Automation & Robotics

uto at o & Robot cs

What is NC/CNC?
h / ? What is the difference between NC and CNC ?
y NC is an acronym for Numerical Control and CNC is an y The
Th difference
diff between
b NC and
d CNC is
i one off age and
d
capability.
acronym for
f Computer Numericall Control.
l
Rev.1 y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
y As the
h technology
h l evolved,
l d the
h machines
h were equiped d
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
y CNC machines have far more capability than their
By  S K Mondal predecessor.
d contd…..
td
Gunjan Chaudhury

What is the difference between NC and CNC ? Where did CNC get started?
h dd d? IAS ‐ 1996
y Some of the enhancements that came along with CNC y 1940 Jhon Parson developed first machine able to drill Assertion
A i (A):
(A) The
Th temperature controll off an
electric iron is an example of servomechanism.
include:
l d Canned
d Cycles,
l Sub
b Programming, Cutter h l at specific
holes f coordinates
d programmed
d on punch
h Reason (R): It is an automatic control system.
Compensation Work coordinates,
Compensation, coordinates Coordinate system cards.
cards (a) Both A and R are individually true and R is the
correct explanation of A
rotation, automatic corner rounding, chamfering, and B
B‐ y 1951 MIT developed servo‐mechanism
(b) Both A and R are individually true but R is not the
spline interpolation. y 1952 MIT developed first NC machines for milling.
milling correct
co ect eexplanation
p a at o oof A
(c) A is true but R is false
y 1970 First CNC machines came into picture
(d) A is false
f l but
b R is true
Now‐a‐day’s
y modified 1970’s
97 machines are used.

Do all machines speak the same CNC 
D ll hi k th CNC What is a “Conversational Control”
h “ l l” Are CNC machines faster than 
language y CNC machine tool builders offer an option what is conventional machines?
l h
y No, while there is fairly standard set of G and M codes, k
known as the
h conversationall control.
l This
h controll lets
l
y Yes, No, Sometimes. When it comes to making a single,
th
there i some variation
is i ti ini their
th i application.
li ti F example
For l the operator/programmer use simple descriptive
simple part it is hard to beat a conventional mill or lathe.
a G0 or G00 command is universally regarded as the language to program the part. The control then
CNC machines move faster in rapid travel than
command for rapid
p travel. Some older machines do not displayed a graphical representation of the instructions
conventional
i l machines.
hi
have a G00 command. On these machines, rapid travel is so the operator/programmer can verify the tool path.
commanded by using the F (feed) word address.
 Are CNC machines more accurate  GATE ‐ 1994 NC/CNC Machines‐Advantages
than conventional machines?
h l h CNC machines
hi are more accurate than
h conventional
machines because they have a high resolution
i l y High Repeatability and Precision e.g. Aircraft parts
y Volume of production is very high
encoder and digital read‐outs for positioning.
y Yes, they
y can be. But like anything
y g else it depends
p on y Complex contours/surfaces need to be machined. E.g.
Turbines
who is running the machine, how well the machines has True or false?
y Flexibility in job change,
change automatic tool settings,
settings less
been maintained, quality of setup and so on. scrap
y More
M safe,
f higher
hi h productivity,
d i i better
b quality
li
y Less ppaper
p work,, faster p
prototype
yp pproduction,, reduction
in lead times

NC/CNC Machines‐Disadvantages IES ‐ 1999 IES ‐ 1995

Consider
C id the
h following
f ll i statements regarding
di Consider
C id the
h following
f ll i characteristics
h i i off
y Costly setup, skilled operators numerically controlled machine tools: production jobs:
y Computers, programming knowledge required 1. They reduce non‐productive time 1. Processing of parts frequently in small lots
2 They reduce fixturing
2. 2 Need to accommodate design changes of products.
2. products
y Maintenance is difficult
3. They reduce maintenance cost 3. Low rate of metal removal
Which of these statements are correct? 4. Need for holding close tolerances
( ) 1, 2 and
(a) d 3 (b) 1 and d2 Th
The characteristics
h t i ti which
hi h favour
f th choice
the h i off
(c) 2 and 3 (d) 1 and 3 numerically controlled machines would include
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1,
1 3 and 4 (d) 1, 1 2 and 4

NC/CNC/DNC
y Direct Numerical Control is a system that uses a Direct numerical control
Direct numerical control DNC
p
central computer to control several machines at the same
time
y Distributed Numerical Control (DNC): the central
computer downloads complete programs to the CNC
machines,
hi which
hi h can be
b workstations
k i or PCs,
PC and d can get
the information for the machine operations.
y The speed of the system is increased, large files can be
handled and the number of machine tools used is
expanded.

16 17 18
 IES ‐ 2009 GATE ‐ 1993 IES ‐ 2007
In
I which
hi h off the
h following
f ll i machining
hi i manuall part With
Wi h reference
f to NC machine, hi which
hi h off the
h What
Wh are the h main i components off an NC machine?hi ?
programming is done? following statement is wrong? 1. Part program
p g
(a) CNC machining (b) NC machining (a) Both closed‐loop and open‐loop control systems are 2. Machine Control Unit
(c) DNC machining (d) FMS machining used 3. Servo
S motor
(b) Paper tapes, floppy tapes and cassettes are used for Select the correct answer using
g the code ggiven below:
data storage
(a) 1, 2 and 3 (b) 1 and 2 only
(c) Digitizers
g t e s may
ay be used as interactive
te act ve input
put dev
devices
ces
( ) 2 and
(c) d 3 only
l (d) 1 and d 3 only
l
(d) Post processor is an item of hardware

JWM 2010 IES ‐ 2009 IES ‐ 1999

Consider the following components regarding numerical What
Wh is
i theh purpose off satellite lli computers ini Consider
C id theh following
f ll i components:
control system : Distributed Numerical Control machines? 1. A dedicated computer
p
1. Programme of instructions (a) To act as stand‐by systems 2. Bulk memory
2 Machine control unit
2. (b) To share the processing of large‐size
large size NC programs 3. Telecommunication
Tl i i lines
li
3. Processing equipment (c) To serve a group of NC machines Which of these components
p are required
q for a DNC
Which of these are correct ? (d) To network with another DNC setup system?
(a) 1,
1 2 and 3 (b) 1 and 2 only ( ) 2 and
(a) d3 (b) 1 andd2
(c) 2 and 3 only (d) 1 and 3 only (c) 1, 2 and 3 (d) 1 and 3

JWM 2010 IES – 2002             S‐1  IES – 2002 Contd….. From S‐1 

d
Consider the following advantages of DNC systems : Match
M t h List
Li t I with
ith List
Li t II and d select
l t theth correctt C.
C DNC system
t 3. The
Th controller
t ll consists
i t off
1. Time‐sharing answer: soft‐wired computer and
List I List II h d wired
hard‐ i d logic
l i Graphic
G hi
2. Greater computational capability display of tool path is
((NC machine tool systems)
y ) ((Features))
3  Remote computer location
3. Remote computer location also
l possible
ibl
A. NC system 1. It has an integrated automatic tool
D. Machining centre 4. The instructions on tape is
changing unit and a component
prepared in binary
Which of the above is/are correct ? indexing device
decimal form and operated
p byy
( )    d    l  
(a) 1 and 2 only  (b)    d    l
(b) 2 and 3 only B CNC system
B. t 2. A numberb off machine hi t l are
tools a series of coded
(c) 2 only
y (d) 1, 2 and 33 controlled by a computer. No tape instructions
reader,
d the
th partt program isi
transmitted directly to the Codes:A B C D A B C D
machine
hi tool
t l from
f th
the (a) 4 2 3 1 (b) 1 3 2 4
computer memory (c) 4 3 2 1 (d) 1 2 3 4
 Punched Tape
Punched Tape Punched Tape and Parity Check
Punched Tape and Parity Check
In the earlier NC machines, the most commonly used
IAS‐2011 main
IAS‐2011 main program storage
t medium
di was paper tape.
t A paper tape
t is
i
yW e numerical
When u e ca data aaree tthee input,
2, 3, 4, and 6 are employed.
put, cchannel
a e numbers
u be s 1,,
one inch wide tape is considered to have eight tracks
E l i att least
Explain, l t two,
t characteristics
h t i ti each
h off NC,
NC (called channels) that run along the length of the tape. y The
Th tapet reader
d makes
k elementary
l t checks
h k on the
th
The channels are numbered 1 through g 8 from right
g to accuracy with which the tape has been punched. This is
CNC and DNC.
DNC
left. Arrays consisting of 1 to 8 holes are punched across called Parity Check.
[10 Marks]
[10‐Marks] the width of the tape.
tape (Small holes between the third y There must be an odd number of holes in each row or
and fourth channels are for the tape drive sprocket teeth. the tape reader and machines stops.
y If a command d needs
d an even no off holes
h l tot be
b punched,
h d
an additional one must be punched in channel 5, the
parity check channel.
y The sprocket drive holes are not considered in the parity
check.

Stepper Motor
Stepper Motor
y The stepper
pp motor is special
p yp of synchronous
type y motor
Prime Movers
Prime Movers which is designed to rotate through a specific angle
y Practically every industrial process requires objects (Called step) for each electrical pulse received from the
to be moved, manipulated, held, or subjected to control unit.
some type of force.
force y The
Th ferromagnetic
f ti multiple
lti l pole
l rotor
t moves inside
i id a
y The three most commonly employed methods for multipole stator. The alternate teeth on rotor and stator
producing the required forces/motions are: are magnetized to act as north and south poles.
¾ Electrical – motors,, solenoids • The 1.8
1 8 degree stepping
¾ Air – Pneumatics motor is the predominant
¾ Liquids ‐ Hydraulics standard
t d d f
for i d ti l
industrial
automation.

Encoders
y A stepping motor provides open loop, digital control
open‐loop IAS‐2009 main
IAS‐2009 main
y A device used to convert linear or rotational position 
of the p
position of a workpiece
p in a numerical control
Wh t is
What i the
th function
f ti off stepper
t motor?
t ?
information into an electrical output signal.
machine. The drive unit receives a direction input (cw
[2  marks]
[2 –
or ccw) and pulse inputs. For each pulse it receives, the
drive unit manipulates the motor voltage and current,
causing
i the
h motor shaft
h f to rotate by
b a fixed
fi d angle
l (one
(
step) The lead screw converts the rotary motion of the
step).
motor shaft into linear motion of the workpiece.
p
 Control Systems
Control Systems Feedback
Open Loop Systems CNC systems use two different feedback principles. The
indirect feedback, which monitors the output of the IFS 2011
IFS 2011
servomotor. The direct feedback monitors the load
Wh t is
What i indirect
i di t feedback
f db k ? [
[2‐marks]
k ]
condition in the feedback loop and that is the reason
that is more accurate than the indirect feedback.

Closed Loop Systems
Indirect Feedback

Optical 
Encoder
Direct Feedback

IAS‐2010 Main IES‐Conventional GATE ‐ 2007

Illustrate with the help of neat sketches the differences
between open‐loop and closed‐loop control in NC
system. Why is feedback not possible in open‐loop
y Schematically illustrate closed loop control system for a
numerical control machine, mentioning the purpose of a
feedback control. Write the advantages of CNC over
Which type of motor is NOT used in axis or spindle 
Whi h    f   i  NOT  d i   i     i dl  
drives of CNC machine tools?
(a) Induction motor (b) DC servo motor
(c) Stepper motor  (d) Linear servo motor

control system
s stem ? con entional NC systems.
conventional s stems [10 marks]

[22 Marks]
[22‐ y Enlist the advantages of DNC over CNC.
CNC

IES ‐ 1994 IES ‐ 2002 Machining Centre

Feed
F d drives
d i in
i CNC milling
illi machines
hi are provided
id d In
I a CNC machine
hi tool,
l encoder
d isi used
d to sense and
d y A machining centre or work centre consists of a single, but
by control sometimes, two machine tools with the specific p feature of an
(a) Synchronous motors (a) Table position automatic tool changer and capable of performing a number of
operations (drilling, tapping, milling, boring and turning etc.) on
(b) Induction motors (b) Table velocity a workpiece.
(c) Stepper motors (c) Spindle speed y Most machines are numerically y controlled, but other types
yp of
(d) Servo‐motors. (d) Coolant flow controls will work as well.
y The major
j advantage g is that the jjob needs clampingp g on the work
holding surface only once; the machine then performs a variety of
machining g operations
p on all the jjob's faces except
p the base.
y Work handling time is thus decreased because there is no
movement of the workpiece from one machine to another.
 Machining Centre
y Some machines are equipped with two work‐tables that can be
moved into or out of the machine. While the work is g
going
g on one
works table, the next component can be set up on the other work‐
table. When the job is complete on the first work‐table, it is
moved out of the way and the second work‐table is moved into
position.
y For storing the preset tools, various magazine systems are used.
These preset tools are removed from their slots by a hand‐arm
mechanism. When a particular machining operation is completed,
the tool is removed from the spindle and returned to its storage
slot, then another tool is picked up and mounted in the tool
spindle.
y A machining centre is mainly used for batch production of main
components of a product.
Machining Centre
y The main components of a product are usually small (about 10%)
but are expensive
p (theyy represent
p about 550% of the p
product value)
because they have considerable material value and usually require
a large amount of machining. For such components, the
machining centre is generally most economical.
y Machining g centres have high
g metal removal rate capabilities.
p The
high degree of accuracy and multi‐operation in the same set up,
make the machining centres highly versatile and increase
productivity. Some models are made with manual tool change
facility.
Fig. 5 axes CNC vertical axis machining centre configuration

Adaptive Control
d l IAS‐2014 main Basic Length Unit (BLU)
h ( )
y An adaptive or self‐optimizing system is one in which y In
I NC machine,
hi the
h displacement
di l length
l h per one pulse
l
Differentiate between open
p loop,
p, closed loop
p and output from machine is defined as a Basic Length Unit
the
h current performance
f off the
h system is measured
d in (BLU).
adaptive control systems used in NC machine tools.
terms of a criterion or objective function and the system y In the CNC computer each bit (binary digit) represents 1
[10 –Marks] BLU.
parameters are modified in a manner as to optimize the
Bit = BLU
system performance. y Example:
a p e: If oonee pu
pulse
se makes
a es a se
servo
vo motor
oto rotate
otate by o
onee
degree and the servo motor moves the table by 0.0001
y For example, in drilling, the torque on the drill is
mm one BLU will be 0.0001
mm, 0 0001 mm.
mm
measured and speed and feed or both are adjusted y The lead of a ball screw is related to the displacement
within programmed limits. unit of the machine tool table.

GATE ‐ 1997 GATE – 2007 (PI)

( )
In
I a point
i to point
i controll NC machine,
hi the
h slides
lid In
I a CNC machine hi feed
f d drive,
di a stepper
t motor
t
are positioned by an integrally mounted stepper with step g of 1.8o drives a lead screw with
p angle
motor drive. If the specification of the motor is pitch of 2 mm. The Basic Length Unit (BLU) for
1o/p
/pulse,, and the p
pitch of the lead screw is 33.6 mm,, this drive is
what is the expected positioning accuracy?
((a)) 10 microns ((b)) 20 microns
( a ) 1μ m (b) 10 μm
(c ) 50 μm (d ) 100 μm (c) 40 microns (d) 100 microns
 GATE – 2008 (PI) Example
A stepper motor has 150 steps. The output shaft of the y A DC servomotor is coupled directly to a leadscrew IFS‐2015
which drives the table of an NC machine tool. A A DC servomotor is coupled directly to a lead
motor is directly
d l coupled
l d to a lead
l d screw off pitch
h 4 mm, digital encoder, which emits 500 pulses per screw which drives the table of an NC machine
which drives a table.
table If the frequency of pulse supply to revolution is mounted on the other end of the
revolution, tool. A digital encoder which emits 500 pulses per
leadscrew. If the leadscrew pitch is 5 mm and the revolution is mounted on the other end of the
the motor is 200 Hz, the speed of the table (in mm/min) motor rotates at 600 rpm,rpm calculate lead screw.
screw If the lead screw pitch is 5 mm and the
motor rotates at 650 rpm, calculate
is (a) The linear velocity of the table
(i) The
Th linear
li velocity
l it off the
th table
t bl
(b) The BLU of the NC system
(a) 400 (b) 320 (c) 300 (d) 280 (ii) The BLU of the NC system
( ) The
(c) Th frequency
f off pulses
l t
transmitted
itt d by
b the
th encoder.
d
(iii) The frequency of the pulses transmitted by the
encoder [8 ‐ Marks]

IES 2011 Conventional GATE – 2010 (PI) GATE‐2016 (PI)

y The
h table
bl off a CNC machine
h is driven
d by
b a Lead
d screw which
h h For
F a 3 –axes CNC table,
bl the
h slide
lid along
l the
h vertical
i l axis
i
of the table is driven by a DC servo motor via a lead A single axis CNC table is driven by a DC servo motor
is rotated by a DC servomotor. A digital encoder which emits
screw‐ nut mechanism. The lead screw has a pitch of 5 that is directly coupled to a lead screw of 5 mm pitch.
1000 pulses per second is mounted on the lead screw as a mm. This lead screw is fitted with a relative
feedback device. If the lead screw pitch is 6 mm and motor (incremental) circular encoder. The basic length unit The circular encoder attached to the lead screw
rotates
t t att 500 rpm, find
fi d (BLU) of the slide along the vertical axis of the table is generates 1000 voltage
oltage pulses per revolution
re olution of the lead
0.005 mm. When the table moves along the vertical axis
1
1. Basic length Units of the system b 9 mm, the
by th corresponding
di number b off pulses
l generated
t d screw The table moves at a constant speed of 6 m/min.
screw. m/min
2. Linear velocity of the table. by the encoder is The corresponding
p g frequency
q y (in kHz) of the voltage
g
(a) 1400 (b) 1800 (c) 4200 (d) 9000
3. Frequency of pulses generated by the feedback device. pulses generated by the circular encoder is_________.
[5 Marks]

GATE – 2014(PI)
I an open loop,
In l point‐to‐point
i i controlledll d CNC drilling
d illi
machine, a stepper motor, producing 200 angular steps per
Statement for Linked Answers questions: S‐1 GATE – 2008 Q‐1 (Statement in S‐2) 
( )
revolution, drives the table of a drilling machine by one In
I the
h feed
f d drive
d i off a Point‐to‐Point
P i P i open loop
l CNC The
Th Basic
B i Length
L h Unit
U i (BLU),
(BLU) i.e.,
i the
h table
bl
g
angular steppp
per each ppulse g
generated byy a ppulse g
generator drive, a stepper motor rotating at 200 steps/rev drives a movement corresponding to 1 pulse of the pulse
(shown in figure). Each angular step moves the table by table through a gear box and lead screw‐nut mechanism generator, is
g Unit ((BLU)) along
one Basic Length g X axis with a lead screw (pitch = 4 mm,, number of starts = 1).
(p ) (a) 0.5
0 5 microns (b) 5 microns
Output rotational speed
having a pitch of 4 mm. If the frequency of pulse generator The gear ratio = Input rotational speed is given by U = 14 (c) 50 microns (d) 500 microns
is doubled,
doubled the BLU will
The
h stepper motor (driven
(d b voltage
by l pulses
l f
from a pulse
l
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
(a) become double of previous value generator is f = 10,000 pulses per minute.
(b) become half of previous value
( ) remain
(c) i the
h same
(d) become zero
GATE – 2008 Q‐2 (Statement in S‐3) 
( ) GATE – 2009 (PI) GATE‐2014 (PI)
A customer insists
i i on a modification
difi i to change
h the
h BLU Each axis of NC machine is driven by a stepper motor
The total angular movement (in degrees) of a lead‐screw
of the CNC drive to 10 microns without changing the drive with a lead screw.
screw The pitch of lead screw is p mm.
mm
table speed. The modification can be accomplished by with a pitch of 5.0 mm to drive the work‐table by a The step angle of stepper motor per pulse input is α
di
distance off 200 mm in
i a NC machine
hi isi degrees/pulse The ratio of gear drive in stepper motor
degrees/pulse.
drive is g(number of turns of the motor for each single
( ) 14400
(a) (b) 28800
88 ( ) 57600
(c) 6 (d) 72000 turn off the
h lead
l d screw). ) The
Th number b off pulses
l required
i d
to achieve a linear movement of x mm is
αg 360 g g 360 g
(a) x (b) x (c ) x (d ) x
360 p p 360 p pα

IAS 2010 Main

IAS‐2010 Main IAS 2013 Main
IAS‐2013 Main Control Systems possible in CNC Machine
p p NC system
In open‐loop y pp g motor is
the shaft of a stepping
An open loop type NC machine has a stepper motor with y Point
P i to point
i mode:
d
connected directly to the lead screw x‐axis of the
a step of 0.9 degree. The lead screw of the machine is of
machine table. The pitch of the lead screw is 3.0 mm.
4 mm pitch.i h
The number of step angles on the stepping motor is 200.
((i)) If the tool has to be moved byy 2.877 mm,, how manyy
Determine how closely the position of the table can be pulses will have to be fed?
controlled assuming that there are no mechanical errors
controlled, (ii) If the
th motor
t is
i rotating
t ti att 15 rpm, what
h t is
i the
th pulse
l
in the positioning system. frequency and the feed rate of the machining operation?
Also, what is the required frequency of the pulse train [10 –Marks]
and the corresponding rotational speed of the stepping
motor in order to drive the table at a travel rate of 100
mm/min? [8 Marks]
[8‐

GATE ‐ 1992 Point‐to‐point  straight line mode IES Conventional

In
I a point‐to‐point
i i type off NC system Discuss point – to – point control,
control and its
((a)) Control of pposition and velocityy of the tool is applications.
essential
(b) Control of only position of the tool is sufficient
(c) Control of only velocity of the tool is sufficient
(d) Neither position nor velocity need be controlled
 GATE ‐ 2006
NC contouring i isi an example l off
((a)) Continuous ppath ppositioning
g
(b) Point‐to‐point positioning
( ) Absolute
(c) Ab l positioning
ii i
((d)) Incremental p
positioningg

GATE‐2005 Co‐ordinate system
d
y All the
h machine
hi tooll use Cartesian
C i Co‐ordinate
C di system.
Which among the NC operations given below are 
continuous path operations?       y The first axis to be identified is the Z – axis,, This is
followed by X and Y axes respectively.
Arc Welding (AW) Milling (M)
Drilling (D) Punching is Sheet Metal (P)
Laser Cutting of Sheet Metal (LC)    Spot Welding (SW)
(a) AW, LC and M (b) AW, D, LC and M
( ) D, LC, P and SW 
(c) d (d)
(d) D, LC, and SW
d

Right‐hand coordinate systems

IES ‐ 2000
Assertion
A i (A):
(A) The
Th axis i off an NC drilling
d illi machine
hi
spindle is denoted as z‐axis.
Reason (R): In NC machine tool, the axis
perpendicular to both x x‐ and y
y‐axis
axis is designated as
z‐axis
( ) Both
(a) h A and d R are individually
d d ll true and d R is the
h
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
 IES ‐ 1996
Assertion
A i (A):
(A) Numerically
N i ll controlledll d machines
hi
having more than three axes do not exist.
Reason (R): There are only three Cartesian
coordinates namely x x‐y‐z
y z.
(a) Both A and R are individually true and R is the
correct explanation
l off A
(b) Both
ot A aand d R aaree individually
d v dua y ttrue
ue but R iss not
ot tthee
correct explanation of A
( ) A is
(c) i true
t b t R is
but i false
f l
(d) A is false but R is true
5 axes CNC vertical axis machining centre configuration

GATE 2015
GATE-2015 IES ‐ 2003             S‐1
Absolute and Incremental Coordinate System
A drill is p
positioned at p
point P and it has to p
proceed to
While
Whil part programming i
point Q. The coordinates of point Q in the in CNC machines, the
input of dimensional
incremental system of defining position of a point in
information for the tool
CNC part program will be path can be given in the
absolute co‐ordinate
a)) (3,12)
( )
system or in incremental
b) (5,7)
(5 7) co‐ordinate
di t system.t Th
The
above figure shows the
c) (7,12)
route to be
b followed
f ll d by
b theh
d) (4,7) tool from O to C, i.e., O ‐ A
‐ B ‐ C.
Absolute Coordinate System Incremental Coordinate System

IES – 2003 Contd.. From S‐1 
d The following are the steps to be followed 
If incremental
i l co‐ordinates
di system is
i used,d theh co‐ GATE ‐2012 
GATE ‐2012 Same Q in GATE‐2012 (PI)
Same Q in GATE 2012 (PI) while developing the CNC part programs.
while developing the CNC part programs
ordinates of each point A, B and C are A CNC vertical milling machine has to cut a y Process planning
p g
(a) A: X 5.0, Y 10.0 (b) A: X 5.0, Y 10.0 straight slot of 10 mm width and 2 mm depth by a y Axes selection
B: X 20.0,
20 0 Y5.0
Y5 0 B: X 25
25, Y 15.0
15 0 cutter of 10 mm diameter between points (0, (0 0) y Tool selection
T l  l ti
C: X 10.0, Y 10.0 C: X 35, Y 5.0 and (100, 100) on the XY plane (dimensions in y Cutting process parameters planning
gp p p g
mm). ) The
Th feed
f d rate usedd for
f milling
illi is
i 50 mm/min.
/ i
(c) A: X 10.0, Y 5.0 (d) A: X 10.0, Y 5.0 y Job and tool setup planning
Milling time for the slot (in seconds) is
B X 15.0, Y 25.0
B: B X 5.0, Y 20.0
B: y Machining path planning
M hi i   th  l i
(a) 120 (b) 170 (c) 180 (d) 240
C: X 15.0, Y 35.0 C: X 10.0, Y 10.0 y Part program writing
p g g
y Part program proving
 IES Conventional IFS‐2015
What is meant by Part Programming ? Discuss point –
to – point control, and its applications. What is the function of MCU in NC machine?
y Part programs for simple components can be carried out
manually. However, if the component has complex features Answer:
which require too many repetitive and/or tedious
calculations for preparing its program for cutter path For a CNC machine control unit (MCU) decides cutting
description, then it is recommended that computer
computer‐aided
aided
part programming be resorted to. To be a good CNC speed,
d feed,
f d depth
d h off cut, tooll selection
l , coolant
l on off
ff
programmer,
p g , one should have a fair knowledge g about the and tool paths.
paths The MCU issues commands in form of
machine tools, cutting tools and fixtures to be used and the y For a CNC machine
h controll unit (MCU)
( ) decides
d d cutting
manufacturing g pprocess. He also should have a g good p
speed, feed, depth
p of cut, tool selection , coolant on off numeric data to motors that position slides and tool
understanding of geometry, algebra and trigonometry. In and tool paths. The MCU issues commands in form of
fact, machine shop experience is the pre‐requisite for a good numeric data to motors that position slides and tool accordingly. It is electronic and computerized interface
programmer as only l careful
f l process planning
l can lead
l d to
efficient and practical programs. accordingly. between operator and m/c.

IFS 2011
IFS 2011 Part Programming CNC i
CNC programming
What is the function of Data Processing Unit (DPU) and Important things to know:
Control Loop Unit (CLU) of MCU. [5‐marks] y FANUC CONTROL
Answer: • Coordinate System
y SIEMENS CONTROL
Data Processing Unit • Units, incremental or absolute positioning
y Input device [RS‐232 port/ Tape Reader/ Punched Tape
Reader]] • Coordinates: X,Y,Z, RX,RY,RZ
, , , , ,
y Data Reading Circuits and Parity Checking Circuits
• Feed rate and spindle speed
p p
y Decoders
D d to t distribute
di t ib t data
d t to
t the
th axes controllers.
t ll
Control Loops Unit • Coolant Control: On/Off, Flood, Mist
Coolant Control: On/Off  Flood  Mist
y Interpolator to supply machine‐motion commands between
data po
points
ts • Tool Control: Tool and tool parameters
y Position control loop hardware for each axis of motion

Table of Important G codes
p Table of Important G codes
p
Programming Key Letters Code Meaning Format Code Meaning Format
y O ‐ Program number (Used for program identification)
G00 Rapid Transverse N__G00 X___ Y___ Z___ G20/G70 Inch Unit
y N 
N ‐ Sequence number (Used for line identification) G01 p
Linear Interpolation N__G01 X___ Y___ Z___ F___ 7
G21/G71 Metric Unit
y G ‐ Preparatory function G02 Circular Interpolation,  N__G02 X__ Y__ Z___ R___ F___ G28 Automatic Return to Reference  
y X ‐ X axis designation
g CW Point
N G  X
N__G02 X___ Y__Z__I ___J __K __ F __
 Y Z I  J  K   F 
y Y ‐ Y axis designation
G03 Circular Interpolation, N__G03 X___ Y___ Z__R__F___ G40 Cutter compensation cancel
y Z ‐ Z axis designation
g
y R ‐ Radius designation CCW G
G41 C tt  
Cutter compensation left
ti  l ft N G D
N__G41D__
N__G03 X__ Y__Z__I __J __K __ F __
y F – Feed rate designation G04 Dwell N__G04P___ G42 Cutter compensation right N__G42D__
y S ‐ Spindle speed designation
G17 XY Plane
y H ‐ Tool length offset designation G43 Tool length compensation  N__G43H__
y D ‐ Tool radius offset designation G8
G18 XZ Pl
XZ Plane (plus)
y T ‐ Tool Designation G19 YZ Plane
y M ‐ Miscellaneous function
 Table of Important G codes
p
Code Meaning Format
G44 Tool length compensation  N__G44H__
N G44H p
Rapid traverse: G00 p
Linear interpolation: G01 
(minus)
y G01: 
G49 Tool length compensation  y G00: 
y linear interpolation at feed speed.
cancel y to make the machine move at maximum speed. 
G91 G0l X200.0 Y100.0 F200.0
G8
G80 C
Cancel canned cycles
l  d  l y It is used for positioning motion. 
It is used for positioning motion  
G81 Drilling cycle N__G81 Z__R__F__ G90  G00  X20.0  Y10.0 Y
G91: 
9 End
G82 Counter Bore Cycle N__G82Z__R__P__F_ End incremental  100.0
G90:  coordinates
(20,10)
G83 Deep Hole Drilling Cycle
eep o e g Cyc e N G83Z__ R
N__G83 R__ Q
Q_F__ absolute 
coordinates (10,10)
G90 Absolute positioning
G
G91 I
Incremental positioning
t l  iti i
Start (0,0)
G92 Absolute preset, change the  N__G92X__Y__Z__ Start 200.0 X
d
datum position, Reposition 
Origin Point

Circular interpolation: G02, G03 
Circular interpolation: G02, G03 Circular interpolation: G02, G03
Circular interpolation: G02, G03 Circular interpolation: G02, G03
Circular interpolation: G02 G03
y G02, G03: 
y For circular interpolation, the tool destination and the circle 
For circular interpolation  the tool destination and the circle  Y y Specify Center with I, J, K
center are programmed in one block  Y End
y G02 is clockwise interpolation, G03 is counterclockwise  X R=-50mm y I, J, K are the incremental 
J
i
interpolation
l i End Specify R with 
S if  R  i h  distance from the start of 
⎧G 02 ⎫ ⎧ R ⎫ sign before it: the arc;
X
G17 ⎨ ⎬ X __ Y __ ⎨ ⎬ F __;;
⎩G 03 ⎭ ⎩ I __ J __ ⎭ ≤180° +R y Viewing the start of arc as 
Start
⎧G 02 ⎫ ⎧ R ⎫ R=50mm >180° ‐R the origin, I, J, K have 
G18 ⎨ ⎬ X __ Z __ ⎨ ⎬ F __;; Start positive or negative signs.
ii     i  i
⎩G 03 ⎭ ⎩ I __ K __ ⎭ j
Center
⎧G 02 ⎫ ⎧ R ⎫
G19 ⎨ ⎬Y __ Z __ ⎨ ⎬ F __;; i
⎩G 03 ⎭ ⎩ J __ K __ ⎭ G91 G02  X60.0  Y20.0  R50.0 F300.0
End  Circle center,  radius
, G91 G02  X60.0  Y20.0  R‐50.0 F300.0
point

GATE 2014
GATE‐2014
Circular interpolation: G02, G03
Circular interpolation: G02, G03 Circular interpolation: G02, G03
Circular interpolation: G02 G03 p p g g p
For the CNC part programming, match Group A with 
Group B:
N0010 G92   X200.0  Y40.0  Z0 ; Annotation for Circular Interpolation
p
N0020 G90   G03  X140.0  Y100.0  I ‐60.0  F300；
Group A Group B
y I0.0, J0.0, and K0.0 can be omitted. 
N0030 G02   X120. 0  Y60.0  I‐ 50.0； G92: P: circular interpolation, counter  I: G02
Or To define working 
T  d fi   ki   y If X,Y,Z are all omitted in the program, that means 
If X Y Z are all omitted in the program  that means 
N0010 G92  X200.0  Y40.0  Z0； coordinate
clock wise
start and end of arc are same points. 
N0020 G90  G03  X140.0   Y100.0  R60.0  F300； N0020 G02 I20 0  (a full circle)
N0020 G02 I20.0  (a full circle) Q: dwell II: G03
N0030 G02  X120.0  Y60.0   R50.0；
y If I, J, K, and R all appears in circular interpolation  R: circular interpolation, clock wise III: G04
Y
G  
G90:  i t ti  R i   lid  d I  J   d K   i
instruction, R is valid and I, J, and K are invalid
lid S: point to point countering IV: G00
absolute  100 R50
coordinates R60
60
40
P Q R S P Q R S
X (a) II III I IV (b) I III II IV
O 90 120 140 200
(c) I IV II III (d) II I III IV
 GATE – 2007 (PI)
( ) GATE ‐ 2004 GATE ‐ 2010
The
Th interpolator
i t l t in
i a CNC machine
hi controls
t l During
D i the h execution
i off a CNC part program block
bl k In
I a CNC program block,bl k N002
N G02
G G91
G X40X Z40…,
Z
(a) Spindle Speed (b) Coolant flow N020 G02 X45.0
45 Y25.05 R5.0
5 the type
yp of tool motion will G02 and G91 refer to
be (a) Circular interpolation in counterclockwise direction
(c) Feed rate (d) Tool change
(a) Circular Interpolation – clockwise and incremental dimension
(b) Circular Interpolation ‐ counter clockwise (b) Circular interpolation in counterclockwise direction
(c) Linear Interpolation andd absolute
b l d
dimension
(d) Rapid
R id feed
f d (c) CCircular
cu a interpolation
te po at o in cclockwise
oc se d
direction
ect o aandd
incremental dimension
(d) Circular
Ci l interpolation
i t l ti i clockwise
in l k i direction
di ti andd
absolute dimension

IES ‐ 2009 GATE 2015

GATE-2015 GATE ‐ 2001
The function of CNC machine controller is to In
I an NC machining
hi i operation,
i the
h tooll has
h to beb
Interpolation in the controller refers to control of
a) Control spindle speed moved from point (5, 4) to point (7, 2) along a
which
h h one off the
h following
f ll in a CNC machine?
h circular path with centre at (5, 2). Before starting the
b)Coordinate feed rates of axes p
operation, , the tool is at (5, 4)
4). The correct G and M
( ) Loading/unloading
(a) L di / l di off jobs
j b on machine
hi
c) Control tool rapid approach speed code for this motion is
(b) Loading/unloading
L di / l di off tools
t l from
f th tool
the t l changer
h (a) N010 G03 X7.0
X 0 Y2.0
Y2 0 I5.0
I 0 J2.0
J2 0
d)Perform miscellaneous(M) functions (tool change,
(b) N010 G02 X7.0 Y2.0 I5.0 J2.0
(c) Axes of machine for contouring coolant control etc.) (c) N010 G01 X7.0 Y2.0 I5.0 J2.0
(d) Coolant and miscellaneous functions on machine (d) N010
N G X7.0
G00 X Y
Y2.0 I
I5.0 J
J2.0

GATE-2015
GATE 2015
GATE ‐ 2005 In a CNC milling operation, the tool has to machine GATE‐2014 (PI)
The
Th tooll off an NC machine hi has
h to move alongl a the circular arc from point (20, 20) to (10, 10) at a
circular arc from (5, 5) to (10,10) while performing an A CNC instruction G91G01X30Y40F100 commands the
operation. The centre of the arc is at (10, 5). Which sequence number 5 of the CNC part program. If the movement of tool along the path at a feed rate of 100
one of the following g NC tool p path commands
center of the arc is at (20,
(20 10) and the machine has
performs the above mentioned operation? mm/min (G91‐ incremental format and G01‐ linear
(a) N010G02 X10 Y10 X5X Y5
Y R5R incremental mode of defining position coordinates, interpolation) The feed rate of the tool (in mm/min)
interpolation).
(b) N010G03 X10 Y10 X5 Y5 R5 the correct tool p
path command is along the X axis will be _______
(c) N010G01 X5 Y5 X10 Y10 R5 a) N05 G90 G01 X‐10 Y‐10 R10
(d) N010G02
N G X5 X Y5
Y X10
X Y10Y R5 R b)N05 G91 G03 X‐10 Y‐10 R10
c) N05 G90 G03 X20 Y20 R10
d)N G90
d)N05 G G02
G X20
X Y20Y R10
R
 p
Tool Compensation p
Tool‐Radius Compensation p
Cancel Tool Compensation: G40
y Tool‐radius compensations make it possible to 
y Tool‐Radius Compensation 
oo Rad us Co pe sat o program directly from the drawing, and thus eliminate 
program directly from the drawing  and thus eliminate  y Note the difference between two ways
y Left hand G41  the tool‐offset calculation 
y Right hand G42  N0060 G01 X2.000 Y1.700
X2 000 Y1 700
G  (G ) D
G41 (G42) D×× N0060 G40 G01 X2.000 Y1.700 M02
N0070 G40 M02
y Cancel tool‐radius compensation G40 y D××: the radius of tool to compensate is saved in a memory unit that 
is named D××
y Tool‐Height Compensation y G41/G42 is directly related with direction of tool movement and 
which side of part is cut. 
y Positive G43 
os e G43
y Negative G44 
y Cancel tool‐height compensation G49
Cancel tool height compensation G49
ramp off block effective to the end point

GATE ‐ 2000 GATE 2014

GATE ‐
In
I finish
fi i h machining
hi i off an island
i l d on a casting i with
ih For machining a rectangular island represented by g p
Tool‐Height Compensation
CNC milling machine, an end mill with 10 mm coordinates P(0, 0), Q(100, 0), R(100, 50) and S(0, 50) on
diameter is employed. The corner points of the a casting
ti using i CNC milling
illi machine,hi an end d mill
ill with
ith a G43 (G44) H××
p
island are represented by
y ((0,, 0),
), ((0,, 330),
), (5
(50,, 330),
), and diameter of 16 mm is used. The trajectory of the cutter
y H××: specified memory unit used to save height 
(50, 0). By applying cutter radius right center to machine
h the
h island
l d PQRS is compensation of tool.
compensation the trajectory of the cutter will be
compensation, (a) ((–8,
8, –8),
8), (108, – 8), (108, 58), ((–8,
8, 58), ((–8,
8, –8)
8) y Positive compensation (G43):  
(a) (‐5, 0), (‐5, 35), (55, 35), (55, ‐5), (‐5, ‐5) (b) (8, 8), (94, 8), (94, 44), (8, 44), (8, 8) real position = specified position + value saved in H××
(b) (0, ‐5), (55, ‐5), (55, 35), (‐5, 35), (‐5, ‐5) ( ) (–8,
(c) ( 8),
) (94,
( 0),
) (94,
( 44),
) (8,
( 44), ) (–8,
( 8)) y Negative compensation (G44): 
(c) (5,
(5 5),
5) (5,
(5 25),
25) (45,
(45 25),
25) (45,
(45 5),
5) (5,
(5 5) (d) (0, 0), (100, 0), (100, 50), (50, 0), (0, 0) real position = specified position ‐
p p p value saved in H××

(d) (5, 5), (45, 5), (45, 25), (5, 25), (5, 5)

Table of Important M codes GATE ‐ 2009 

Tool‐Height Compensation
Tool‐Height Compensation y M00 Program stop
y Example: y M01 Optional program stop
y N0010   G91  G00  X12.0   Y80.0  G91:  y M03 Spindle on clockwise
y N0020   G44   Z‐32.0  H02；
N    G    Z   H iincremental 
t l  y M04 Spindle on counterclockwise
M  S i dl     t l k i
coordinates
y M05 Spindle stop
y If we put 0.5mm into H02,  y M06 Tool change
y real position = ‐32.0 ‐
p 3 0.5 = ‐32.5
5 3 5 y M08 Coolant on
y M09 Coolant off
y Cancel tool‐height compensation: G49 y M10 Clamps on
y M11 Clamps off
y M02 or M30 Program stop, reset to start
M    M  P        
 GATE 2016
GATE‐2016
Match the following part programming codes with their 
respective functions. Block Format
Block Format
Part Programming 
g g Functions N135 G01 X1.0 Y1.0 Z0.125 F5 Sequence and format of words:

Codes Sample Block N3     G2      X+1.4      Y+1.4      Z+1.4      I1.4     J1.4     K1.4       F3.2       S4      T4      M2

• Restrictions on CNC blocks
P  G01
P. G01 I  Spindle Stop
I. Spindle Stop • Each may contain only one tool move
• Each may contain any number of non-tool move G-codes sequence no destination coordinates dist to center of circle tool
Q. G033
Q II. Spindle rotation, clockwise
p , • Each mayy contain onlyy one feed rate
• Each may contain only one specified tool or spindle speed feed rate spindle speed
preparatory function
R. M03 III. Circular interpolation,  • The block numbers should be sequential
• Both the program start flag and the program number must be miscellaneous function
i ll  f ti
anticlockwise
i l k i independent of all other commands (on separate lines)
• The data within a block should follow the sequence shown
S. M055 IV. Linear interpolation
p in the above sample block

(a)P‐II, Q‐I, R‐IV, S‐III
Q (b) P‐IV, Q‐II, R‐III, S‐I
Q
(c) P‐IV, Q‐III, R‐II, S‐I (d) P‐III, Q‐IV, R‐II, S‐I

Programming Formats P i F t
Programming Formats Programming Formats
y TAB Sequential Format or interchangeable format
y Fixed
Fi d Block
Bl k Format
F
y Word Address Format or variable block format
Here the alphabets
p are replaced
p byy a Tab code,, which is In fixed block format no letter address of Tab code are
This type of format uses alphabets called address, inserted between two words. The MCU reads the first used and none of words can be omitted. The main
advantage of this format is that the whole instruction
identifying the function of numerical data followed. This Tab and stores the data in the first location then the block can be read at the same instant, instead of reading
format is used by
b most of the NC machines.
machines second
d word
d is recognized
d by
b reading
d the
h record
d Tab.
b Iff character
h t byb character.
h t All instructions
i t ti mustt be
b given
i i
in
every block, including those instructions which remain
N20 G00 X1.200
X1 200 Y0.100
Y0 100 F325 S1000 T03 M09 <EOB> the word remains same in the succeeding block,
block the
unchanged from the preceding blocks. This format can
The MCU uses this alphabet for addressing a memory word need not be repeated
p but TAB is required
q to onlyy be used for p
positioning
g work only.
y
maintain the sequence of words. 20 00 1.200 0.100 325 1000 03 09 <EOB>
location in it.
>20 >00 >1.200 >0.100 >325 >1000 >03 >09

IES ‐ 1993  IES ‐ 1996 Example 1

Example‐1
p g g g
Part program for Drilling three holes without using Canned 
A 'block'
'bl k' off information
i f i in
i N.C.
N C machine
hi program In
I manuall programmingi and d tape preparation
i for
f a Cycle.
means NC drilling machine, the spindle speed was coded
(a) One row on tape as S 684 (using the magic‐three code). The spindle
(b) A word comprising several rows on tape p
speed in rpm
p will be
(c) One complete instruction (a) 684
(d) One complete program for a job (b) 68.4
(c) 840
(d) 6840
 % real position = specified position + value saved in H××
N120 G00 Z2.0<EOB>(Rapid return to X55.00 Y50.0 Z2.0)
01001 <EOB> (Program number) N075 G00 X25.00 Y35.0 Z2.0 <EOB>(Rapid travel X25.0,
N130 X75.0
X75 0 Y70.0<EOB>(Rapid
Y70 0<EOB>(Rapid travel to X75.00Y70.0Z2.0)
X75 00Y70 0Z2 0)
N010 G92 X0 Y0 Z50 <EOB>(Absolute presetting at A) Y35.0, Z27.0 real position = 2 + 25)
N140 G01 Z-18.0 F125 <EOB>(X and Y not changing no
N020 G90 <EOB> (Absolute programming) N080 G01 Z-18.0 F125 <EOB> ((X and Y not changing g g no
needd so specify, if Z = -15
15 (thickness
(thi k off plate)
l t )-3
need so specify, Z = -15 (thickness of plate) - 3
N030 G71 <EOB> (Dimension in metric unit) (Breakthrough distance or cone height) G01-
((Breakthrough g distance or cone height)
g ) G01-
N040 T01 M06 <EOB> (Tool change, M06-Tool Change) li
linear iinterpolation
t l ti cutting
tti ffrom X75
X75.00
00 Y70
Y70.0 0
linear interpolation cutting from X25.00 Y35.0
N050 S500 M03 M07 M10 <EOB>
EOB (Speed 500 rpm, Z2.0 to X75.00 Y70.0 Z-18.0)
Z2.0 to X25.00 Y35.0 Z Z-18.0)
18.0)
M03 – Spindle on, CW N150 G00 Z2.0<EOB>(Rapid return to X75.00 Y00.0 Z2.0)
N090 G00 Z2.0<EOB>(Rapid return to X25.00 Y35.0 Z2.0)
N160 M05 M09 <EOB>(M05 – spindle off off, M09 – Coolant off)
M04 – Spindle
S i dl on, CCW N100 X55
X55.00 Y50
Y50.0<EOB>(Rapid
0 EOB (R id ttravell tto X55X55.00
00 Y50
Y50.0Z2.0)
0Z2 0)
M05 – Spindle stop) N170 X0 Y0 Z50<EOB> (Rapid travel to X75.00 Y00.0 Z2.0)
N110 G01 Z-18.0 F125 <EOB> (X and Y not changing no
need so specify, Z = -15 (thickness of plate) - 3 N180 M11 <EOB>
EOB (U l
(Unclamp) )
M07 – Coolant 1 on M10- Clamp on
N060 G49 <EOB> (Cancel tool
tool-height
height compensation) ((Breakthroughg distance or cone height)
g ) G01- N190 M30 <EOB> ((Program
g Stop) p)
linear interpolation cutting from X55.00 Y50.0
N070 G43 H25.00<EOB> (Positive compensation (G43) Z2.0 to X55.00 Y50.0 Z-18.0)

Example 2
Example‐2 F
Format
t off Canned
C d cycle
l %
p g g g y
Part program for Drilling three holes using Canned Cycle. N___G81 X___Y___Z___R___F___ 01001<EOB> (Program number)
N010 G92 X0 Y0 Z50<EOB> (Absolute presetting at A)
R is Position of the clearance plane (same as the zz- axis N020 G90 <EOB> (Absolute programming)
position of the clearance plane) N030 G71 <EOB> (Dimension in metric unit)
F is
i the
th feed
f d rate.
t N040 T01M06 <EOB> (Tool change, M06-Tool Change)
N050 S500 M03 M07 M10 <EOB>
EOB (Speed 500 rpm,
G80 is cancel Canned cycle M03 – Spindle on, CW
M04 – Spindle
S i dl on, CCW
M05 – Spindle stop)
M07 – Coolant 1 on M10- Clamp on
N060 G49 <EOB> (Cancel tool
tool-height
height compensation)
N070 G43 H25.00 <EOB> (Positive compensation (G43)

real position = specified position + value saved in H×× IFS‐2013 ‐ Conventional

N075 G00 X25.00
X25 00 Y35.0
Y35 0 Z2.0
Z2 0 <EOB> (Rapid travel X25
X25.0,
0 N010 G80 <EOB> Canned
C d Cycle
C l cancell Two holes are to be drilled with a 10 mm diameter drill on a 
Y35.0, Z27.0 real position = 2 + 25) job as shown below.
N120 M05 M09 <EOB>(M05 – spindle off
off, M09 – Coolant off) The drill rotates at 500 rpm and feed rate is 200 mm/min. 
h d ll df d
N080 G81 Z-18.0 R2.0 F125<EOB>(X and Y not changing
no need so specify, Z = -15
15 (thickness of plate) - N130 X0 Y0 Z50 <EOB>
EOB (Rapid travel to X75.00 Y00.0 Z2.0) How do you code the information in‐‐‐‐
3 (Breakthrough distance or cone height) G81- (i) Fixed block format
drill hole on X25
X25.00
00 Y35
Y35.0
0 Z2
Z2.0
0 to X25
X25.00
00 Y35
Y35.00 N140 M11 <EOB> (Unclamp) (ii) TAB sequential format
Z-18.0 and come back) N150 M30 <EOB> (Program Stop) (iii) Word address format
N090 X55.0 Y50.0<EOB>(Rapid travel to X55.00 Y50.0
Z2.0 and drill second hole and come back))
N100 X75.0 Y70.0 <EOB> (Rapid travel to X75.00 Y70.0
Z2.0) and drill third hole and come back)
 Answer: Answer: Answer:
(i) Fixed Block Format (ii) TAB sequential format (iii) Word address format
10 00 0.0 0.0 2.0 200 500 01 06 <EOB> 10 > 00 > 0.0 > 0.0 > 2.0 > 200 > 500 > 01 > 06 N010 G00 X0.0 Y0.0 Z2.0 F200 S500 T01 M06 <EOB>
20 00 15
15.0
0 20
20.0
0 22.0
0 200 500 01 03 <EOB> 20 > > 15
15.0
0 > 20
20.0
0 > > > > > 03 N020 X15.0 Y20.0 M03 <EOB>
30 01 15.0 20.0 -13.0 200 500 01 07 <EOB> 30 > 01 > > >-13.0 > > > > 07 N030 G01 X15.0 Y20.0 Z-13.0 M07 <EOB>
40 00 15.0 20.0 2.0 200 500 01 07 <EOB> 40 > 00 > > > 2.0 > > > > N040 G00 Z2.0 <EOB>
50 00 75.0 20.0 2.0 200 500 01 07 <EOB>
EOB 50 > > 75.0 > > > > > > N050 G00 X75X75.0
0 Y20
Y20.0
0 <EOB>
60 01 75.0 20.0 -13.0 200 500 01 07 <EOB> 60 > 01 > > >-13.0 > > > > N060 G01 Z-13.0 <EOB>
70 00 75
75.0
0 20
20.0
0 22.0
0 200 500 01 05 <EOB>
EOB 70 > 00 > > 0 0.0
0 > 22.0
0 > > > > 05 N070 G00 Z2.0 M05 <EOB>
80 00 0.0 0.0 2.0 200 0 01 09 <EOB> 80 > > 0.0 > > > >0.0 > > 09 N080 X0X0.0
0 Y0
Y0.0
0 M09 <EOB>

IES ‐ 1995  IAS‐2011 Main

Match List I with List II and select the correct answer In an NC drilling operation,
operation the tool tip is at location (‐
( V = π DN
using the codes given below the lists: 100, 0, 100). The datum (0, 0, 0) is left hand lower corner 32 = π × 0.010 × N
List I List II on top surface
f off the
h workpiece,
k i which
hi h is
i rectangular
l N = 1019 rpm
(A function connected (Associated parameter)
(300 mm x 300 mm x 1.5 mm thick). A thru' hole of 10
with NC m/c tool)
A. Interpolation 1. Tape preparation
mm diameter is to be drilled in the centre of the
workpiece. Using only rapid positioning and linear %
B Parity check
B. 2 Canned cycle
2.
C. Preparatory function 3. Drilling interpolation functions, write the program blocks, in O1001
D Point
D. P i t to
t point
i t control
t l 4. Contouring
C t i absolute mode.
mode N  G  X
N010 G92 X‐100.0 Y0.0 Z100.0 <EOB>
 Y  Z   EOB
5. Turning Assume permitted cutting speed = 32 m/min and feed N020 G90 G71 <EOB>
C d A
Code:A B C D A B C D rate = 150 mm/min. [10‐Marks] N040 T01 M06 <EOB>
(a) 4 1 2 3 (b) 4 1 2 5
N050 S1019 M03 M07 M10 <EOB>
( ) 5
(c) 1 3 2 (d) 1 4 3 2

IES 2016
IES‐2016
N060 G49 <EOB> A part programme for any arbitrary object is given as IFS 2011
N070 G43 H25.0 <EOB>
N070 G43 H25 0 <EOB> follows: How is Feed Rate Number (FRN) expressed?
N080 G00 X150.0 Y150.0 Z2.0 <EOB> N001 G91 G71 M03 S600 EOB
N090 G01 Z‐2.5 F150 <EOB> N002 G00 X10.00 Y10.00 EOB Answer: [
[2‐marks]
]
N100 Goo Z2 0 <EOB>
N100 Goo Z2.0 <EOB> N003 G00 Z
Z-10
10.00
00 EOB Feed rate ((mm/min))
Feed rate number =
N110 Mo5 Mo9 <EOB> N004 G83 Z-60.00 F100 EOB Distance of travel
Ex For a feed rate of 50 mm/min and a distance travel 66.0
Ex.For 0 mm
N120 X‐100.0 Y0.0 Z100.0 <EOB> N005 G80 EOB
50 mm/min
N130 G49M11 <EOB>
3 49 N006 M02 EOB Feed rate number = = 8.3min -1

6 mm
N140 M30 <EOB> The above programming format will be used as Canned
If the controlsystem accepts inverse time feed rate coding and a
Cycle for
four-digit feed rate field, then 50 mm/min will be expressed by F1 0083
(a) Drilling (b) Tapping
(c) Boring (d) Grooving
 APT Language W d
Words
y APT (Automatically
(A i ll Programmed
P d Tools)
T l )
y The words to be used in the statements are built up from
y The APT language consists of many different types of
statements made up of the following valid letters, numerals one to six letters
l or numerals
l with
h the
h first
f one being
b a
and ppunctuation marks.
letter No special character is allowed in the words.
letter. words
y Letters: ABCDEFGHIJKLMNOPQRSTUVWXYZ
y Numerals: 0 1 2 3 4 5 6 7 8 9
/ A slash divides a statement into two sections. eg., 
GO/PAST, 
,,  A comma is used as a separator between the elements in 
p
a statement generally to the right of the slash.
= An equals is used for assigning an entity to a symbolic 
name, e.g., P1 = POINT/25,50,30.

IES ‐ 1998 The complete APT part program consists of  Other Part Programming Languages

Which
Whi h off the h following
f ll i are theh rules
l off the following four types of statements
the following four types of statements y ADAPT (ADaptation
(AD i APT) was the
h first
fi attempt to adapt
d APT
programming system for smaller computers
programming NC machine tools in APT language?
y Geometry y AUTOSPOT (AUTOmatic
(AUTO ti Sytem
S t f POsitioning
for PO iti i T l ) was
Tools)
1. Only capital letters are used developed by IBM and first introduced in 1962
2 A period is placed at the end of each statement
2. y Motion  y EXAPT (EXtended subset of APT) was developed jointly in
German in about 1964 by several universities to adapt APT for
3. Insertion of space does not affect the APT word y Post processor p
European use. It is compatible
p with APT and thus can use the
same processor as APT
Select the correct answer using the codes given below:
y Compilation control y COMPACT was developed p byy Manufacturingg Data Systems,
y Inc.
( ) 1 and
(a) d2 (b) 2 and d3 (
(MDSI))
(c) 1 and 3 (d) 1 alone y SPLIT (Sundstrand Processing Language Internally Translated)
was developed
d l d by
b Sundstrand
S d d Corporation,
C i i
intended
d d for
f its
i own
machine tools
y MAPT (Micro‐APT)
(Mi APT) isi a subset
b t off APT,
APT to t be
b run on the th
microcomputers 159

Point (POINT)
APT Language
APT Language
APT Language Other capabilities of APT, the macro facility, with use variable argument as in a 
Oh   bili i   f APT   h  
FORTRAN subroutine, for example:
 f ili   i h    i bl      i    
A = POINT/ 3,4,5
P0 = POINT/0.0, 0.3, 0.1
Additional statements:
FROM/P0
¾ MACHIN/DRILL, 2 CALL/DRILL, X=1.0, Y=1.0, Z=0.1, DEPTH=0.7
¾ COOLNT/ y
CALL/DRILL,
/ , X=2.0,
, Y=1.0,
, Z=0.1,
, DEPTH=0.7
For example: COOLNT/MIST COOLNT/FLOOD COOLNT/OFF GOTO/P0 (3, 4, 5)

¾ FEDRAT/
when the definition of the macro DRILL is:
h  th  d fi iti   f th    DRILL i A
¾ SPINDL/ DRILL = MACRO/X, Y, Z, DEPTH
For example: SPINDL/ON SPINDL/1250, CCLW GOTO/X,Y,Z z
¾ TOOLNO/ GODLTA/0,0, -DEPTH
¾ TURRET/ GODLTA/0,0, DEPTH
TARMAC
¾ END x

160 161
 Point (POINT)
( ) Point (POINT)
( ) Point (POINT)
( )

B = POINT/ INTOF, L1, L2 y

E = POINT/ YLARGE, INTOF, C1, C2
D = POINT/ YSMALL, INTOF, L3, C1
D = POINT/ XSMALL, INTOF, L3, C1 E = POINT/ XLARGE, INTOF, C1, C2 y
C = POINT/ YLARGE, INTOF, L3, C1 F = POINT/ YSMALL, INTOF, C1, C2
C = POINT/ XLARGE, INTOF, L3, C1 C F = POINT/ XSMALL, INTOF, C1, C2 C1

E
L2

L3
B C1
L1
F C2
D

x x

Point (POINT) Line (LINE) Line (LINE)

P7 = POINT/ CENTER, C6 L4 = LINE/ PT6, 15, -30, 3

L1 = LINE/ P1, P2

y y
y
C6 PT6
P2

P7
P1
L4 (15, ‐30, 3)

L1

x x
x

Line (LINE)
( ) Line (LINE)
( ) Line (LINE)
( )
L12 = LINE/ P4, ATANGL, 20, XAXIS LIN = LINE/ SLOPE,
SLOPE SLOPE VALUE,
VALUE INTERC,
INTERC MODIFIER,
MODIFIER d
LIN = LINE/ POINT,
POINT ATANGL,
ATANGL ANGLE (in degrees),
degrees) LINE
L14 = LINE/ P1, ATANGL, 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
where the slope value is y/x. The modifier options are [XAXIS,
L16 = LINE/ P3, ATANGL, 40, YAXIS YAXIS] and d is the corresponding intercept value on the selected
YAXIS],
y
L2
axis (i.e., modifier).
y
P3 y
L14
P1

40°
P1 L12
L16 30° L1
L1
P4

L2 = LINE/ P1, ATANGL, 30, L1 
3 L1 = LINE/ SLOPE, 1, INTERC, XAXIS, 6
40° 20°
x
x
15°
15 x (6,0)  Point of X Intercept
(6,0)  Point of X‐Intercept
L15
(32, ‐3, 2)
 Line (LINE)
( ) Line (LINE)
( ) Line (LINE)
( )

LIN = LINE/ ATANGL,

ATANGL DEGREES,
DEGREES INTERC,
INTERC MODIFIER,
MODIFIER d L2 = LINE/ P5,
P5 RIGHT,
RIGHT TANTO,
TANTO C1
The LEFT & RIGHT modifier indicates whether the line
The modifier options are [XAXIS, YAXIS], and d is the L3 = LINE/ P4, RIGHT, TANTO, C1
is at the left or right
g tangent
g ppoint,, depending
p g on how
corresponding intercept value on the selected axis (i.e., modifier). L4 = LINE/ P4, LEFT, TANTO, C1
one looks at the circle from the point.
L3 Right
y
L1 = LINE/ P5, LEFT, TANTO, C1
P4
L1

L1 Left
L1

C1 Left L4
L1 = LINE/ ATANGL, 30, INTERC, d
θ = 30° P5 P5

x
Right L2
d

Line (LINE)
( ) Line (LINE)
( )
L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4
L6
IAS‐2012 Main
IAS‐2012 Main
L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3
C4
Left
C3
Right L6
Right
C4
L8 L9
C3
L7

Left
The descriptive words LEFT and RIGHT are used by L8 L9
In the above figure define the lines L1, L2, L3 and L4 in 
looking from the first circle written towards the L7
the APT language. [10 Marks]
second
d circle.
i l

Line (LINE)
( ) Line Plane (PLANE)
( )

L3 = LINE/ P6, PARLEL, L5 L5 = LINE/ INTOF, PL1, PL2 PL1 = PLANE/ P6, P12, P15
L4 = LINE/ P5,
P5 PERPTO,
PERPTO L3
L5
PL1
y P15

P6 P5
L3 P6 P12

L4 y 3.0

L5 PL1
L3 P4
z
PL2
PL2

x
x
 Plane (PLANE)
( ) Circle (CIRCLE) Circle (CIRCLE)

PL2 = PLANE/ P4, PARLEL, PL1

C1 = CIRCLE/ 3, 6, 5, 4.3 C3 = CIRCLE/ CENTER, P6, TANTO, L4
PL2 = PLANE/ PARLEL,
PARLEL PL1,
PL1 YSMALL,
YSMALL 3.0
30
C1 = CIRCLE/ CENTER, P3, RADIUS, 4.3 C7 = CIRCLE/ CENTER, P8, P5
PL1
y y y
P15
C1 L4
y P6 P12 P5
3.0 4.3

P3 P6 P8
P4
4 (3,6,5) C7
C3
z
PL2
x x x
x

The Machining Plan The Machining Plan The Machining

g Plan

Contouring: z
Check surface
y Part surface: the surface on which the end of the Drive surface CS CS CS

y
tool is riding.
riding
Direction of 
y Drive surface: the surface against
g which the edge
g of cutter cutter motion

the tool rides. x

DS DS DS

y Check surface: a surface at which the current tool

motion is to stop. Part surface
TO ON PAST

GOUP
The Machining Plan FROM/PTARG
GO/TO, L1, TO, PL2, TO, L3
Motion commands: GORGT/L3, PAST, L4
GOLFT
GOLFT/ : Move left along the drive surface GOFWD
GORGT/ : Move right along the drive surface
Present tool
GOUP/ : Move upp along
g the drive surface GOBACK position
p
GODOWN/ : Move down along the drive surface GORGT
GOFWD/ : Move forward from a tangent position
GODOWN
GOBACK/ : Move
M b k d from
backward f a tangent
t t position
iti

Previous
tool position
 Machining Specifications Machining Specifications Machining Specifications
Postprocessor commands for a particular machine tool are: FEDRAT/ : specifies the feed rate for moving the tool along the TOLERANCE SETTING: Nonlinear motion is accomplished in
MACHIN/ : used d to
t specify if the
th machine
hi t l and
tool d call
ll the
th part surface
f i inches
in i h per minute:
i straight-line
straight line segments,
segments and INTOL/ and OUTTOL/ statements
postprocessor for that tool: dictate the number of straight-line segments to be generated.
FEDRAT/ 4.5
MACHIN/ DRILL, 3 INTOL/ 0.0015
SPINDL/ : gives the spindle rotation speed in revolutions per
COOLNT/ : allows the coolant fluid to be turned on or off: OUTTOL/ 0.001
minute:
i
COOLNT/ MIST SPINDL/ 850
COOLNT/ FLOOD TURRET/ : can be used to call a specific tool from an automatic
COOLNT/ OFF t l changer:
tool h
TURRET/ 11

Machining Specifications Machining Specifications

PARTNO: identifies the part program and is inserted at the start of FINI: specifies the end of the program.
APT Language
APT Language
Other Motion statements:
the program.
program ¾ GO/{TO}, Drive surface, {TO} Part surface, {TO},
Check surface
CLPRNT: indicates that a cutter location printout is desired. Or
CUTTER: specifies a cutter diameter for offset (rough versus finish ¾ GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
cutting).
g) If a milling
g cutter is 0.5 in. in diameter and we have …And the same with PAST or ON instead of TO
¾ GOLFT/
CUTTER/ 0.6 ¾ GORGT/
¾ GOUP/
then the tool will be offset from the finish cut by 0.05 in. ¾ GODOWN/
¾ GOFWD/
¾ GOBACK/
For example:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST L1
GO/PAST, L1, TO,
TO PS PS, TANTO
TANTO, C1

195

30 40
Answer:
IES‐2008
Name the four types of statements in a complete APT
20

L2
P5
C1
PARTNO CONTOUR
L3 20 MACHIN/MILL,, 1
R
part program. Prepare part program for geometry 135°
P3
CLPRNT
p4 UNITS/MM
p
description of the contour shown in the figure
g below:
Y P0 = POINT/0
POINT/0.0,
0 0.0,
0 0 0.0
00
[15‐Marks] L4
P1 = POINT/110.0, 20.0, 0.0
30 40 80 L1 P2 = POINT/20.0, 20.0, 0.0
20 C2 P3 = POINT/90.0, 110.0, 0.0
L5 P4 = POINT/20.0, 100.0, 0.0
L2
L3
C1 20
20 R P1 P5 = POINT/50
POINT/50.0,
0 130.0,
130 0 0.0
00
R P2 20
135° L1 = LINE/P2, ATANGL, 90, XAXIS
X
L2 = LINE/P4, ANTNGL, 45, XAXIS
L4 L3 = LINE/P5, ATANGL, 135, L2
80 L1
L4 = LINE/P1, PERPTO, L3
L5 = LINE/P1,
LINE/P1 PERPTO,
PERPTO L4
C2
C1=CIRCLE/CENTER, P3, RADIUS, 20.0
L5
20 C2=CIRCLE/CENTER, P1, RADIUS, 20.0
R P1
P2 20 PL1=PLANE/P1, P2, P3
X
 Contd…. Contd….
CUTTER/25.0 RAPID IES‐2007
Prepare part using APT language for milling the contour
TOLER/0.1 GOTO/P0
INTOL/0.05 COOLNT/OFF shown in Fig. in a single pass. D [20‐Marks]
OUTTOL/0.05 SPINDL/OFF C 110

FEDRAT/200 END R30

B
SPINDL/500, CLW FINI Q
COOLNT/ON
FROM/P0
GO/TO, L1, TO, PL1, TO, L5 110
GOLFT/L1, PAST, L2 120

GORGT/L2, PAST, L3
GORGT/L3 TANTO,
GORGT/L3, TANTO C1
E
+

+
R40
GOFWD/C1, PAST, L4 40

GOFWD/L4 PAST,
GOFWD/L4, PAST C2 A F
GORGT/C2, PAST, L5 100 + 40 P

+
GORGT/L5, PAST, L1 Material : M S.

8 mm

Answer: Contd….
PARTNO CONTOUR CUTTER/25.0
MACHIN/MILL, 2 TOLER/0.1
CLPRNT INTOL/0.05
UNITS/MM OUTTOL/0.05
P0 = POINT/
POINT/-50.0,
50.0, -50.0,
50.0, 0.0
FEDRAT/200
A = POINT/0.0, 0.0, 0.0
B = POINT/0.0, 120.0, 0.0 SPINDL/500, CLW
C = POINT/30.0,
POINT/30 0 150.0,
150 0 0.0
00 COOLNT/ON
D = POINT/140.0, 150.0, 0.0 FROM/P0
E = POINT/140.0, 40.0, 0.0 GO/TO, LAB, TO, PL1, TO, LAF
F = POINT/100.0, 0.0, 0.0 GOLFT/LAB, TANTO, CBC
Q = POINT/30.0, 120.0, 0.0
GOFWD/CBC, PAST, LCD
P = POINT/140.0, 0.0, 0.0
GOFWD/LCD PAST,
GOFWD/LCD, PAST LDE
LAB = LINE/A, B
LCD = LINE/C, D GORGT/LDE, PAST, CEF
LDE = LINE/D,
LINE/D E GORGT/CEF PAST,
GORGT/CEF, PAST LAF
LAF = LINE/A, F GORGT/LAF, PAST, LAB
CBC = CIRCLE/CENTRE, PTQ, RADIUS, 30.0
CEF = CIRCLE/CENTRE, PTP, RADIUS, 40.0
PL1=PLANE/A, B, C

C2
R30
Y L2 •
Contd…. P3
C1
RAPID IES‐2006
Prepare part program to machine the contour shown in
R20
•
GOTO/P0 P2
COOLNT/OFF the figure using APT on CNC milling machine. L3
SPINDL/OFF
R30
5
[15‐Marks] 100 mm
END • L1
80
FINI
R20
•

X
100 mm 60 50
P1 L4 P4
80 200 mm

60 50
200 mm

Material: MS Thickness: 8.0 mm

 C2
R30
Y L2 •
P3 Contd…. Contd….
C1
R20 CUTTER/25.0 RAPID
Answer: •
P2 TOLER/0.1 GOTO/P0
PARTNO CONTOUR INTOL/0.05 COOLNT/OFF
L3
MACHIN/MILL, 3 OUTTOL/0.05 SPINDL/OFF
100 mm
CLPRNT COOLNT/ON END
80 L1
UNITS/MM SPINDL/500, CLW FINI
P0 = POINT/-50
POINT/-50.0,
0 -50.0,
-50 0 0.0
00 FEDRAT/200
P1 = POINT/0.0, 0.0, 0.0 FROM/P0
P2 = POINT/60.0,, 80.0,, 0.0 X GO/TO, L1, TO, PL1, TO, L4
P3 = POINT/150.0, 100.0, 0.0 50 GOLFT/L1, TANTO, C1
P1 60 L4 P4
P4 = POINT/200.0, 0.0, 0.0 200 mm GOFWD/C1, PAST, L2
C1 = CIRCLE/ CENTER, P2, RADIUS, 20 GOFWD/L2 TANTO,
GOFWD/L2, TANTO C2
C2 = CIRCLE/CENTER, P3, RADIUS, 30 GOFWD/C2, PAST, L3
L1 = LINE/P1,
LINE/P1 LEFT,
LEFT TANTO,
TANTO C1 GOFWD/L3 PAST,
GOFWD/L3, PAST L4
L2 = LINE/LEFT, TANTO, C1, LEFT, TANTO, C2 GORGT/L4, PAST, L1
L3 = LINE/P4,, RIGHT,, TANTO,, C2
L4 = LINE/P1, P4
PL1=PLANE/P1, P2, P3

Home Work PARTNO CONTOUR
/
MACHIN/MILL, 1,
L1 = LINE/RIGHT, TANTO, C1, RIGHT, TANTO, C3
L2 = LINE/LEFT, TANTO, C1, LEFT, TANTO, C2
Write a complete part program in APT for machining
CLPRNT C4=CIRCLE/XLARGE, OUT, C2, OUT, C3, RADIUS, 62
the product which is given in the diagram. Thickness of
th workpiece
the k i i 6 mm. All dimensions
is di i are in
i mm. UNITS/MM PL1 PLANE/P1, P2, P3
PL1=PLANE/P1, P2, P3
REMARK POSTPROCESSOR STATEMENT FOLLOW
[15] P0 = POINT/‐25.0,‐25.0, 25.0
CUTTER/50 0
CUTTER/50.0
P1 = POINT/0.0, 0.0, 6.0
TOLER/0.01
P2 = POINT/117 0  32 0  6 0
P2 = POINT/117.0, 32.0, 6.0 INTOL/0.05
P3 = POINT/117.0, ‐32.0, 6.0 OUTTOL/0.05
C1=CIRCLE/CENTER, P1, RADIUS, 10.0 FEDRAT/200
C2=CIRCLE/CENTER, P2, RADIUS, 12.5
/ , , , 5 SPINDL/1000, CLW
C3=CIRCLE/CENTER, P3, RADIUS, 12.5 COOLNT/ON

REMARK MOTION STATEMENT FOLLOW
FROM/P0
GO/TO, L1, TO, PL1, TANTO, C1 IES 2011 Conventional IES ‐ 1997
GORGT/L1, TANTO, C3
GORGT/L  TANTO  C State the method of defining line segment of Which
Whi h off the h following
f ll i are valid
lid statements forf
GOFWD/C3, TANTO, C4 point to point motion of the tool in APT language?
GOFWD/C4, TANTO, C2
cutter
tt motion
ti using
i APT program format.
f t
1. GO/TO/............
GOFWD/C2, PAST, L2 [5 Marks] 2 GO DLTA/............
2. DLTA/
GOFWD/L2, TANTO, C1
3. GO/TO, ……….
GOFWD/C  PAST  L
GOFWD/C1, PAST, L1
Select the correct answer using the codes given below:
RAPID
GOTO/P0
( ) 1 and
(a) d2 (b) 2 and d3
COOLNT/OFF (c) 1 and 3 (d) 1, 2 and 3
SPINDL/OFF
END
FINI
 IES ‐ 1995 GATE 2008 (PI)
GATE ‐2008 (PI)
In
I APT language,
l the
h cutter motion
i in
i incremental
i l Suppose point P1 in APT programming is coded by statement Robotics
coordinate mode is addressed as P1 = POINT/XSMALL, INTOF, LN1, CR1
(a) GO/TO/..... The
h coded
d d geometric situation without
h causing error is

(b) GO/TO.....
GO/TO
(c) GO DLTA/....
(d) GO FWD/...

What is an industrial robot?
IES‐2017 Syllabus
IES‐2017 Syllabus Origin of the word  ROBOT
Origin of the word ‘ROBOT’ A robot is a reprogrammable, multifunctional
y Robotics  y Origin of the word ‘robot’
robot can be traced in the Czech
p
manipulator designed
g to handle material,, pparts,, tools or
specialized devices through variable programmed
y Robot Classification word ‘robota’, which means ‘forced’ or compulsory
p y motions for the performance of a variety of tasks.
tasks
y Robot Specification, notation
p , labour.

y Direct and Inverse Kinematics 

y Homogeneous Coordinates and Arm Equation of four 
Axis SCARA Robot

History of Robots Indian Scenario

Indian Scenario  Indian Scenario 
y Centre for Artificial Intelligence and Robotics (CAIR) is a
laboratory of the DRDO develops NETRA, an y Defence
f robot
b ‘Daksh’
‘ k h’ by
b DRDO
y 1954‐ Devol & Engleburger – establish Unimation
Unmanned Aerial Vehicle ((UAV).
) It is mainlyy a y It is an electrically
y p
powered and
Incorporation. surveillance robot. remote controlled robot which is
used to locate,
locate handle and destroy
y 1961‐ Robots are used in die casting application.
risky objects safely.
y 1968‐ AGVs (automated
( d guided
d d vehicles)
h l ) implemented.
l d y The main role of this military robot is
to recover improvised
p explosive
p
y 1970‐ Stanford
S f d arm developed.
d l d devices.
y 1979‐ SCARA robot
b t for
f assembly
bl developed
d l d in
i Japan.
J y This
Thi robot
b t can even climb
li b stairs.
t i
Moreover, it can also scan objects
using its portable X‐ray Device. Used
for Bomb disposal also.
 Indian Scenario  Indian Scenario
Indian Scenario 
y Developments
eve op e ts related
e ated to robotics
obot cs from
o tthe
eN S
NISTEP
(National Institute of Science and Technology
MCQ
y DRDO labs to develop military robots for next gen
Policy) 2030 report: Which of the following is a flying robot?
warfare and would be deployed in difficult warfare zones y By 2013‐2014 — Agricultural robots (a) PUMA
y By 2013‐2017 — Robots that care for the elderly (b) KUKA
like the LoC with the abilityy to differentiate between a (c) NETRA
y By 2013 – 2020 ‐ Nano robot
(d) SCARA
y By 2015 — To have one third of its fighting capacity
threat and friend.
friend
provided by robots
y By 2017 ‐Medical
Medical robots performing low
low‐invasive
invasive surgery
y By 2017‐2019 — Household robots
y By 2035 — To have first completely autonomous robot
soldiers on the battlefield

What Can Robots Do?
Ad t fR b t
Advantages of Robots Di d t fR b t
Disadvantages of Robots
y Robotics and automation can, in many situation, increase y Robots lack capability to respond in emergencies, this can cause:
productivity, safety, efficiency, quality, and consistency of – Inappropriate and d wrong responses
products – A lack of decision‐making power Industrial Robots
– A loss of power
y Robots
b h
have repeatable
bl precision at all
ll times – Damage to the robot and other devices •Material handling
y Robots can work in hazardous environments (Painting, welding, – Human injuries •Material transfer
h dli toxic
handling i materials,
i l handling
h dli explosive)
l i ) y Robots
b may have
h l
limited
d capabilities
bl in •Machine loading and/or unloading
y Remote areas (Deep sea, space and other planets) – Degrees of Freedom •Spot welding
– Dexterity •Continuous
C ti arc welding
ldi Material Handling 
y Robots work continuously without any humanity needs and – Sensors Manipulator
illnesses, need no environmental comfort. •Spray coating
– Vision systems Assembly
•Assembly
y R b
Robots can be
b much h more accurate than
h humans,
h they
h may have
h – Real‐time Response
•Inspection
mili‐ or micro inch accuracy due to sensors. y Robots are costly, due to
y R b t can process multiple
Robots lti l stimuli
ti li or tasks
t k simultaneously,
i lt l – Initial cost of equipment
humans can only one. – Installation Costs
– Need for peripherals Assembly 
y Robots replace human workers who can create economic – Need for training Manipulator
problems – Need for Programming Spot Welding 
Manipulator

Ai
Asimov's three laws of robotics
' h l f b i
MCQ IES‐Conventional First law (Human safety):
Which of the following places would be LEAST  Briefly describe some of the similarities between a  y A robot may not injure a human being, being or,
or through
robot and an NC machine. inaction, allow a human being to come to harm.
likely to include operational robots?
y p
S
Second d law
l (R b
(Robots are slaves):
l )
(a) warehouse
y A robot must obey y orders ggiven it byy human beings,
g,
(b) factory except where such orders would conflict with the First
( ) h
(c) chemical research laboratories
l hl b Law.
Law
Third law (Robot survival):
(d) private homes
y A robot must protect its own existence as long as such
protection does not conflict with the First or Second
Law.
 Subsystems of Industrial Robots Actuators
Anatomy of Robot
Anatomy of Robot y Actuators y Actuators are basically prime movers providing both
force and motion.
y Anatomy and Sub‐System of robots
Anatomy and Sub System of robots y Transmission systems
T i i   t y Pneumatic cylinders, hydraulics, permanent magnet
y Manipulators y Power supplies & power storage system motors,, stepper
pp motors,, linear motors are some
conventional actuators.
y Robot control y Sensors
y More
M advanced
d d ones are based
b d on hi‐tech
hi t h polymers,
l
y Microprocessors & controllers shape memory alloys, piezo patches, and pneumatic
muscles.
y Algorithms & software (higher level & lower level)
y Brushless servo motors also exist for low noise levels,
and printed armature motors are used for quick
response.
response

T
Transmission Systems
i i S P
Power Supplies
S li S
Sensors and Electronics
d El i
y The transmission system used in robot to transmit power y Hydraulic and Pneumatic power packs:
y The sensors for feedback in robots consists of
and motion consists of chains, timing belts, metal belts, These consist of a motor driving a positive displacement
cables
bl and d pulleys
ll andd linkages.
li k pump or compressor to generate the h high
h h pressure fluid
fl d flow.
fl t h
tachometers
t and
d encoders
d and
d potentiometers
t ti t t sense
to
y Gear boxes and harmonic drives serve to p provide speed
p In using hydraulic systems the necessity of having an oil tank
motor motions
motions, simple switches
switches, force sensors
sensors,
reduction. increases the weight of the system, additionally the issue of
ensuring that the oil is free of contaminants is to be handled. acceleration sensors, optical
p systems,
y special
p cameras
y Ball
B ll screws are usedd with
ith suitable
it bl mechanisms
h i t convertt
to In pneumatics power pack dry air is desired.
rotary motion to linear motion and if needed back to and vision systems.
y Electric motors:
oscillatory motion.
It use what ate known as PWM (pulse width modulation)
y Drive stiffness is an important consideration in robotics amplifiers These are electronic devices,
amplifiers. devices consisting of
and so also is backlash. transistors used as switches to rapidly switch on and off the
supply
l in
i a controlled
t ll d manner to t control
t l motor
t speeds.d Such
S h
drives have higher efficiency.

S
Sensors and Electronics
d El i Software
MCQ y The software used consists of several levels.
y Electronics y Motor control software consists of algorithms which help
What is the name for information sent from robot the servo to move smoothly utilizing the data from feed
feed‐
There are a host of electronic circuits, motor controllers,
sensors to robot controllers? back units.
( ) 
(a) temperature analog to digital converters and digital to analogue y At the
th nextt level
l l there
th i software
is ft t plan
to l theth trajectory
t j t
(b) pressure converters, frame grabbers and so on utilized to handle of the end effector and translate the same into
(c) feedback commands to individual motor controllers.
( ) g
(d) signal sensors and vision systems and convert the inputs from y The output of sensors is also to be interpreted and
them into a form usable by the processor for control of decisions made.
y At
A theh highest
hi h l l there
level h i software
is f which
hi h accepts
the entire system in conjunction with the algorithms and
commands from the user of the robot and translates it
software developed specifically for the purpose. into appropriate actions at the lower level.
 Manipulators The relationships among the five major systems that make
y The mechanical unit,
unit often called the "arm
arm," that MCQ p an industrial robot are shown in this diagram.
up g
does the actual work of the robot.
Which of the following terms is NOT one of the
y It is composedd off mechanical
h l linkages
l k andd joints with
h five basic parts of a robot?
actuators to drive the mechanism directlyy or
(a) peripheral tools
indirectly through gears, chains, or ball screws.
(b) end effectors
y Manipulator are built as serial chains or parallel
(c) controller
chains or occasionally a combination of both.
(d) drive and sensor
y Links and joints (revolute
( and prismatic)) that are
mostlyy used in manipulators.
p
y In spatial manipulators (open chains) adjacent axes
are parallel or perpendicular to each other.
other

Wrist Configurations
Robot control
Robot control IES Conventional
IES Conventional
For control of the robot we have several levels: Name the basic components of all robots  Write in 
Name the basic components of all robots. Write in  y Wrist assembly is attached to end‐of‐arm
Wrist assembly is attached to end of arm
y End effector is attached to wrist assembly 
y Control of individual motors and actuators.
Control of individual motors and actuators short about welding robot.  
g
yFFunction of wrist assembly is to orient end effector 
i   f  i   bl  i     i   d  ff  
y Planning trajectory & individual actuators in motion.
g j y [5 Marks] y Body‐and‐arm determines global position of end 
effector
y Planning trajectories of end effector. y Two or three degrees of freedom:
g
y Roll 
y Acting upon sensors input
y Pitch
y Planning tasks y Yaw

E d Eff
End Effectors
MCQ y The special tooling for a robot that enables it to  Grippers and Tools
Grippers and Tools
Which of the following terms refers to the perform a specific task
rotational motion of a robot arm? y Two types:
(a) swivel y Grippers – to grasp and manipulate objects (e.g., 
to grasp and manipulate objects (e g  
(b) retrograde parts) during work cycle
( ) roll
(c) ll y Tools –
Tools  to perform a process, e.g., spot welding, spray 
to perform a process  e g  spot welding  spray 
painting
((d)) yyaw
 R b tC t lS t
Robot Control Systems
IES 2010 Conventional
IES 2010 Conventional Joint Drive Systems
Joint Drive Systems y Limited sequence control –
q p p
pick‐and‐place 
operations using mechanical stops to set positions
y Electric
What are a manipulator, wrist and end y Playback with point‐to‐point control –
Playback with point to point control  records 
y Uses electric motors to actuate individual joints
effectors for a robot ? work cycle as a sequence of points, then plays back 
y Preferred drive system in today's robots
y y
th  
the sequence during program execution
 d i     ti
y Hydraulic
y Playback with continuous path control –
y p
y Uses hydraulic pistons and rotary vane actuators
greater memory capacity and/or interpolation 
y Noted for their high power and lift capacity
p y p ( p
capability to execute paths (in addition to points))
y Pneumatic
y Intelligent control – exhibits behavior that makes 
y Typically limited to smaller robots and simple material 
yp y p
it seem intelligent  e g  responds to sensor inputs  
it seem intelligent, e.g., responds to sensor inputs, 
transfer applications
makes decisions, communicates with humans

Degrees of Freedom D
Degrees of Freedom (contd.)
fF d ( td ) D
Degrees of Freedom (contd.)
fF d ( td )
y A total of six degrees of freedom is needed to locate a ¾ The radial traverse: is the extension and retraction
y The degree of freedom or grip of a robotic system can be
robot’s hand at any point in its work space. of the arm or the in‐and‐out motion relative to the
compared to the way in which the human body moves. y Although
g six degrees
g of freedom are needed for base.
y For each degree of freedom a joint is required. maximum flexibility, most robot employee only three to ¾ The vertical traverse: provides the up‐and‐down
g
five degrees of freedom.
motion
ti off the
th arm off the
th robotic
b ti system.
t
y The degrees of freedom located in the arm define the y The more the degrees of freedom, the greater is the
y The three degrees of freedom located in the wrist,
configuration.
fi ti complexity of motions encountered.
encountered
which bear the names of aeronautical terms, are
y The three degrees of freedom located in the arm of
y Each of the five basic motion configurations utilizes three ¾Pitch or bend: is the upup‐and‐down
and down movement of the
a robotic
b i system are:
degrees of freedom in the arm. wrist.
¾The e rotational
otat o a reverse:
eve se: iss tthee movement
ove e t o
of tthee aarm
¾Yaw:
Y i the
is h right‐and‐left
i h d l f movement off the
h wrist.
i
y Three degrees of freedom located in the wrist give the end assembly about a rotary axis, such as left‐and‐right
swivel of the robot
robot’ss arm about a base.
base ¾Roll or swivel: is the rotation of the hand.
effector all the flexibility.

MCQ Types of Robot (Based on Coordinate axis)
y Cartesian
C t i or Gantry
G t
The number of moveable joints in the base, the robot(3P):
arm, and the end effectors of the robot determine? y It's
I ' a robot
b whose
h arm
has three prismatic
( ) degrees
(a) d off freedom
f d joints whose axes are
joints,
coincident with a
(b) payload capacity Cartesian coordinator.
coordinator
y Used for pick and place
((c)) operational
p limits work
work, application of
(d) flexibility sealant, assembly
operations
operations, handling
machine tools and arc
welding.
 Types of Robot
y Cylindrical
C li d i l
robot(R2P):
y It's a robot whose axes
form a cylindrical
coordinate system.
y Used for assembly y
operations, handling at
ac e too
machine tools,
s, spot
welding, and handling
at die casting
machines.

IES 2016
IES‐2016 Types of Robot Types of Robot
Types of Robot
A Cylindrical Robot can reach any point in a cylinder of p p
Articulated or Revolute or Anthropomorphic (3 )
Robot(3R):
y Spherical
S h i l or Polar
P l
a height
g L and radius 2L, except
p for the p
points in an robot(2RP): y It's a robot whose arm
y It's a robot whose axes has at least three
inner cylinder of height L and radius L. The volume for form a polar coordinate rotary joints.
the Cylindrical Robot work envelope will be system.
y Used for assembly
y Used for handling g at operations die casting,
operations, casting
(a) 9.42 L3 (b) 6.24 L3 machine tools, spot fettling machines, gas
welding,
e d g, diecasting,
d ecast g, welding arc welding
welding,
9 12 L3
( ) 9.12
(c) 9 86 L3
(d) 9.86
fettling machines, gas and spray painting.
welding and arc
welding. y Needs smaller
workspace
y Ex. PUMA560

These five revolute (5R) joints Types of Robot

Types of Robot y This is an example of
are associated with the basic y SC R robot(2R1P)
SCARA obot( R ) a basic SCARA robot
manipulator movements of a y The SCARA acronym stands configuration.
vertically articulated robot.
robot f
for S l ti
Selective C
Compliant
li t Assembly
A bl y Note the three rotary
Robot Arm or Selective Compliant joints and the single
Articulated Robot Arm. vertical joint used in
y It
It'ss a robot which has two parallel this horizontally
rotary joints to provide compliance articulated
in a plane g
configuration. (3R1P))
(3
y Can move very fast.
y Used for pick and place work,
application of sealant, assembly y Best suited to
planner task
operations
p and handling
g machine
tools
 Types of Robot IES 2016
IES‐2016 PUMA Robot
PUMA Robot
y Parallel
P ll l robot
b Which of the following Robots has application for
One use is a mobile mobile platform
p handling
g in cockpit
p flight
g
platform handling
simulators?
cockpit flight
simulators. It's a robot (a) SCARA Robot  (b) Articulated Robot PUMA robot

whose
hose arms ha e
have
concurrent prismatic (c) Parallel Robot  (d) Cylindrical Robot
or rotary joints.

y PUMA is an industrial robot.

IES ‐ 2012
IES ‐
IES ‐ Conventional The configuration of a robot using a telescoping arm that 
Th   fi i   f    b   i     l i    h  
y Programmable Universal Machine for Assembly, can be raised or lowered on a horizontal pivot mounted 
What are the five different types of robot systems?
or Programmable Universal Manipulation Arm) on a rotating base is called
(a) Polar 
y The functioning of this robot is like a human arm. Answer: 
(b) Cylindrical
1 Cartesian or Gantry robot
1.
y A totall off 6 variables
bl are required,
d for
f specifying
f the
h (c) Cartesian coordinate 
2. Cylindrical robot
position and orientation of a rigid body in space.
space (d) Jointed arm
3. Spherical or Polar robot
y Therefore PUMA has 6 axis of rotation with 1 DOF 4 Articulated or Revolute Robot
4.
(degree of freedom) per axis. 5. SCARA robot

y Each DOF has an actuator for motion.

IES 2011 Classification Based On Locomotion 
Trajectory of a robot mean : MCQ
y Walking Robots. Eg. Humanoids
(a) Path traced by the end effectors What is the name for the space inside which a 
(b) Kinematics of Robot y Tracked Robots. Eg. NASA’s Urban Robot Urbie
robot unit operates?
p
(c) Robot joints y Flying Robots. Eg. Cruise Missiles,  NETRA (By DRDO)
(a) environment
(d) Robot programming
(b) spatial base y Snake Robots. Eg. Japanese ACM‐ R5
( )d
(c) danger zone y Swimming Robots. Eg. Aqua Penguin Germany.  
(d) work envelop
y Legged Robots – DARPA Eg. Big Dog 
 R b i A W ldi C ll
Robotic Arc‐Welding Cell R b tP i
Robot Programming TTeach by lead through or Lead through 
hb l d h h L d h h
yO e p
On line og a g: Here
programming: e e tthee robot
obot aarm itself
tse iss
used during the direct programming operation.
programming
y Robot performs 
flux‐cored arc 
fl d    ¾ Teach by lead through y Work cycle is taught to robot by moving the
welding (FCAW)  ¾ teach by pendent manipulator through the required motion cycle and
operation at one 
i       y Off line Programming: It involves creating the simultaneously
i lt l entering
t i th program into
the i t controller
t ll
workstation  p g
program for a robot task,, without the need to be memory for later playback.
while fitter 
hil  fi   connected physically to the robot or even to be anywhere
changes parts at 
near its physical presence.
presence We may coupled it with y This is used for programming continuous path
the other 
workstation
simulation. Program is prepared at a remote computer operations such as are found in spray painting.
terminal and downloaded to robot controller for
execution.

Lead through Programming Advantages Teach by Pendant

Teach by Pendant
Lead through Programming q
y For work that requires p
point to p
point, and p
point to
y Advantages:
Ad t point with coordinated path, movements this is the
1. Powered lead through  y Easily learned by shop  normal method of programming.
y Common for point‐to‐
C  f   i personnel
point robots y It involves the programmer using a hand‐held pendant
y Logical way to teach a robot
g y
y Uses teach pendant which
hi h transmits
t it commands d though
th h a cable
bl to
t theth
y No computer programming
2. Manual lead through 
g robot controller, the robot then responds to these
y Disadvantages:
Disad antages commands.
y Convenient for 
y Downtime during 
continuous path  y In this way the programmer can lead the robot
control robots programming
through a task.
y Human programmer  y Limited programming logic 
p g g g
capability  y Tech
T h pendants
d h
have as many different
diff configurations
fi i
physical moves 
manipulator y Not compatible with 
as there robot models. Essentially they all contain
supervisory control sufficient controls to send the necessary instruction to
the controller.

Teach by Pendant
Teach by Pendant Teach by Pendant
Teach by Pendant IES‐Conventional
y The robot arm is p g
programmed byy moving
g the end p p
point 2 at a speed of 200 mm/s. At p point 2 it mayy be
Discuss some important aspects of pendant
effectors to a desired position using the joystick, and instructed to open its gripper, operate a spot welding
programming in robotics.
once the arm is at the required position and gun, or open a valve to allow adhesive to be dispensed.
orientation a key in the keyboard is pressed to record y Thus two files will be constructed, one with the
the point in memory.
memory d i d end
desired d effector
ff t l ti
locations, and
d one with ith the
th
y On a six axis robot this will be recorded as a six instructions connecting the robot operation and
coordinate location x, y, z, α, β, γ. sequence and speed of movements.
y In this way all the points to which the robot is desired y We may use a computer for on line programming, this
to go will be recorded in memory within a ‘point file’. makes more complex programs easier to create.
y An
A ‘instruction
‘i i file’
fil ’ is
i then
h created d using
i the
h keyboard
k b d
command. This file contains the instructions as to
what the robot should do between each point, e.g. the
robot may be instructed to move from point 1 to
R b
Robot programming languages
i l Fi G
First Generation Languages
i L S
Second Generation Languages
dG i L
y Textual programming language to enter commands y Combine teach pendant procedures with the y Structured programming languages
into robot controller.
y When
Wh using
i on‐line
li programmingi methods,
h d command
d statements.
t t t y Capability:
C bilit motion
ti control,
t l can use sensor data,
d t can
instructions can be given to the robot by using control y Mainly control motions ( Motion level language) communicate with other computers.
computers
switches, knobs and buttons in conjunction with
simple coded commands. This method allows simple y Example:
p VAL (Victor’s Assemblyy Language)‐
g g for p
Example
programs to be constructed. PUMA Robot. y AML: A Manufacturing Language
y For more complex programs a robot language must be
used and for off‐line working a programming language y Incapable to use complex sensor data, limited y MCL: Manufacturing control Language
i essential.
is ti l communication ability with other computer. y RAIL
y Commercial robot languages are all termed ‘explicit’
languages. Each robot manufacturer provides their
own language with the control system.

F
Future Generation Languages
G i L IES 2010 IES ‐ 2006
Consider the following statements: Which
Whi h one off theh following
f ll i is
i the
h third
hi d basic
b i
y They should be model based or task based language.
Good dynamic performance is usually difficult to achieve component of robots besides power supply and
y If we give
i command
d ‘Tighten
‘Ti ht a nut’
t’ it mustt find
fi d the
th i robots
in b which
hi h contain i a rotary base
b b
because control (memory) console?
1. Position, speed and acceleration of the other joints cause
nut and the spanner,
spanner pick them up,
up and place them in (a) Software (b) Coaxial cable
variations in the reflected torque and moment of inertia.
an orderlyy fashion and finally,
y it should tighten
g the p
2. The moment of inertia reflected at the base depends upon
p the (c) Mechanical unit arm (d) Microcomputer
weight of the object being carried.
nut with the spanner.
3 The moment of inertia reflected at the base also depends upon
3.
y These languages should allow complete offline the distance between the base axis and the manipulated object.
Which of the above statements is/are correct?
programming.
(a) 1, 2 and 3 (b) 2 and 3 only
(c) 1 only (d) 1 and 3 only

IES ‐ 2000 Links and Joints

Links and Joints
y The individual bodies that make up
p a robot are called
Consider
C id theh following
f ll i characteristics
h i i off a robot:
b links.
1. The tip of the robot arm moves from one point to
y For example an assembly of two gears connected by a
another with its in‐between path not being defined.
common shaft is treated as one link.
2. It can be used for drilling holes at difference points in a
workpiece.
3. It can be used for V butt joint welding between two
T
Transformations
f ti y Links of a robot are coupled by kinematic pairs and
j
joints.
points. y A joint couples to links and provide physical constraints
4. The memory capacity required for its control unit is low. on the relative motions between the links.
links
Which of these are the characteristics associated with a point
p y They are termed as either lower or higher pair joints.
to point robot? y Lower pair‐ surface contact (Hinge of the door)
(a) 1 and 2 (b) 1,1 3 and 4 y Higher pair – line or point contact (Ball rolling on plane)
(c) 1, 2 and 4 (d) 2, 3 and 4
 Revolute joint
Revolute joint Prismatic Joint
Prismatic Joint Helical Joint
y Also known as turning
g p
pair, y Also known as sliding
gppair
hinge or pin joint y It allows two paired links to
y It allow two paired links to
rotate about and translate at
y It permits two paired links to slide with respect to each
the same time along the axis
rotate with respect to each other along its own axis.
of the joint
j
other
th about
b t the
th axis
i off the
th y It
I also
l allows
ll one DOF.
DOF
y The translation is not
joint.
independent and it is
y It allows only one degree of related to the rotation by
freedom the pitch of the screw.
screw
y It allows one DOF.

Transformation Transformation
y In
I order
d to develop
d l a scheme
h for
f controlling
lli the
h motion
i y The
Th modeling
d li off robot
b t comprises
i off establishing
t bli hi a All will be discussed in class
All will be discussed in class
of a manipulator it is necessary to develop techniques for special relationship between the manipulator and the
representing the position of the arm at points in time. manipulated
i l t d object.
bj t
y The position of links in space and their motion are
y We will define the robot manipulator using the two basic described by spatial geometry.
elements, JOINTS and LINKS.
y A systematic
y and ggeneralized approach
pp for mathematical
y Each joint represents 1 degree of freedom. modeling of position and orientation of links in space
with
t respect
espect to a reference
e e e ce frame
a e iss ca
carried
ed out with
t tthee
y The
Th joint
j i t may involve
i l either
ith linear
li motion
ti or rotational
t ti l
help of vector and matrix algebra.
motion between the adjacent links.
y Because the motions of each link can be described with
y The links are rigid structures that connect the joints. respect to a reference co‐ordinate frame, it is convenient
to have a co‐ordinate frame attached to the body of each
link.

GATE‐2013 GATE‐2014 GATE‐2016

The
Th figure
fi below
b l represents
t a triangle
ti l PQR with
ith initial
i iti l
In a CAD package, mirror image of a 2D point A robot arm PQ with end coordinates P(0, 0) and Q(2, 5) 
coordinates of the vertices as P(1,3), Q(4,5) and R(5,3.5).
P(5,10)
( ) is to be
b obtained
b d about
b a line
l which
h h passes rotates counter clockwise about P in the XY plane by 90
l k b h l b o.  Th triangle
The ti l is
i rotated
t t d in
i the
th X‐Y
X Y plane
l about
b t the
th vertex
t
P by angle θ in clockwise direction. If sinθ = 0.6 and cosθ
through the origin and makes an angle of 45o The new coordinate pair of the end point Q is = 0.8,
8 the
th new coordinates
di t off the
th vertex
t Q are
counterclockwise with the X
X‐axis.
axis. The coordinates (a) (–2  5)
(a) (–2, 5) (b) (–5  2)
(b) (–5, 2) (a) (4.6, 2.8)      
(b) (3.2, 4.6)
of the transformed point will be (c) (–55,  –2)
(c) ( 2) (d) (2  –5)
(d) (2,  5) (c) (7.9, 5.5)
(a) (7.5, 5) (b) (10, 5) (c) (7.5, ‐5) (d) (10, ‐5) (d) (5.5, 7.9) 
 GATE 2016
GATE‐2016 CAD CAM
A point
i t P(1,
P( 3, ‐5)) is
i translated
t l t d by
b 2îî + 3ĵĵ ‐ 4k
k and
d then
th Computer Aided Manufacturing (CAM):
d d f ( )
Computer Aided Design (CAD): Used for creating the
rotated counter clockwise by 90o about the z
z‐axis.
axis. The y Computer Aided Process Planning (CAPP)
p g( )
product database y Computerized material Resource Planning (MRP)
new position of the point is
y NC part programming
y Geometric Modeling
(a) (‐6, 3, ‐9) y Robot Programming
y Engineering Analysis
l y Computerized Scheduling
(b) (‐6, ‐3, ‐9)
y Computerized process control
(c) (6, 3, ‐9) y D i Review
Design R i and
d Evaluation
E l i
y Computerized Manufacturing Control by FMS
(d) (6, 3, 9) y A t
Automated
t d Drafting
D fti y Shop floor control
Sh  fl   t l
y Computer Aided Quality Control (CAQC)
y Computer Aided Inspection

IES ‐ 2006 Automation

y Automation is the process of following a predetermined
Which
Whi h item
i best
b describes
d ib a CAM technology?
h l ? ISRO‐2011 sequence of operations with little or no human intervention,
intervention
using specialized equipment and devices that perform and
((a)) Geometric modeling
g ((b)) Documentation control the manufacturing gp
process.
I CAM,
In CAM " Part
P t programming"
i " refers
f to t Why go for Automation?
(c) Drafting (d) Numerical control
1. Increased productivity
p y
(a) Generation of cutter location data
2. Reduced cost of labour
(b) On‐line
On line Inspection 3. Improved quality
4. Reduced in‐process inventory
(c) Machine Selection 5 Reduce Manufacturing time
5.
6. Increased safety
(d) Tool Selection There are three types of Automation
1. Fixed Automation
2 Flexible Automation
2.
3. Programmable Automation

Fixed Automation or Hard automation

Fixed Automation or Hard automation Flexible Automation
Flexible Automation Programmable Automation
Programmable Automation
y Used to produce a standardized product, High initial y It is also known as FMS,, and uses C
CAD/CAM
/C yC
Can change
g the design
g of the p
product or even change
g the
investment for custom‐engineered equipment
y High investment for a custom‐engineered system product by changing the program.
y Used for very large quantity production (Mass
Production) of one or few marginally different y Produce different products on the same equipment in
anyy order or mix. Continuous p production of variable y Used for the low quantity production of large number of
components Relatively inflexible in accommodating
components.
product variety. mixtures of products different components.
y Highly specialized tools, devices, equipment, special y Medium
M di P d ti Rates
Production R t
y Equipment are designed to be flexible or programmable.
purpose
p p machine tools,, are utilized to p produce a y Flexibility
y to deal with product design
g variations
product. y e.g., CNC milling machine High investment in general purpose equipment
y Very efficient,
efficient high production rate , low unit cost.
cost y Most suitable for batch production
y e.g., single spindle and multi‐spindle lathes, sewing,
y Lower production rates than fixed automation
small parts.
 IES ‐ 2012 What is an FMS?
y A flexible manufacturing system (FMS) is a
Programmable automation is suitable for
manufacturing system in which there is some
(a) Low production volume and large varieties of parts amount off flexibility
fl ibili that
h allows
ll the
h system to
react in the case of changes.
g
(b) Low production volume and small varieties of parts y Two categories of flexibility
( )
(c) High production volume and small varieties of parts y Machine
M hi flexibility,
fl ibilit covers the
th system's
t ' ability
bilit to
t be
b
changed to produce new product types, and ability to
(d) Hi h  d i   l
(d) High production volume and large varieties of parts
  d l   i i   f  change
h the
h order
d off operations
i executed
d on a part.
y Routing g flexibility,
y which consists of the abilityy to
use multiple machines to perform the same operation
on a ppart, as well as the system's
y abilityy to absorb
large‐scale changes, such as in volume, capacity, or
capability.

FMS Components FMS Goals Advantages of FMS

y Reduction in manufacturing cost by lowering direct y Faster,
F t lower‐
l costt changes
h from
f one partt to
t another
th
y Most FMS systems comprise of three main
labor cost and minimizing scrap, re‐work, and material which will improve capital utilization
y
systems
wastage.
t y Lower direct labor cost, due to the reduction in number
y Work machines (typically automated CNC
y Less skilled labor required.
q of workers
machines) that perform a series of operations;
y Reduction in work‐in‐process inventory by eliminating y Reduced inventory, due to the planning and
y An integrated material transport system and a p g
programming gp
precision
the need for batch processing.
processing
computer that controls the flow of materials, y Consistent and better quality, due to the automated
tools,, and information ((e.g.
g machining g data y Reduction in production lead time permitting
control
and machine malfunctions) throughout the manufacturers to respond more quickly to the variability
of market demand. y Lower cost/unit of output, due to the greater
system; productivity
d ti it using
i the
th same number
b off workers
k
y Auxiliary work stations for loading and y Better process control resulting in consistent quality.
y Savings from the indirect labor, from reduced errors,
unloading,
l d cleaning,
l inspection, etc. rework, repairs and rejects

Disadvantages of FMS IES ‐ 1996 IES ‐ 2006 

y Limited
Li i d ability
bili to adapt
d to changes
h in
i product
d or product
d Which of the following pairs are correctly matched?
Whi h  f  h  f ll i   i     l   h d? Flexible
Fl ibl manufacturing
f i allows
ll for:
f
mix (e.g., machines are of limited capacity and the 1. CNC machine…… Post processor
p ((a)) Tool designg and pproduction
tooling necessary for products, even of the same family, 2. Machining centre….Tool magazine (b) Automated design
y feasible in a g
is not always given FMS))
3. DNC…………. FMS
DNC  FMS ( ) Quick
(c) Q i k and d inexpensive
i i product
d change
h
y Substantial pre‐planning activity
((a)) 1, 2 and 3
, 3 ((b)) 1 and 2 ((d)) Q
Qualityy control
y Expensive, costing millions
ll off dollars
d ll
(c) 1 and 3 (d) 2 and 3
y Technological
ec o og ca p problems
ob e s o of eexact
act co
component
po e t pos
positioning
to g
and precise timing necessary to process a component
y Sophisticated
S hi ti t d manufacturing
f t i systems t
 IES ‐ 2004 IES ‐ 2012 Types of Material Handling Devices
Consider
C id theh following
f ll i characteristics:
h i i Rank order clustering as applied to manufacturing 
R k  d   l i     li d    f i  
automation is y Industrial truck
1. Single
g machine tool
2. Manual materials handling system (a) A technique of identifying process sequence in  y Automated Guided Vehicles (AGVs)
3. Computer
C controll production of a component
y Conveyors
4. Random sequencing
4 q g of p
parts to machines (b) A just in time (JIT) method
(c) An approach of grouping the machines into cells in  y Cranes and Hoists 
Which of the above characteristics are associated with
fl ibl manufacturing
flexible f t i system?t ? a
an FMS system
S syste
(a) 1, 2 and 3 (b) 1 and 2 (d) A tool to generate bill of materials
(c) 3 and 4 (d) 2, 3 and 4

IES-2010 Conv. IES‐2016 FMC‐Flexible

Automated Guided Vehicles (AGVs)
y These are battery‐powered, driverless vehicles for automatic
transport of parts and tooling on the shop floor.
y These moves on fixed paths laid underneath the factory
p materials from the workstation to storage
floor, and transport
locations, load stations, etc.
y Thoughg the p path of travel is laid underneath the factoryy
floor, it is made of segments which allow the AGV to have a
flexible p path. These are one of the first choices for
automating the material movement.
y A class of AGVs called rail‐guided
g vehicles ((RGVs)) have fixed
rails on which they move. This is far more restricted in terms
of the path the RGV can take and service only a few
workstations.
FMC machining cell
Flexible machining cell
Statement (I) : Automated guided vehicle (AGV) is a y An arrangement with more than one machining centre
programmable
bl mobilebil vehicle
hi l without
ith t human
h
with integrated material handling arrangement is
intervention and used for material handling.
Statement (II) : Automated storage and retrieval called as FMC.
g
system (AS/RS) is a part of CNC machine and used
for machining operation.
(a) Both Statement (I) and Statement (II) are individually true and 
Statement (II) is the correct explanation of Statement (I).
( ) p ()
(b) Both Statement (I) and Statement (II) are individually true but 
Statement (II) is not the correct explanation of Statement (I).
Statement (II) is not the correct explanation of Statement (I)
(c) Statement (I) is true but Statement (II) is false.
(d) Statement (I) is false but Statement (II) is true

IAS‐2011
y What is the difference between FMS and FMC? 
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