designed to produce example
2) Programmable Logic Controller (PLC) – A PLC is an industrial solid-state computer that
a standard product, such as a gear, a shaft, or an engine block.
matches the NC to the machine, which follows a pre-programmed sets of rules and carry
1) Automotive engines 2) Mechanized assembly 3) Machining transfer lines 4) Automated
out outputs based on inputs to control system and make logic-based decisions for the CNC
material handling.
machine. It is used to minimize manual operation and can survive harsh conditions such as
extreme heat, cold, dust, and moisture. 2 Attempt any THREE of the following
3) Servo Control Unit – The servo control unit is responsible for precise position control as it
receives the position feedback signals for the actual movement of the machine tool axes a Working of Abrasive Jet Machining: 02 marks
from the feedback devices. It generates suitable signals as command values, which are sketch,
interfaced with the axes and the spindle motors. 02 marks
4) Feedback Devices – The feedback devices, which is also referred to as the measuring explanati
system, consist of position and speed transducers that act as sensors to monitor the current on
position of the cutting tool at any instant.
5) Display Unit – The display unit is a monitor or an interactive device between the machine
and the operator which displays the present status of the programs, commands, and other
necessary data of the CNC machine. It can also be useful for maintenance and installation
work because it can display other important information such as machine parameters, logic
diagram of the program controller, error messages, and diagnostic data.
6) Machine Tool- Machine tool element of an CNC system is the equipment that processes
the work piece
In abrasive-jet machining (AJM), a high-velocity jet of dry air, nitrogen, or carbon dioxide
7) Program of instruction- the part program is called as program of instruction. It is the
containing abrasive particles is aimed at the workpiece surface under controlled conditions.
detail step by step set of instruction which tells the machine tool what to do.
The impact of the particles develops a sufficiently concentrated force to perform operations
The gas-supply pressure is on the order of 850 kPa, and the abrasive-jet velocity can be as
high as 300 m/s and is controlled by a valve. The nozzles are usually made of tungsten
e Meaning of CNC code M03 & M06 01 mark carbide or sapphire, both of which have abrasive Wear resistance. The abrasive size is in the
each range from 10 to 50 um.
M03:- Starts the spindle CLOCKWISE.

M06: Tool change command

f Home Position: 01 mark

each
Machine homing gives a reference position of each axis, this position is used to allow for job
fixtures, jigs, and automatic tool changer. Each CNC machine has a built-in location that is
called machine zero.
All three axes are moved to extreme positive locations until limit switches are reached.

Once the sensor is tripped, the control software sets a zero position for that axis.
Programme Zero :
Each part program sets a starting location called program zero. Unlike machine zero, the
programmer selects the program zero for each work piece. This location acts as the origin
from which all the other dimensions are calculated during the program and it is usually
located on the edge of a work piece.
3 4
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
b Column and Knee Type of Milling Machine 02 marks d CNC machine simulation provides following features: 04 marks
for 1. View and proof cut paths from any angle for
sketch 2. Set machine travel limits and detect over travels correct
(any 1 3. Check for part errors – including machine, tool, and tool holder collisions answer
type of 4. Utilize you machine’s kinematics to visually see your machine tool in action
machine) 5. See exactly how the part will look cut on your machine at any point during the machining
02 marks process in a virtual environment
for 6. Set up an unlimited amount of virtual machines that match the machines in your shop
functions 7. Assign transparency levels of the simulated machines for enhanced part viewing ability
(1/2 8. Accurately calculate cycle times
mark 9. Use dynamic viewing functionality for better inspections
each any 10. Identify machine-part deviations to know where tools were unable to machine within the
4 parts) associated operations.

3 Attempt any THREE of the following

a Gear Hobbing process 02 marks

Column and base: Column including base is the main casting that supports all other parts of for
milling machine.  Hobbing is a process of generating a gear by means of cutter called Hob, which revolves sketch,
& cuts like milling cutter. 02 marks
Knee: It consists of a table feed mechanism and various controls. A knee is used to support  There are three types of gear hobbing according to the direction of feeding the hob as, for
saddles, work tables, and workpiece clamping devices. Axial hobbing explanati
Radial hobbing on
Saddle: The top of the saddle is machined in precision to provide guideways for the table. Tangential hobbing

Radial hobbing
Work Table: A work table is the most important part of a milling machine on which the
workpiece or a job holds tightly and performs many operations.

Spindle: The spindle is located at the top of the column and rotates through receives power
from belts, gears, and clutches and transmits it to the arbor.

Overarm: It is mounted at the top of the column and rises in front of the column face.
It is commonly used to support arbor and spindle.

Arbor: It is the extension parts of spindles on which milling cutters are held or rotated.  In radial hobbing the feed is given to the hob such that it moves radially towards the
centre of blank.
c Cutter radius Compensation : 02 marks  Radial feeding is suitable for cutting worm wheels having a helix angle of less than 6 or
Cutter compensation is used to offset the center of the cutter, and shift it the distance of for 7 degrees.
the radius, to the specified side of the programmed path. explanati
 Radial feed stops when the hob reaches the full depth of cut.
Complex part geometries having angled lines, lines tangent to arcs, and lines intersecting on, 02
 Radial hobbing may affect the accuracy of tooth profile of final cut gear.
arcs involve substantial trigonometric computations to determine the center of the cutter. marks
Cutter compensation involves programming the part geometry directly instead of the tool for
center. The cutter compensation commands are Cutter Comp. Left (G41), Cutter example
Comp Right (G42) and Cutter Comp Cancel (G40).

5 6
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
b Compare CNC & DNC machines 01 mark 4 Attempt any THREE of the following
each any
four a Gear Hobbing Gear Shaping 01 mark
CNC DNC It use as multipoint cutter Know as Hob. It uses a rack cutter or pinion each any
CNC is transferring machine instruction. DNC controls the information distribution
points
cutter. four
to a wide variety of machines Generates teeth on gear by means of Reciprocating motion of the cutter
In the CNC program feeds directly into the DNC part program is feed to the machine points
Rotating cutter called as Hob. based on
computer by a small keyboard similar to our through the main computer. Shaping process.
traditional keyboard
It cannot generate internal gear It can be used to produce internal
Using CNC PC manipulates one NC machine Using the DNC programmer can manage
more than one NC laptop as required
gears also
CNC has low processing power when compared DNC has high processing energy when The tooth profile error level is higher. The tooth profile error level is
to DNC compared to CNC. lower.
It has memory storage ability in which part Same part program can be run on different Gear hobbing process is less precise than gear Gear shaping process
program can be store machines at the same time shaping process. is more precise than
System can import CAD files and convert it to The data can be processed using the MIS gear hobbing process.
part program software so as to effectively carry out the It provides less accuracy in surface finish than It provides more accuracy in
production planning and scheduling
gear shaping. surface finish than gear hobbing.
CNC machine maintenance is high Maintenance is low in DNC machines.
The transmission chain used in mechanical The transmission chain used in
c Preparatory function of CNC 02 marks gear hobbing is less complex. mechanical gear shaping is more
each complex.
 It is representing by 2 digit number prefixed by the letter G. It is rapid, economical and highly It required more time than hobbing.
 The purpose of preparatory function is to command the machine tool to perform the Productive.
function represented by the selected code number. b Working & Importance of Re-circulating ball screw used in CNC 02 marks
 ISO has standardized a number of these preparatory function. machine for
 Ex.G90 specifies absolute input dimension. working,
 It is the mechanical component increasingly used in movement transmission, used to
02 marks
transform a rotary motion into translation motion in CNC machines.
Miscellaneous function of CNC for
 It is precise & provides superior performances in CNC machine.
importan
 This function involves actions that are necessary for machining.  Between the threaded shaft & nut screw are inserted steel balls which have task to ce
 These are used to designate a particular mode of operation for a CNC machine tool. transform the sliding friction into rolling friction.
 They are not related to actual machining but execute auxiliary functions like start/stop Importance
of spindle, ON/OFF coolant, etc.  It provides high efficiency & durability to CNC machine.
 A miscellaneous function of CNC is represented by letter M.  It improves wear resistance.
 It reduces friction between parts in contact.
 It reduces backlash.
d Pneumatic actuators are widely used in Robotics 04 marks  X-Y recorders of CNC machine.
As pneumatic actuators fulfil all necessary requirements of Robotics like- for  It used in power actuators.
 It converts energy formed by compressed air at high pressure into either linear or correct
rotary motion. explanati
 It gives quickly respond in operation which is necessary in Robotics. on
 Pneumatic cylinders provide more force & speed per unit size than any other actuator.
 Force speed of pneumatic actuator is easily adjustable & is independent of each other.
 It is most economical when the scale of deployment matches the capacity of the
compressor.
 Cost of pneumatic actuator is less as compared to other actuators.

7 8
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
c 04 marks d
Tool Position Co – ordinate
X Z
P0 0 5
P1 0 0
P2 40 0
P3 40 -30
P4 60 -80
P5 60 -120

P6 70 -120

Tool path A- P0- P1-P2-P3-P4-P5-P6-A

O0001 Program Number

N100 G28 U0 W0 ; Machine Referance position
N110 G90 G21 G95 ; Absolute mode , input in mm , Feed mm/rev.
04 marks
N120 M06 T01 ; Select Tool T01
N130 M03 S1500 ; Spindle on, Spindle speed
N140 M08 ; Coolant on
N150 G00 X0 Z5 ; Rapid positining tool @ position P0
N 160 G01 X 0 Z0 F0.2; Linear interpolation ,feed ,tool @ postion P1
N 170 G01 X 40 Z0 F0.2; Linear interpolation ,feed ,tool @ postion P2
N 180 G01 X 40 Z-30 F0.2; Linear interpolation ,feed ,tool @ postion P3

N 190 G01 X 60 Z -80 F 0.2 ; Linear interpolation ,feed ,tool @ postion P4 ( Taper
turning operation)
N 200 G01 X 60 Z-120 F0.2; Linear interpolation ,feed ,tool @ postion P5

N 210 G00 X70 Z -120 ; Rapid positining tool @ position P6

N 220 G28 U0 W0 ; Machine Referance position

N 230 M05 ; Spindle Off
N 240 M09 Coolant Off
N 250 M30 Program end and tape revind

9 10
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous) (Autonomous)
(ISO/IEC - 27001 - 2013 Certified) (ISO/IEC - 27001 - 2013 Certified)
__________________________________________________________________________________________________ __________________________________________________________________________________________________
e Cellular manufacturing 04 marks 5 Attempt any TWO of the following
for
It is one of the main tools of Lean Manufacturing, helps to create a concept known as single or one- explanati a Ultrasonic Machining:- 03 marks
piece flow. on for
sketch,
Equipment and the workstations are arranged in sequences to allow for a smooth flow of materials 03 marks
and components through the process. for
functions
The cell is made up of workers and the equipment required performing the steps in creating the (any
product. The layout of the equipment and the workstations is determined by the logical sequence of three 01
production. marks
each)
By grouping similar products into families that can then be processed on the same equipment in the
same sequence, cellular manufacturing offers companies the flexibility to give customers the variety
they require.

Factories converted to cellular manufacturing benefit by the reduction of overproduction and waste,
shorter lead time, improved quality and productivity, improved teamwork and communication.

The main requirement of Cellular Manufacturing is to ensure that all equipment required for
production is operating at 100% efficiency at all times.

Through short daily inspections, cleaning, lubricating, and making minor adjustments, minor
problems can be detected and corrected before they become a major problem that can shut down a
production line.

The basic concept of cellular manufacturing is the integration of management practices with
technological advances. To be truly successful requires a thorough understanding of the causes and
elimination of waste at all levels, and that means both operations and processes. High power sine wave generator This unit converts low frequency (60 Hz) electrical power to high
frequency (20kHz) electrical power.
There are several important considerations involved in order to achieve the best benefits:
Transducer The high frequency electrical signal is transmitted to traducer which converts it into high
 Reduction of lead time frequency low amplitude vibration. Transducer converts electrical energy to mechanical vibration.
 Utilization of available space
 Maximizing flexibility Tool holder. OR Horn. The tool holder holds and connects the tool to the transducer
 Emphasizing teamwork
Tool Tools are made of relatively ductile materials like Brass, Stainless steel or Mild steel so that
 Improving communications
Tool wear rate (TWR) can be minimized.
 Productivity and quality improvement

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b c Axes Nomenclature in CNC machine 03 marks
CNC Milling Center:- each (01
In CNC milling center (CNC vertical machining center) , the workpiece is held on the table base and mark for
the spindle which contains the cutting tool is fixed on vertical spindle Z axis. The table moves in X sketch,
and Y axis and spindle with cutting tool moves in Z axis. 02 marks
for axis)

CNC Turning Center:-

X- in horizontal direction
Z – perpendicular to both axis
Z axis defines the tool movement
i.e tool movement towards work piece Z negative (Z –ve)
and away from the workpiece Z positive (Z + ve)

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6 Attempt any TWO of the following c Need for Gear Finishing: 02 marks
for need,
a 02 marks - To improve the accuracy
02 marks
for for
- The achieve uniformity of gear tooth element
sketch, sketch
04 marks - To achieve quite operation at high speeds and to transmit heavy loads with better life. (any
for one), 02
paramet - To remove heat treatment distortions
marks
er ranges Gear Grinding Gear Shaving for
(01 mark process
each) paramet
Discharge Current Range: The capacitor discharge is repeated at rates between 200 and 500 kHz,
with and currents from 0.1 to 500 A. ers (any
Voltage Range: voltages usually ranging between 50 and 380 V. two)
Type of Dielectric: The most common dielectric fluids are mineral oils, although kerosene and
distilled and deionized water also are used in specialized applications.

Type of Electrode material: Electrodes for EDM usually are made of graphite, although brass, copper, or
copper-tungsten alloys, Tungsten-wire electrodes also are used.

Gear Burnishing

Process parameters:-

1) Workpiece material
2) Type of gear
3) Whether the gears have been hardened by heat treatment or not.
4) Dimensional accuracy required.
5) Surface quality of the gears.

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22563

Q. Sub Answer Marking

No. Q. N. Scheme

e) Write only classification of CNC machines. Classificatio

n on any one
Ans: Classification of CNC machines basis = 2
1. As per feedback system : a) Open loop Type b) Closed loop type marks

2. As per motion control : a) Point to point path motion b) Continuous path motion

3. As per application: a) CNC milling b) CNC Turning c) CNC drilling

f) Write meaning of following G and M codes 1 meaning=

Ans: 1. G02 : Circular interpolation clockwise 1 mark

2. M30: Program end , reset to start

g) State any two examples of fixed automation Two

examples=2
Ans: Examples of fixed automation are mark

a. Transfer lines used in automotive industry

b. Automatic assembly machines or systems installed for assembly without need of

human being

c. Industrial robots installed or fixed for performing repetitive operations

Q.2 Attempt any THREE of the following 12

a) Explain the purpose of electrolyte in ECM. 4 points= 4

marks
Ans: Purpose of electrolyte in ECM process

1. It is conductive medium without which ECM process cannot be performed.

2. It carries the current between the tool and the work piece.

3. It removes the particles of ECM process from the cutting region

It helps to remove heat produced by the current flow in the operation

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b) Compare between Vertical and horizontal milling machine

Ans Parameter Vertical milling Horizontal milling

1. Position of arbor It is mounted vertically It is mounted horizontally

2. Spindle and worktable Spindle is vertical and Spindle is horizontal and

perpendicular to the work parallel to the work table
table
4 points= 4
3.Cutter movement It can be moved up and It can be moved up and
marks
down. down.

4.spindle tilting It can be tilted for angular It cannot be tilted

milling operations

5.Opertions Angular milling, slot Plain milling, gear cutting,

milling, T- slot milling, flat form milling, gang milling,
milling, etc etc

C) Describe Automatic tool changer (ATC) of CNC machine

Ans:
Concept of Automatic tool changer (ATC):
1. Tool changing in CNC machines is carried out automatically by using Automatic
tool changer according to the sequence of operations given in the part program
2. Tool magazine is provided with various tools mounted sequentially and identified
by specific tool number which helps for tool changing using ATC concept -2
Marks

Function : 2
marks

Fig. Automatic tool changer

Function of automatic tool changer:
1. It will improve the production rate and tool carrying capacity of the machine.
2. It will help to save time required for changing tools as per number of operations
to be performed on the work piece.
3. It will automatically unload the tool from the spindle of machine and load the
new cutting tool from tool magazine using tool changing arm.
4. The arm of ATC can be rotated through 180 degree to unload the tool from
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12 Higher load on cutter(Hob) Lower load on Cutter (Honing Tool) EOB – End of Block.
13 Higher feed rate. Lower feed rate.
d) Describe fixed and programmable automation0
Fixed Automation (Hard automation): Fixed automation refers to the use of special purpose
Ans equipment to automate a fixed sequence of processing or assembly operations. Each of the
14 operation in the sequence is usually simple, involving perhaps a plain linear or rotational motion 02 Marks
or an uncomplicated combination of two. It is relatively difficult to accommodate changes in the
product design.
b) Compare “Point to Point” and continuous path CNC machine Advantages: Disadvantages:
1. Low unit cost 1. High initial Investment
Ans S.
Point to Point Continuous Path 2. Automated material handling 2. Relatively inflexible in accommodating
N.
3. High production rate. product changes.
The primary function of point to point Contouring system generates a
path control system, is to move a cutting continuously controlled tool path by the Examples: Transfer Lines, Assembly lines etc.
1 Programmable Automation: In programmable automation, the production equipment is
tool form one point location to another capability of computing the points of the
02 Marks
predefined point on the worktable path Any Four = 01 designed with the capability to change the sequence of operations to accommodate different
2 It is the cheapest tool control system It is the most expensive. Mark Each. product configurations. The operation sequence is controlled by a program, which is a set of
It is generally used for hole operations Contouring system had the ability to instructions coded. So that they can be read and interpreted by the system. New programs can
3 such as drilling, boring, reaming, tapping perform linear and circular or parabolic be prepared and entered into the equipment to produce new products.
and punching. interpolation.
Example: Numerical controlled machine tools, industrial robots and programmable logic
It is the lowest level of motion control It is the highest level of control between
4 controller
between the tool and workpiece. the tool and workpiece.
Point-to-point (PTP) is also sometimes Continuous Path is also called Contouring
5 Advantages: Disadvantages:
called a positioning system. path system.
6 It is simple and easy. Contouring is the most complex 1. Flexible to deal with design variations. 1. High investment in general purpose
Only two axis movement can complete Simultaneous movement of more than one 2. Suitable for batch production. equipment
7 PTP operation. axis movement can take place to complete 2. Lower production rate than fixed
the operation.
automation.
It is not capable to perform Contouring It is capable of performing both PTP and
8 4 Attempt any THREE of the following: 12
operations. straight-cut operations.
No cutting is performed between holes, Contouring system generates a Classify the different methods of gear manufacturing.
a)
there is no need for controlling the continuously controlled tool path by the
9
relative motion of the tool and workpiece capability of computing the points of the Ans Classification of Gear Manufacturing Methods:
between hole locations path (interpolating). A) Cutter Method
1) By formed disc cutter in milling machine
2) By formed end mill
3) By formed single point cutting tool
10 4) By formed cutter in a shear speed gear shaper
5) By formed cutter in a broaching machine
B) Template method in gear cutting machine Correct
C) Generating method Answer = 04
1) By rack tooth cutter in gear cutting machine Marks
c) Explain the meaning of following block format of CNC.
N020 G03 X12 Y14 Z-0.5 I0 J12 EOB 2) By a pinion cutter in gear cutting machine
Ans 3) By a hob cutter
N0020 – Block Number. 4) By Bevel gear genarator
G03 – Circular interpolation (Counter- Clockwise). Correct Ans. D) Casting
X12 – X coordinate of the arc end point = 12. = ½ Mark 1) Sandcasting
Y14 – Y coordinate of the arc end point = 14. Each 2) Die casting
Z-0.5 – Depth of Cut in Z - Direction= 0.5. 3) Investment casting
I0 – Distance along X – axis from the arc start point to the arc center point = 0. E) Stamping
J12 – Distance along Y – axis from the arc start point to the arc center point = 12. F) Powder metallurgy

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G) Plastic molding
H) Extruding

b) Apply right hand rule for axes identification of CNC vertical milling with neat diagram
Part Name:- Question No. 4 (c) Name of Operator:-
Ans Right Hand Rule for Axes Identification of CNC Vertical Milling : Part Material:- Aluminium Name of Machine :- Centre Lathe
Part No.:- Figure No. 1 Part Size:- Dia. 14 X 42 Length.
Depth
Spindle Feed in
Operation Machine of Cut
Description Tools / Fixture Speed in mm/rev
No. Tool in
Sketch 01 rpm. .
mm
Mark
Clamp the blank Cetre
1 3 jaw chuck,
The main axis of movement and the direction of movement along this axis is identified as in chuck Lathe
follows: Single point
Facing Cetre
Z- Axis: The Z- axis motion is always the axis of the main spindle of the machine. It does not & 2 cutting tool. 2043 0.2 1
matter whether the spindle carries the work piece or the cutting tool. On vertical machines the
Operation Lathe
(Facing Tool)
Z-axis is vertical. Positive Z movement is in the direction is towards the tip of middle finger. Single point
X-Axis: The X-axis is always horizontal and parallel to the work holding surface. If the Z-axis is Cetre
3 Turning cutting tool. 2043 0.2 1
vertical in vertical milling machine, positive X-axis movement is identified as being to the tip of Explanation = Lathe
(Turning tool)
thumb. 03 Marks
Y-Axis: The Y-axis is always at right angle to both the X-axis and Z-axis. Positive Y-axis movement 4 Unloading Job Chuck Key
is identified as being to the tip of Fore finger. d) Develop full G and M code manual part program of CNC lathe for the component shown in Fig.
A- Axis: Direction of curled finger about X – axis is rotary motion along X-axis is consider as No. 1 using word address format (WAF).
positive.
B- Axis: Direction of curled finger about Y – axis is rotary motion along Y-axis is consider as Point X Z
positive. Ans P0 0.0 2.0
C- Axis: Direction of curled finger about Z– axis is rotary motion along Z-axis is consider as P1 0.0 0.0
positive. P2 12.0 0.0
c) Calculate the cutting parameters and prepare process sheet for the component shown in Fig. P3 12.0 -25.0
No. 1 with neat diagram. All the dimensions are in mm. P4 14.0 -25.0
Given: Raw material - Aluminium, Stock Size – Dia.14 X 42 length, Feed ( f ) = 0.2 mm/rev., P5 14.0 -41.0
Figure No. 1 P6 20.0 -41.0
Cutting Speed (V) = 90 m/min., Consider work zero (W) as per Fig. No. 1.
Correct
O1234; Answer = 04
Ans N001 G28 U0.0 W0.0; Marks
N002 G90 G21 G95;
N003 M03 S2043 M08;
N004 G00 X0.0 Z2.0;
01 Mark for N005 G01 X0.0 Z0.0 F0.2;
Calculation N006 G01 X12.0 Z0.0;
Figure No. 1 N007 G01 X12.0 Z -25.0;
and
Given Data: N008 G01 X14.0 Z -25.0;
03 Marks for
V = 90 m/min., f = 0.2 mm/rev., D = 14 mm, Depth of cut, dc = 1 mm, Length of Cut, l= 25 mm N009 G01 X14.0 Z -41.0;
Process Sheet
Cutting Parameters: N010 G01 X20.0 Z -41.0;
Spindle Speed: V = πDN/1000 N011 G28 U0.0 W0.0;
N = 2043 rpm. N012 M05;
Feed: f = 0.2 mm/rev. N013 M09;
Depth of Cut: dc = 1 mm N014 M30;
e) Justify the need of Group Technology in today’s manufacturing situation

Ans Group technology is an approach to organizing manufacture which can be applied in any
industry (machining, welding, foundry, press work, forging, plastic molding, etc.) where small-
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batch variety production is used. [5] Servo system :- To circulate the electrolyte
The basic approach enables all aspects of manufacturing, from design, through estimating and b) Draw internal mechanism of universal dividing head and label the parts
planning, to production, to be rationalized. It forms the basis for the development of computer- Any Four
aided procedures and flexible automation. Group technology is a manufacturing philosophy or Advantages = Ans 4 Marks for
principle whose basic concept is to identify and bring together related or similar parts and 01 Mark neat
processes, to take advantage of the similarities which exist, during all stages of design and Each. diagram
manufacture.
Advantages of Group Technology: And
The following are the advantages of introducing GT in manufacturing:
1. Work in progress and finished stock levels are re­duced. 2 Marks for
2. Simplified estimating, accounting and work man­agement. labeling
3. Improved plant replacement decisions, and.
4. Improved job satisfaction, morale, and communica­tion.
5. Short throughput times because machines are closed together.
6. Better quality because the group complete parts and the machines are closed together
under one foreman.
7. Lower material handling costs because machines are closed together under one
foreman. Figure:- Internal Mechanism of Universal Dividing Head
8. Better accountability because of machines complete parts. c) Explain need of virtual CNC machine simulators
9. The foreman can be made responsible for costs, quality, and completion by the due Need of Virtual CNC Machine Simulator:-
date. Ans [1] Manufacturing process can be defined and verified in early stage 1 Mark each
10. Training for promotion since GT provides a line of succession because a group is a mini- [2] allows designers to conduct machining process planning, generating tool path for any 6
department. [3] easy to visualize the process and simulate operations correct
11. Automation GT is the first evolutionary step in automation.
[4] Automatically calculate machining time points
12. Reduced set up time since similar parts brought together on the same.
[5] The tool path generated can be converted into CNC codes
13. Morale and job satisfaction since most workers prefer to work in groups.
[6] Editing in the program is easy sue to prior information
The output is improved due to improved resource utilization.
[7] Errors can be found out easily
5 Attempt any TWO of the following 12
[8] Provides analysis features
Draw set up diagram of ECM processes showing all the elements. State the function of each 6 Attempt any TWO of the following 12
a)
element a) Draw a set up diagram of wire cut EDM and label the parts, also suggest the approximate 3 Marks for
Ans range of following process parameters with its measuring units neat
Ans (i) Discharge current OR Pulse frequency diagram and
2 Marks for (ii) Wire speed OR Wire tension 1 mark for
diagram
labeling
And
1 mark each
for any 4 1 mark for
correct
any 1
function of
correct point
elements

1 mark for
any 1
Functions of each element:- correct point
[1] Fixture :- To hold the work piece rigidly and securely (i) Discharge current OR Pulse frequency
Discharge current is limited to 30 A
[2] DC Supply :- To supply current to cathode and anode
Pulse frequency is about 1 MHz
[3] Tank :- To store the electrolyte (ii) Wire speed OR Wire tension
[4] Tool (Cathode) :- To remove the material by controlled dissolution of anode Wire speed is about 2.5 to 150 mm/s

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Wire tension is about 50 – 60 % of tensile strength of wire

b) Apply compound indexing method to divide 51 divisions on circular blank

Index crank movement (T) = 40 /N
Ans Where ,
N = No of divisions required
T = 40 / 51

Let’s try circle17 and 18 holes

Factors of divisions required x factors of difference of hole circles 2 Marks for
Factors of 40 x Factors of first circle x Factors of second circle formula
= 3 x 17 x 1
10 x 4 x 17 x 3 x 6 4 Marks for
= 1 / 240 correct
As all the factors from numerator can be cancelled we can select the 17 and 18 hole circle plate stepwise
240 / 17 – 240 / 18 OR 240 / 18 – 240 / 17 answer
14 x 2 / 17 – 13 x 6 / 18 OR 13 x 6 / 18 – 14 x 2 / 17

The above equation can be written as = 2 / 17 + 12 / 18 OR -12 / 18 – 2 / 17

Similar signs show that both the movements will be in the same direction. By adopting
the
first result we get the required movement.
c) Use the different milling cutter to cut T Slot on rectangular block with neat diagram also
mention the sequence of operations and types of milling cutter used
Ans
[1] T Slot cutter
Different milling cutter used for the T slot Milling 2 Marks for
[1] End milling cutter / Plain milling cutter neat
[2] Special type T Slot Milling Cutter diagram

2 Marks for
Sequence of
operation

Figure :- T Slot Milling Operation

Sequence of Operation
[1] ]Using plain / end milling cutter plain slots are produced
[2] The T slot cutter is used to enlarge and face the bottom of the slots

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