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ME8691 Book
ME8691 Book
A. Jacob Moses
M.E. (Ph.D.)
Assistant Professor,
Department of Mechanical Engineering,
Loyola-ICAM College of Engineering & Technology (LICET),
Chennai
Renjin J. Bright
M.E. (Ph.D.)
Assistant Professor,
Department of Mechanical Engineering,
National Engineering College, Kovilpatti
Ruchi Agarwal
B.E. (MECH), GATE Qualified
®
TECHNICAL
PUBLICATIONS
SINCE 1993 An Up-Thrust for Knowledge
(i)
Computer Aided Design
& Manufacturing
Subject Code : ME8691
Published by :
®
TECHNICAL Amit Residency, Office No.1, 412, Shaniwar Peth, Pune - 411030, M.S. INDIA
PUBLICATIONS P h . : + 9 1 - 0 2 0 - 2 4 4 9 5 4 9 6 / 9 7 , Te l e f a x : + 9 1 - 0 2 0 - 2 4 4 9 5 4 9 7
An Up-Thrust for Knowledge
SINCE 1993
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Yogiraj Printers & Binders
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Price : ` 395/-
ISBN 978-81-943825-1-5
9 788194 382515 AU 17
The book uses plain, lucid language to explain fundamentals of this subject. The
book provides logical method of explaining various complicated concepts and stepwise
methods to explain the important topics. Each chapter is well supported with necessary
illustrations, practical examples and solved problems. All the chapters in the book are
arranged in a proper sequence that permits each topic to build upon earlier studies. All
care has been taken to make students comfortable in understanding the basic concepts
of the subject.
Representative questions have been added at the end of each Chapter to help the
students in picking important points from that Chapter.
The book not only covers the entire scope of the subject but explains the philosophy
of the subject. This makes the understanding of this subject more clear and makes it
more interesting. The book will be very useful not only to the students but also to the
subject teachers. The students have to omit nothing and possibly have to cover nothing
more.
We wish to express our profound thanks to all those who helped in making this
book a reality. Much needed moral support and encouragement is provided on
numerous occasions by our whole family. We wish to thank the Publisher and the
entire team of Technical Publications who have taken immense pain to get this book
in time with quality printing.
Any suggestion for the improvement of the book will be acknowledged and well
appreciated.
Authors
Anup Goel
A. Jacob Moses
Renjin J. Bright
Ruchi Agarwal
(iii)
Syllabus
Computer Aided Design and Manufacturing
[ME8691]
Unit I Introduction
Product cycle- Design process- sequential and concurrent engineering - Computer aided design
- CAD system architecture- Computer graphics - co-ordinate systems - 2D and 3D
transformations- homogeneous coordinates - Line drawing - Clipping - viewing
transformation-Brief introduction to CAD and CAM - Manufacturing Planning, Manufacturing
control- Introduction to CAD/CAM - CAD/CAM concepts - Types of production - Manufacturing
models and Metrics - Mathematical models of Production Performance. (Chapter - 1)
(iv)
Table of Contents
Unit - I
(v)
1.15.3 Manufacturing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 79
Unit - II
(vi)
2.11.1 Classification of Surfaces in Geometric Modeling . . . . . . . . . . . . . . . . . . . . . . 2 - 24
2.11.2 Blending Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 26
Unit - III
(vii)
3.4.4 PDES - Product Data Exchange Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
3.4.5 DXF (Data Exchange Format) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Unit - IV
(viii)
4.10 Computerized Numerical Control (CNC)....................................................... 4 - 14
4.11 Constructional Features of CNC Machines ................................................... 4 - 15
4.11.1 Machine Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 16
4.11.2 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 17
4.11.3 Actuation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 18
4.11.4 Slideways for Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 21
4.11.5 Automatic Tool Changer (ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 24
4.11.6 Automatic Pallet Changer (APC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 25
4.11.7 Transducers/Control Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
4.11.8 Feedback Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 27
(ix)
4.26 Canned Cycle ................................................................................................ 4 - 93
4.26.1 Comparison between Subroutine and Canned Cycle . . . . . . . . . . . . . . . . . . . 4 - 93
4.26.2 Slot Milling (G74) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 93
4.26.3 Rectangular Pocket Milling (G75) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 95
Unit - V
5.4 Structures used for Classifying and Coding the Parts ..................................... 5 - 5
5.4.1 Hierarchical Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
5.4.2 Chain-type Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
5.4.3 Mixed Mode Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
(x)
5.5 OPTIZ Coding System ....................................................................................... 5 - 6
5.5.1 Solved Examples of Optiz Part Coding System . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 8
(xi)
5.14 Types of Flexibility ....................................................................................... 5 - 26
5.14.1 Single Machine Cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
5.14.2 Flexible Manufacturing Cell (FMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
5.14.3 Flexible Manufacturing System (FMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 28
5.14.4 Difference between FMC and FMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 29
(xii)
Unit - I
Chapter - 1
Introduction
Syllabus : Product cycle- Design process- sequential and concurrent engineering-
Computer aided design – CAD system architecture- Computer graphics –
co-ordinate systems- 2D and 3D transformations- homogeneous coordinates -
Line drawing -Clipping- viewing transformation-Brief introduction to CAD
and CAM – Manufacturing Planning, Manufacturing control- Introduction to
CAD/CAM –CAD/CAM concepts ––Types of production - Manufacturing
models and Metrics – Mathematical models of Production Performance
Shake-out
Sales
Saturation
Take-off
Time
· Low sales · Increasing sales · Peak sales · Falling sales
· High cost per · Cost per customer falls · Cost per customer · Cost per customer low
customer lowest · Profits fall
· Profits rise
· Financial losses · Profits high · Customer base contracts
· Increasing No.
· Innovative customers of customers · Mass market · Number of competitors fall
· Few (if any) competitors · More competitors · Stable number
of competitors
Manu
s ign fac
tu
De
rin
g
Product
d of Li e
Distribu
f
Lifecycle
En
tion
Customer
Synthesis of design :
· The philosophy, functionality, and uniqueness of the product are all determined
during synthesis.
· During synthesis, a design takes the form of sketches and layout drawings that
show the relationship among the various product parts.
· Most of the information generated and handled in the synthesis sub process is
qualitative and consequently it is hard to capture in a computer system.
Analysis of design :
· The analysis begins with an attempt to put the conceptual design into the context
of engineering sciences to evaluate the performance of the expected product.
· This requires design modeling and simulation. An important aspect of analysis is
the questions that helps to eliminate multiple design choices and find the best
solution to each design problem.
· Bodies with symmetries in their geometry and loading are usually analyzed by
considering a portion of the model. Example : Stress analysis pressure vessels,
couplings etc.
· The quality of the results obtained from these activities is directly related to and
limited by the quality of the analysis model chosen.
· Prototypes may be built for the design evaluation. Prototypes can be constructed
for the given design by using software packages (CAM).
· The outcome of analysis is the design documentation in the form of engineering
drawings.
ii) Manufacturing process
· Manufacturing process begins with process planning, using the drawings from the
design process, and it ends with the actual products.
· Process planning is a function that establishes which processes and the proper
parameters for the processes are to be used.
· It also selects the most efficient sequence for the production of the product.
· The outcome of the process planning is a production plan, tools procurement,
materials order, and machine programming.
· Other special requirements, such as design of jigs and fixtures, are also planned.
The relationship of process planning to the manufacturing process is analogous to
that of synthesis to the design process. It involves considerable human experience
and qualitative decisions.
· This description implies that it would be difficult to computerize process
planning.
· Once process planning has been completed, the actual product is produced and
inspected against quality requirements.
· Parts that pass the quality control inspection are assembled, functionally tested,
packaged, labeled, and shipped to customers.
· Market feedback is usually incorporated into the design process.
· This feedback give birth to a closed-loop product cycle.
The design process
Synthesis
Analysis
The CAD process
Production
planning
Design and
procurement
of new tools
Process Quality
Production Packaging Shipping
planning control
Order
material
NC, CNC,
DNC
programming
Marketing
Define problem
Problem statement Production architecture
Benchmarking Arrangement of physical
QFD
elements to carry out
PDS
functions
Project planning
Configuration design
Gather information Preliminary selection of
Internet Embodiment
material and
Patents design
manfacturing
Trade
Conceptual modeling/sizing of parts
Literature
design
Evaluation of
concepts Detail design
Pugh concept selection Detail drawing and
Decision matrix specifications
Recognition of need
Definition of problem
Synthesis
Yes
Fails No
Evaluation
Presentation
· Presentation : After the product design passing through the evaluation stage,
drawings, diagrams, material specification, assembly lists, bill of materials etc.
which are required for product manufacturing are prepared and given to process
planning department and production department.
· The designers design the product's form, fit, and function to meet all the
requirements, and pass on the design to the manufacturing department.
· After the product is manufactured it goes through the phases of assembly, testing
and installation. This type of approach to life-cycle development is also known as
`over the wall' approach, because the different life-cycle phases are hidden or
isolated from each other.
· Each phase receives the output of the preceding phase as if the output had been
thrown over the wall. In such an approach, the manufacturing department, for
example, does not know what it will actually be manufacturing until the detailed
design of the product is over.
· There are a lot of disadvantages of the sequential engineering process. The
designers are responsible for creating a design that meets all the specified
requirements. They are usually not concerned with how the product will be
manufactured or assembled.
· Problems and inconsistencies in the designs are therefore, detected when the
product reaches into the later phases of its life-cycle.
· At this stage, the only possible option is to send the product back for a re-design.
The whole process becomes iterative and it not until after a lot of re-designs has
taken place that the product is finally manufactured.
···· ····
Information flow
Concurrent Engineering
· Due to the large number of changes, and hence iterations, the product's
introduction to market gets delayed. In addition, each re-design, re-work,
re-assembly etc. incurs cost, and therefore the resulting product is costlier than
what it was originally thought to be. The market share is lost because of the
delay in product's introduction to market, and customer faith is lost.
· Concurrent engineering is a dramatically different approach to product
development in which various life-cycle aspects are considered simultaneously
right from the early stages of design as shown in Fig. 1.4.2.
· These life-cycle aspects include product's functionality, manufacturability,
testability, assimilability, maintainability, and everything else that could be
affected by the design. In addition, various life-cycle phases overlap each other,
and there in no "wall" between these phases.
· The completion of a previous life-cycle phase is not a pre-requisite for the start
of the next life-cycle phase. In addition, there is a continuous feedback between
these life-cycle phases so that the conflicts are detected as soon as possible.
· The concurrent approach results in less number of changes during the later phases
of product life-cycle, because of the fact that the life-cycle aspects are being
considered all through the design.
· The benefits achieved are reduced lead times to market, reduced cost, higher
quality, greater customer satisfaction, increased market share etc.
Preliminary Design
Detailed Design
Manufacturing
Assembly
Testing
Time
· In concurrent engineering, different tasks are tackled at the same time, and not
necessarily in the usual order. This means that info found out later in the process
can be added to earlier parts, improving them, and also saving a lot of time.
Requirements definition
Product definition
Process definition
geometry of the object can be done easily, it can be stored in the computer
memory, and can be retrieve back on the computer screen for review analysis or
alteration.
Conventional Design Process Computer - aided design
Recognition of need
Problem definition
Analysis and
Engineering analysis
optimization
· CAD may be used to design curves and figures in two-dimensional (2D) space;
or curves, surfaces, and solids in three-dimensional (3D) space.
· CAD is an important industrial art extensively used in many applications,
including automotive, shipbuilding, and aerospace industries, industrial and
architectural design, prosthetics, and many more. CAD is also widely used to
produce computer animation for special effects in movies, advertising and
technical manuals, often called DCC (Digital Content Creation).
· Fig. 1.6.1 explains CAD system architecture.
System
Major classes :
Main frame
Database Application
Mini computer software
Workstation (CAD model)
Microcomputer
Based
Graphics User
Application areas : utility interface
Mechanical
Architectural
Construction Device
Circuit design drivers
Chip design
Cost :
High end
Input - output
Low end
devices
· Through these input devices it is possible to provide input to the computer and
display device is an output device which shows the image.
Control signals
Link to Display
Control Display file Display
host computer processor
processor screen
unit
Input
devices
(Xmax'Ymax)
Z'
Z Y'
Z
Y Y Y1
X'
X X
(0,0) X1
Fig. 1.8.1
· It is the reference space of the model with respect to which all the model
geometrical data is stored.
· It is a Cartesian system which forms the default coordinate system used by a
particular software program.
· The X, Y, and Z axes of the MCS can be displayed on the computer screen.
· The choice of origin is arbitrary.
· The three default sketch planes of a CAD/CAM system define the three planes of
MCS, and their intersection point is the MCS origin.
· When a CAD designer begins sketching, the origin becomes a corner point of the
profile being sketched. The sketch plane defines the orientation of the profile in
the model 3D space.
· Existing CAD/CAM software uses the MCS as the default WCS.
· The MCS is the only coordinate system that the software recognizes when storing
or retrieving graphical information from a model database. Many existing
software package allow the user to input Cartesian and cylindrical coordinates.
This input information is transformed to (x, y, z) coordinates relative to the MCS
before being stored in the database.
b) Working Coordinate System (WCS) or User Coordinate System (UCS)
· This is basically an auxiliary coordinate system used in place of MCS. For
convenience while we develop the geometry by data input this kind of coordinate
system is useful.
· It is very useful when a plane (face) in MCS is not aligned (easily defined) along
any orthogonal planes.
· It can be established at any position and orientation in space that the user desires.
· The user can define a Cartesian coordinate system whose XY plane is coincident
with the desired plane of construction. That new system is called as WCS.
· It is a user defined system that facilitates the geometrical construction. While user
inputs data in WCS the software transforms it to MCS before storing the data.
· There is only one active WCS at any one time. If the user defines multiple
WCSs in one session, the software recognizes only the last one.
c) Screen Coordinate System (SCS)
· In contrast to MCS and WCS, Screen Coordinate System is a two-dimensional
device-independent system whose origin is usually located at the lower left corner
of the graphic display (display screen).
· The physical dimensions of the device screen and the type of device determine
the range of the SCS. A 1024 ´ 1024 display has an SCS with a range of (0, 0)
to (1024,1024).
· The SCS is important for display, screen input and digitizing tasks.
· A transformation operation from MCS coordinates to SCS coordinates is
performed by the software before displaying the model views and graphics.
· For a geometric model, there is a data structure to store its geometric data
(relative to MCS), and a display file to store its display data (relative to SCS).
Window and View Port
Window
· When a design package is initiated, the display will have a set of co-ordinate
values. These are called default co-ordinates.
· A user co-ordinate system is one in which the designer can specify his own
coordinates for a specific design application.
· These screen independent coordinates can have large or small numeric range, or
even negative values, so that the model can be represented in a natural way.
· It may, however, happen that the picture is too crowded with several features to
be viewed clearly on the display screen.
· Therefore, the designer may want to view only a portion of the image, enclosed
in a rectangular region called a window.
· Different parts of the drawing can thus be selected for viewing by placing the
windows.
· Portions inside the window can be enlarged, reduced or edited depending upon
the requirements. Fig. 1.8.2 (a) depicts the use of windowing to enlarge an image.
View Port
· It may be sometimes desirable to display different portions or views of the
drawing in different regions of the screen.
· A portion of the screen where the contents of the window are displayed is called
a view port. Fig. 1.8.2 (b) explains a view port.
Window
130,100 View port 1 View port 2
Original
drawing
Fig. 1.8.2
a) 2D Translation
· This moves a geometric entity in space in such a way that the new entity is
parallel at all points to the old entity. Translation of a point is shown in
Fig. 1.9.1.
· Let's consider a point on the object, represented by P which is translated along X
and Y axes by DX and DY respectively to a new position P '.
· The new coordinates after transformation are given by following equations.
P' = [x', y' ] …(1.9.1)
x' = [x+Dx] …(1.9.2)
y' = [y+Dy] …(1.9.3)
é x ¢ù é x + D xù é xù é D xù
[P'] = ê ú = ê = + …(1.9.4)
ë y ¢û ë y + D yúû êë yúû êë D yúû
Y'
Z'
P'
P X'
P Z
Y
X
X
2D Translation of an object
Fig. 1.9.2 explains the transformation of a rectangle. Consider a rectangle of
coordinates (1,1), (4,1), (1,5) and (4,5). The rectangle is translated by 3 units along
x-direction (Dx) and 3 units along y-direction (Dy). (See Fig. 1.9.2 on next page)
b) 2D Scaling
· Scaling is the transformation applied to change the scale of an entity.
· To achieve scaling, the original coordinates would be multiplied uniformly by the
scaling factors.
Sx = Scaling factor along x-direction
Sy = Scaling factor along y-direction
Ts = Scaling matrix
· The scaling operations could be explained by the equations stated below.
P ¢ = [x', y' ]=[Sx ´ X, Sy ´ Y] …(1.9.5)
10
9
(5, 8) (8, 8)
8
6 After translation
Y
(1, 5) (4, 5)
5
4
(5, 4) (8, 4)
3
Original rectangle
2
1
(1, 1) (4, 1)
0
0 1 2 3 4 5 6 7 8 9 10
éS x 0 ù é xù
[P ¢] = ê
S y úû êë yúû
…(1.9.6)
ë0
éS x 0ù
[Ts] = ê Y
S y úû
…(1.9.7)
ë0
[P ¢] = [Ts] × [P] …(1.9.8)
· Fig. 1.9.3 depicts the scaling of an
object. P'
c) 2D Rotation
· Rotation is another important P
SY
geometric transformation. The
Y
P'
Y'
P
r
Y
X
0
X'
X
é cos q - sin q ù
[TR ] = ê …(1.9.10)
ë sin q cos q úû
8
D1 After X-shear
D
7
Original part
Y 6
E1 C C1
4 E
2
A1
1 B1
A B
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13
X
· The Y-shear as shown in the Fig. 1.9.5 (b) preserves the X coordinates and
changes the Y coordinates which causes the horizontal lines to transform into
lines which slopes up or down.
10 D1 C1
After X-shear
9
7 E1
D
6 B1 Original part
Y
4 E C
3 A1
1
A B
0
0 1 2 3 4 5 6 7 8 9 10
X
Y
–X X
–Y Y X
P' P
P'
· For reflection about x-axis the y coordinate will be negative and the following
equations should be utilized,
P ¢ = [X ¢, Y ¢] = [X, – Y] …(1.9.16)
é1 0 ù é xù
[P ¢] = ê ú ê yú …(1.9.17)
ë0 -1û ë û
The translation matrix is given as,
é1 0 ù
[Tm ] = ê ú …(1.9.18)
ë0 -1û
[P ¢] = [Tm ] × [P] …(1.9.19)
· For reflection about y-axis the x coordinate will be negative and the following
equations should be utilized,
P ¢ = [X ¢, Y ¢] = [X, – Y] …(1.9.20)
é - 1 0ù é xù
[P ¢] = ê ú ê ú …(1.9.21)
ë 0 1û ë yû
The translation matrix is given as,
é -1 0ù
[Tm ] = ê ú …(1.9.22)
ë 0 1û
[P ¢] = [Tm ] × [P] …(1.9.23)
· Thus the general form of reflection matrix could be written as,
é± 1 0 ù
[Tm ] = ê ú …(1.9.24)
ë 0 ± 1û
P'
P
r
r
A
Y
X
O X
iii) Translate the point back to its original position from origin.
é 1 0 0ù
ê
[T 3 ] = [T] = 0 1 0ú
ê ú
êë DX DY 1úû
Example 1.9.1 : Translate a point P(2, 3) by four units in x-direction and 5 units in
y-direction.
Dx = 4; Dy = 5
Tranformation matrix
é Dx ù
T = ê ú
ë Dy û
New position of a point is,
P¢ = P + T
é x1¢ ù é x1 ù é Dx ù é2ù é 4ù é6ù
ê y ¢ ú = ê y ú + ê Dy ú = ê3ú + ê5ú = ê8ú
ë 1û ë 1û ë û ë û ë û ë û
Y
P'(6, 8)
y=5
P
(2, 3)
X
x=4
Fig. 1.9.8
Example 1.9.2 : A line AB, A(2, 4) and B(5, 6) is to be translated 1 unit along +ve
direction of 'x' and 3 units along +ve direction of y. Find the translated coordinates.
Solution : Given :
For line AB ® A(x1 , y 1 ) = (2, 4)
B(x 2 , y 2 ) = (5, 6)
T(Dx, Dy ) = (1, 3)
1 - 29 Computer Aided Design and Manufacturing
Introduction
\ A¢ = A + T
é2ù é1ù é 3ù
A¢ = ê ú + ê ú = ê ú
ë 4û ë3û ë 7û
é5ù é1ù é6ù
Similarly B¢ = B + T = ê ú + ê ú = ê ú
ë6û ë3û ë9û
Y
B' (6, 9)
A' (3, 7)
y=3
B (5, 6)
A
(2, 4)
x=1
Fig. 1.9.9
Example 1.9.3 : Translate a triangle ABC having coordinates A(1, 1), B(3, 1) and
C(1, 3) about the origin by 3 - units in x - direction and 2 - units in y - direction.
A = (x1 , y 1 ) = (1, 1)
B = (x 2 , y 2 ) = (3, 1)
C = (x 3 , y 3 ) = (1, 3)
Dx = 3; Dy = 2 Þ T = (3, 2)
é1ù é3ù é 4ù
A¢ = A + T = ê ú + ê ú = ê ú
ë1û ë2û ë3û
C' (4, 5)
C (1, 3)
B' (6, 3)
A' (4, 3)
y=2
B (3, 1)
A (1, 1)
X
x=3
Fig. 1.9.10
Example 1.9.4 : A rectangular lamina ABCD having co-ordinates A(2, 2), B(4, 2),
C(4, 5) and D(2, 5) is translated by 4 units in x - direction and 4 units in y - direction.
Find out the translated coordinates and plot the rectangle before and after translation.
A (2, 2) = (x1 , y 1 )
B (4, 2) = (x 2 , y 2 )
C (4, 5) = (x 3 , y 3 )
D (2, 5) = (x 4 , y 4 )
Dx = 4; Dy = 4 Þ T( Dx , Dy ) = (4, 4)
é2ù é 4ù é6ù
[A] = [A] + [T] = ê ú + ê ú = ê ú
ë2û ë 4û ë6û
é 4ù é 4ù é8ù
[B ¢] = [B] + [T] = ê ú + ê ú = ê ú
ë2û ë 4û ë6û
é 4ù é 4ù é8ù
[C ¢] = [C] + [T] = ê ú + ê ú = ê ú
ë5û ë 4û ë9û
é2ù é 4ù é6ù
[D ¢] = [D] + [T] = ê ú + ê ú = ê ú
ë5û ë 4û ë9û
Y
A' (6, 6)
B' (8, 6)
(2, 5) D C (4, 5)
y=4
(2, 2) A B (4, 2)
X
x=4
Fig. 1.9.11
Example 1.9.5 : A polygon ABCD is having the coordinates A(2, 3), B(6, 3), C(6, 6),
D(2, 6). Scale the polygon by 2 units along x-axis and y-axis.
Solution : Given :
B(x 2 , y 2 ) = (6, 3)
C(x 3 , y 3 ) = (6, 6)
D(x 4 , y 4 ) = (2, 6)
éS x 0 ù é2 0ù
\ Scaling matrix, [S] = ê ú =ê ú
ë 0 S y û ë0 2û
é2 0ù é2ù é 4ù
= ê ú´ê ú = ê ú
ë0 2û ë3û ë6û
é2 0ù é6ù é12ù
= ê ú´ê ú = ê ú
ë0 2û ë3û ë 6 û
é2 0ù é6ù é12ù
= ê ú´ê ú = ê ú
ë0 2û ë6û ë12û
é2 0ù é2ù é 4 ù
= ê ú´ê ú = ê ú
ë0 2û ë6û ë12û
Y
D' (4, 12) C' (12, 12)
D (2, 6) C (6, 6)
B' (12, 6)
A' (4, 6)
A (2, 3) B (6, 3)
Fig. 1.9.12
Example 1.9.6 : Rotate the point P(6, 8) about the origin at an angle 30 ° in
anti-clock wise direction and obtain the new position of the point.
Solution : Given
P(6, 8)
°=
30
X
Fig. 1.9.13
Example 1.9.7 : A triangle ABC, A(5, 2), B(3, 5), C(7, 5). Find the transformed
position if,
i) The triangle is rotated by 45 ° in clockwise direction.
ii) The triangle is rotated by 60 ° in anti-clockwise direction.
\ q = – 45°
é 4.97 ù
Þ [A]¢ = ê ú
ë - 2.12û
é x ¢2 ù écos( - 45° ) - sin ( - 45° )ù é3ù
Similarly, [B]¢ = ê ú = ê ú ê5ú
ë y ¢2 û ë sin ( - 45° ) cos( - 45° ) û ëû
é 5.65ù
Þ [B]¢ = ê ú
ë1.41û
é x ¢3 ù écos( - 45° ) - sin ( - 45° )ù é 7ù
Similarly, [C]¢ = ê ú = ê ú ê 5ú
ë y ¢3 û ë sin ( - 45° ) cos( - 45° ) û ë û
é 8.48 ù
Þ [C]¢ = ê ú
ë -1.414û
ii) Rotated by 60° in anticlockwise direction (counter-clockwise) :
\ q = 60°
Y
(–0.830, 8.582) C"
B"
A" (0.767, 5.330)
(–2.830, 5.098)
B(3, 5)
C(7, 5)
A(5, 2)
60° B' (5.65, 1.41)
45°
X X
0
C' (8.48, –1.41)
Fig. 1.9.14
Example 1.9.8 : A square with an edge length of 10 units is located in the origin with
one of the edges inclined at an angle 30 ° with X-axis. Calculate the new position of the
square, i) If it is rotated by an angle 30 ° in clock-wise direction. ii) If it is rotated by
60° in counter-clockwise direction.
Fig. 1.9.15
B(x 2 , y 2 ) : Y
y2 10
y 2 = 10 sin 30 = 5 units l=
30°
\ B(x 2 , y 2 ) = (8.66, 5) A (0, 0) x2
X
Fig. 1.9.16
Similarly, C(x 3 , y 3 ) :
Y
(x3, y3)
10 sin 60 l = 10
60°
B (x2, y2)
30°
y2
30°
X
A (0, 0) 10 cos 60
x2
Fig. 1.9.17
\ x 3 = x 2 - 10 cos 60
= 8.66 – 5 = 3.66 units
Y
y 3 = y 2 + 10 sin 60
= 5 + 8.66 = 13.66 units D(x4, y4)
\ D(x 4 , y 4 ) = (– 5, 8.66)
\ q = – 30°
\ q = 60°
(3.66, 13.66)
C
60° 30°
D'' A (0, 0) B' (10, 0)
(–10, 0) A', A"
Fig. 1.9.19
Example 1.9.9 : For a planar lamina ABCD with A(3, 5), B(2, 2), C(8, 2) and D(4, 5)
in XY plane with point P(4, 3) in the inetrior is to be
é8ù
i) Translated by a translation matrix [T] = ê ú
ë5û
A (3, 5) D (4, 5)
P
(4, 3)
B (2, 2) C (8, 2)
Fig. 1.9.20
Sol. : i) Translation :
é Dx ù é8ù
[T] = ê ú = ê ú
ë Dy û ë5û
\ Dx = 8; Dy = 5
é x1 ù é Dx ù é3ù é8ù é11ù
[A]¢ = ê ú + ê ú = ê ú + ê ú = ê ú
ë y 1 û ë Dy û ë5û ë5û ë10 û
é x 2 ù é Dx ù é2ù é8ù é10 ù
[B]¢ = ê ú + ê ú = ê ú + ê ú = ê ú
ë y 2 û ë Dy û ë2û ë5û ë 7 û
é x 3 ù é Dx ù é8ù é8ù é16ù
[C]¢ = ê ú + ê ú = ê ú + ê ú = ê ú
ë y 3 û ë Dy û ë2û ë5û ë 7 û
é x 4 ù é Dx ù é 4ù é8ù é12ù
[D]¢ = ê ú + ê ú = ê ú + ê ú = ê ú
ë y 4 û ë Dy û ë5û ë5û ë10 û
é 4ù é Dx ù é 4ù é8ù é12ù
[P]¢ = ê ú + ê ú = ê ú + ê ú = ê ú
ë 3û ë Dy û ë3û ë5û ë 8 û
ii) Rotate through 60° in counter clockwise direction :
q = 60°
14
13
12
11
10 A' D'
1 - 41
C''
8 P'
7
B' C'
D''
Fig. 1.9.21
6
A D
A'' 5
P"
3
P
B"
2
B C
X
X 0
–3 –2 –1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
é1 0 ù é x1 ù
[A]¢ = ê ú êy ú
ë0 -1û ë 1û
é1 0 ù é 3ù é 3 ù
Þ [A]¢ = ê ú ê 4ú = ê - 4ú
ë0 -1û ë û ë û
é1 0 ù é7 ù é 7 ù
[B]¢ = ê ú ê ú =ê ú
ë0 -1û ë 4û ë - 4û
é1 0 ù é7 ù é 7 ù
[C]¢ = ê ú ê ú =ê ú
ë0 -1û ë 6û ë - 6û
é1 0 ù é 3ù é 3 ù
[D]¢ = ê ú ê 6ú = ê - 6ú
ë0 -1û ë û ë û
(3, 6) (7, 6)
D C
A B
(3, 4) (7, 4)
X X
(3, – 4) B'(7, – 4)
A'
D' C'
(3, – 6) (7, – 6)
Y
Fig. 1.9.22
é -1 0ù é x1 ù
[A]¢ = ê ú ê ú
ë 0 1û ë y 1 û
é -1 0ù é 3ù é - 3ù
Þ [A]¢ = ê ú ê ú=ê ú
ë 0 1û ë 4û ë 4û
é -1 0ù é7 ù é - 7 ù
[B]¢ = ê ú ê ú =ê ú
ë 0 1û ë 4û ë 4 û
é -1 0ù é7 ù é - 7 ù
[C]¢ = ê ú ê ú =ê ú
ë 0 1û ë 6û ë 6 û
é -1 0ù é 3ù é - 3ù
[D]¢ = ê ú ê ú=ê ú
ë 0 1û ë 6û ë 6 û
Y
(–7, 4)
B'' A''(–3, 4) A(3, 4) B(7, 4)
X X
Fig. 1.9.23
é -1 0 ù é x1 ù
[A]¢¢¢ = ê ú êy ú
ë 0 -1û ë 1û
1 - 43 Computer Aided Design and Manufacturing
Introduction
é -1 0 ù é 3ù é - 3 ù
Þ [A]¢¢¢ = ê ú ê 4ú = ê - 4ú
ë 0 -1û ë û ë û
é -1 0 ù é7 ù é - 7 ù
[B]¢¢¢ = ê ú ê 4ú = ê - 4ú
ë 0 -1û ë û ë û
é -1 0 ù é7 ù é - 7 ù
[C]¢¢¢ = ê ú ê 6ú = ê - 6ú
ë 0 -1û ë û ë û
é -1 0 ù é 3ù é - 3ù
[D]¢¢¢ = ê ú ê 6ú = ê - 6ú
ë 0 -1û ë û ë û
Y
(3, 6) D C (7, 6)
(3, 4) A B (7, 4)
X X
O
Y
Fig. 1.9.24
2-D Transformation Problems based on Homogeneous Coordinate System
(Concatenation)
Example 1.9.11 : A rectangle ABCD has coordinates A(2, 3), B(6, 3), C(6, 6) and
D(2, 6). Calculate the combined transformation matrix (concatenation) for the following
operations. Also find the resultant coordinates.
i) Translation by 2 units in x - direction and 3 units in y - direction.
ii) Scaling by 4 - units in x - direction and 2 - units in y - direction.
iii) Rotation by 30 ° in counter clockwise direction about z - axis, passing through a
point (3, 3).
Solution : Given :
Rectangle ABCD ® A(2, 3) Þ (x1 , y 1 )
B(6, 3) Þ (x 2 , y 2 )
C(6, 6) Þ (x 3 , y 3 )
D(2, 6) Þ (x 4 , y 4 )
i) Translation matrix in homogeneous form :
Given, Dx = 2
Dy = 3
Homogeneous Translation Matrix
é1 0 0ù
[T](2,3) = ê0 1 0ú
ê ú
êë2 3 0úû
Step 1 : Translation matrix for translating ABCD to origin form point (3, 3) [TI ]
Here, DxI = – 3, Dy I = – 3
é 1 0 0ù é 1 0 0ù
\ [TI ] = ê 0 1 0ú ê 0 1 0ú
ê ú ê ú
êë DxI Dy I 1úû êë –3 –3 1úû
é0866
. 0.5 0ù
Þ ê
[T] = – 0.5 0866
. 0ú
ê ú
êë 0 0 1úû
é 0.866 0.5 0ù
Þ ê
[R] = –0.5 0.866 0 ú
ê ú
êë1 . 902 – 1.908 1úû
So we obtained all the three matrixes for evaluating the combined matrix [m ]
é1 0 0ù
[T](2,3) = ê0 1 0ú
ê ú
êë2 3 0úû
é 4 0 0ù
[S](4,2) = ê0 2 0ú
ê ú
êë0 0 1úû
é0866
. 0.5 0ù
[R]( q= 30°) ê
= – 0.5 0866
. 0ú
ê ú
êë1902
. –1098
. 1úû
é3.464 2 0ù
Þ [Tc ] = ê –1 1.732 0 ú
ê ú
êë 5.93 8.098 1úû
4×3×3×3
é A ¢ù é 9.858 17.294 1ù
ê B¢ ú ê 23.714 25.294 1ú
ê ú = ê ú
êC ¢ú ê 20.714 30.49 1ú
ê D ¢ú ê 6.888 22.49 1ú
ë û ë û
A ¢ = (x1¢ , y 1¢ ) = (9.858, 17.294)
B ¢ = (x ¢2 , y ¢2 ) = (23.714, 25.294)
C ¢ = C (x ¢3 , y ¢3 ) = (20.714, 30.49)
D ¢ = (x ¢4 , y ¢4 ) = (6.888, 22.49)
Y (20.714, 30.49)
C'
B'
(23.714, 25.94)
D'
(6.88, 22.49)
A'
(9.858, 17.294)
D(2,6) C(6,6)
A(2,3) B(6,3)
X
Fig. 1.9.25
Example 1.9.12 : Find the transformartion matrix to transform polygon ABCD to 3/4
of its original size, with uts centre (4, 4.5) remians at the same position. Coordinates of
ABCD are A(2, 3), B(6, 3), C(6, 6), D(2, 6).
A (x1 , y 1 ) = (2, 3)
B (x 2 , y 2 ) = (6, 3)
C (x 3 , y 3 ) = (6, 6)
D (x 4 , y 4 ) = (2, 6)
1 - 48 Computer Aided Design and Manufacturing
Introduction
3
Step 2 : Scaling to of its size at origin (0,0)
4
Here, S x = 0.75; S y = 0.75
\ [S] in homogeneous form,
éS x 0 0ù é 0.75 0 0ù
[TII ] = ê 0 S y ú
0 = 0ê 0.75 0ú
ê ú ê ú
êë 0 0 1úû êë 0 0 1úû
é1 0 0ù é1 0 0 ù
\ [T]III ê
= 0 ú
1 0 = ê0 1 0 ú
ê ú ê ú
êë Dx Dy 1úû êë 4 4.5 1úû
é0.75 0 0ù
Þ [S]æ 3 = ê 0 0.75 0 ú
3ö ê ú
ç , ÷
è 4 4ø êë 1 1.125 1úû
Resultant Co-ordinates
Given, A (x1 , y 1 ) = (2, 3)
B (x 2 , y 2 ) = (6, 3)
C (x 3 , y 3 ) = (6, 6)
D (x 4 , y 4 ) = (2, 6)
ABCD in homogeneous form,
éA ù é x1 y1 1ù é 2 3 1ù
ê Bú êx y2 1ú ê6 3 1ú
ê ú = ê 2 ú = ê ú
êCú êx 3 y3 1ú ê6 6 1ú
ê Dú êx y4 1úû êë 2 6 1úû
ë û ë 4
Resultant Co-ordinates
é A ¢ù ìA ü
ê B¢ ú ïï B ïï
ê ú = í ý ´ [S ](3/ 4 , 3/ 4 )
êC ¢ú ïC ï
ê D ¢ú ïî D ïþ
ë û
é A ¢ù é2 3 1ù é 2.5 3.375 1ù
ê B¢ ú ê6 ú é0.75 0 0ù ê
3 1 ê 5.5 3.375 1ú
Þ ê ú = ê ú´ 0 0.75 0ú = ê ú
êC ¢ú ê6 6 1ú ê ú ê 5.5 5.625 1ú
ê D ¢ú ê2 ú êë 1 1125
. 1úû ê
ë û ë 6 1û ë 2.5 5.625 1úû
\ A ¢ = (2.5, 3.375)
B ¢ = (5.5, 3.375)
C ¢ = (5.5, 5.625)
D ¢ = (2.5, 5.625)
D(2, 6) C(6, 6)
P (4, 4.5)
A(2, 3) B(6, 3)
Fig. 1.9.26
1.10 3D Transformations
· It is often necessary to display objects in
3-D on the graphics screen.
· The transformation matrices developed
for 2-dimensions can be extended to 3-D.
· Fig. 1.10.1 represents 3D translation of a
donut.
3D Translation
· 3D translation matrix is explained by,
é 1 0 0 0ù
ê 0 1 0 0ú
[T] = ê ú
ê 0 0 1 0ú Fig. 1.10.1.3D Translation of a donut
êD ú
ë x D y D z 1û
· D x , D y and D y explains distance of translation along x, y and z direction
respectively.
3D Scaling
· 3D scaling matrix is explained by,
éS x 0 0 0ù
ê0 S 0 0ú
y
[ Ts ] = ê ú
ê0 0 S y 0ú
ê0 0 0 1úû
ë
· S x ,S y and S z represents the scaling factors along x, y and z direction
respectively.
3D Rotation
· 3D rotation matrices are given by,
i) Rotation along Z-axis by angle 'q'
é cos q sin q 0 0ù
ê – sin q cos q 0 0ú
[R z ] = ê ú
ê 0 0 1 0ú
ê 0 0 0 1úû
ë
ii) Rotation along X-axis by angle 'f'
é1 0 0 0ù
ê0 cos f – sin f 0ú
[R x ] = ê ú
ê0 sin f cosf 0ú
ê0 0 0 1úû
ë
iii) Rotation along X-axis by angle 'f'
é cos f 0 sin f 0ù
ê 0 1 0 0ú
[R y ] = ê ú
ê sin f 0 cos f 0ú
ê 0 0 0 1úû
ë
· The process of turning on the pixels for a line segment is called vector
generation. If the end points of the line segment are known, there are several
schemes for selecting the pixels between the end pixels. One method of
generating a line segment is a symmetrical Digital Differential Analyzer (DDA).
· If m £ 1, Assume D x = 1
¡ Then, D y = mDx = ( y 2 – y 1 ) = m (x 2 – x1 )
¡ This could be written as,
y i + 1 - y i = m(x i+1 – x i ), where(i = 1, 2, 3,¼ )
and since, D x = 1, y i+1 – y i = m
· Therefore, If m £ 1
x i+1 - x i - = 1
y i+1 - y i = m
· From this it could be observed that x value will be incremented by 1 and y value
will be incremented by slope 'm'.
· If m >1, Assume D y = 1
Dy
¡ Then, m =
Dx
Dy
Dx =
m
1
( x 2 - x1 ) = (y – y1)
m 2
¡ This could be written as,
1
( x i+1 – x i ) = (y – y i ), where (i = 1, 2, 3, …)
m i+1
· Therefore, If m > 1
x i+1 – x i - = 1/m
y i+1 – y i = 1
· From this it could be observed that x value will be incremented by 1/m and y
value will be incremented by 1.
Step 4 : Find x and y increment values
Dx
x increment =
No. of steps
Dy
y increment =
No. of steps
Note :
1. If m £ 1, increment 'x' by 1 and increment
'y' by 'y-increment' value and round off to
nearest value.
2. If m > 1, increment 'y' by 1 and increment
'x' by 'x-increment value and round off to
nearest value.
Step 5 : Plot the x and y points in raster scan
display as shown in Fig. 1.11.2.
Fig. 1.11.2
1 - 54 Computer Aided Design and Manufacturing
Introduction
Start
Yes
xi+1– xi– = 1
yi+1– yi = m
Stop
Start
No
If e 0 ei+1 – ei + 2 y – 2 x
Yes
ei+1 = ei + 2 y
Stop
Fig. 1.11.4
Example 1.11.1 : Explain rasterization by performing DDA algorithm for a line AB,
A(2, 3) and B(12, 8).
Solution :
Given, Line AB Þ A(x1 , y 1 ) = (2, 3)
A(x 2 , y 2 ) = (12, 8)
Step 1 : Identity (x1 , y 1 ) and (x 2 , y 2 )
x1 = 2; y1 = 3
x 2 = 12; y2 = 8
Step 2 : Calculate the number of steps
Dy = y 2 - y 1 = 5
Dx = x 2 - x1 = 10
Q Dx > Dy Þ No. of steps = Dx = 10
Step 3 : Find the slope (m)
Dy 5
Slope, (m) = = = 0.5
Dx 10
m = 0.5 < 1
\ when m £ 1 ü
ï ' x' will be intremented by 1
xi + 1 - xi = 1 ý
y i+ 1 - y i = m ï ' y' will be intremented by m
þ
Step 4 : Find the increment value
Dx 10
x increment = = =1
No. of. steps 10
Dy 5
y increment = = = 0.5 = m
No. of. steps 10
Sample solution
x i = 2; yi = 3
First increment : x i + 1 =2+1=3
y i +1 = 3 + 0.5 = 3.5
Second step : xi + 2 =3+1=4
y i + 2 = 3.5 + 0.5 = 4
1 - 57 Computer Aided Design and Manufacturing
Introduction
Similarly Step 3 : x i +3 = 4 + 1 = 5
yi +3 = 4 + 0.5 = 4.5
Follow the iterations until 10 steps are completed as shown in table.
Step 5 : Identify initial and final values
Step 6 : Plot
yvalues 8
0 1 2 3 4 5 6 7 8 9 10 11 12 xvalues
Step 6 : Plot
Fig. 1.11.5
Example 1.11.2 : Using DDA algorithm rasterize line AB, A(0, 0), B(4,6).
Solution :
x1 = 0; y1 = 0
x 2 = 4; y2 = 6
Dy = y 2 - y 1 = (6 – 0) = 6
Dx = x 2 - x1 = (4 – 0) = 4
Dy 6
Slope (m) = = = 1.5
Dx 4
Q m >1 ü
1 ï ' x' will be incremented by 1 and
xi + 1 - xi = ý m
m
yi + - yi =1 ï ' y' will be intremented by '1'
1 þ
Also, 1 1
0.66 = =
m 1.5
Dy 6
y increment = = =1
No. of steps 6
Initial values : xi = 0 ; yi = 0
0 0 0 0 0
1 0.66 1 1 1
2 1.32 2 1 2
3 1.98 3 2 3
4 2.64 4 3 4
5 3.30 5 3 5
6 3.96 6 4 6
Step 6 : Plot
0 1 2 3 4
Fig. 1.11.6
Example 1.11.3 : Rasterize line A,B, A(3,3) and B(11, 7) using Bresenham's line
drawing algorithm.
Solution :
Þ e1 = 0 + 8 – 16 = –8 y=y+1=3+1=4
\ e 2 = e7 + 2Dy x=x+1=4+1=5
Þ = –8+8=0 y=4
0 3 3 0
1 4 4 –8
2 5 4 0
3 6 5 –8
4 7 5 0
5 8 6 – 8
6 9 6 0
7 10 7 – 8
8 11 7 0
0 1 2 3 4 5 6 7 8 9 10 11
Fig. 1.11.7
· If any part of the geometry is not inside the window, it is made invisible by the
CAD software through a process known as clipping.
· Clipping is the process of determining the visible portions of a drawing lying
within a window.
· Clipping, in the context of computer graphics, is a method to selectively enable
or disable rendering operations within a defined region of interest.
· In clipping each graphic element of the display is examined to determine whether
or not it is completely inside the window, completely outside the window or
crosses a window boundary.
· Portions outside the boundary are not drawn. Any geometry lying wholly outside
the view boundary is not mapped to the screen, and any geometry lying partially
inside and partially outside is cut off at the boundary before being mapped.
· Typical clipping algorithm : Cohen-Sutherland clipping algorithm.
· If clipping is not done properly a CAD system will produce incorrect pictures
due to an overflow of internal coordinate registers. This effect is known as wrap
round.
Applications of Clipping :
· Extracting part of defined scene for viewing
· Identifying visible surfaces in 3D Views
· Anti-aliasing line segments or object boundaries
· Creating objects using solid modelling procedures
· Drawing and painting operations
Types of Clipping :
i. Point clipping ii. Line clipping iii. Area clipping (Polygon)
iv. Curve clipping v. Text clipping
i. Point Clipping
ywmax
· The clip window is a rectangle
as shown in the Fig. 1.12.1.
· The point P = (x,y) will be
displayed if the following P (x, y)
inequalities are satisfied :
x wmin £ x < x wmax
ywmin
y wmin £ y < y wmax
xwmin xwmax
(x wmin , x wmax ) and (y wmin , y wmax ) are the edges of the clip window.
· If any one of these four inequalities is not satisfied, the point is clipped.
ii. Line Clipping
· Line that do not intersect the clipping window are either completely inside the
window or completely outside the window.
· In the case of line clipping, four different cases are possible.
Different Cases for line Clipping
· Case1 : Both endpoints of the line lie within the clipping area as shown in
Fig. 1.12.2. This means that the line is included completely in the clipping area,
so that the whole line must be drawn.
B B
A
A
Clip
rectangle
· Case 2 : One end point of the line lies within the other outside the clipping area
as shown in Fig. 1.12.3. It is necessary to determine the intersection point of the
line with the bounding rectangle of the clipping area. Only a part of the line
should be drawn.
D' D'
B B
C C
A
A
Clip
rectangle
D'
Clip
rectangle
· Invisible : Any lines that have a 1 in the same bit position in the region code for
each endpoint are completely outside the clipping rectangle and the line segment
is invisible, and these lines will be trivially rejected. The line that has a region
code of '0001' will be discarded. For one endpoint and a code of '0101' for the
other endpoint. Both end points of the line are at left of the clipping rectangle, as
indicated by the '1' in the first position of each region code.
· Clipping candidate or indeterminate : A line segment is said to be indeterminate
if the bitwise logical AND of the region codes of the end points is equal to
'0000'.
· For example : Line segment P3P4 having endpoint codes '0100' and '0010' and
P7P8 having endpoints codes '0010' and '1000' in the figure. These line segments
may or may not process the window boundaries as line segment P7P8 is invisible
but line segment P3P4 is partially visible and must be clipped.
iii. Polygon Clipping
· The simplest curve is a line segment or simply a line.
· A sequence of line where the following line starts where the previous one ends is
called a polyline.
· If the last line segment of the polyline ends where the first line segment started,
the polyline is called a polygon.
· A polygon is defined by 'n' number of sides in the polygon.
· We can divide polygon into two classes.
a) Convex polygon
b) Concave polygon Q
· A convex polygon as shown in Fig. 1.12.8 (a), is
P
a polygon such that for any two points inside
the polygon, all the point of the line segment
connecting them are also inside the polygon. A
Fig. 1.12.8 (a) Convex polygon
triangle is always a convex one.
· A polygon is said to be a concave, if the line
joining any two interior points of the polygon
does not lie completely inside the polygon, as
shown in Fig. 1.12.8 (b)
· There are four possible cases when processes
vertices in sequence around the parameter of the
polygon. As each pair of adjacent polygon Fig. 1.12.8 (b) Concave polygon
vertices is passed to a window boundary clipper,
the following test could be made,
· Case 1 : If the first vertex is outside the window boundary and second vertex is
inside the window boundary then both the intersection point of a polygon edge
with the window boundary and second vertex are added to the output vertex list.
1 - 67 Computer Aided Design and Manufacturing
Introduction
· Case 2 : If both input vertices are inside the window boundary. Only the
second vertex is added to the vertex list.
· Case 3 : If the first vertex is inside the window boundary and the second vertex
is outside the window boundary then only the edge intersection with the
window boundary is added to the output vertex list.
· Case 4 : If both the input vertices are outside the window boundary then
nothing is save to the output list.
· Fig. 1.12.9 explains an example for polygon clipping.
10 13
11 12 1
9
5 6 7 8
2
4
3
x
5 8
6 7
2
4
v. Text Clipping
Text clipping can be of two types : Widow
a) All or none string-clipping : In this
clipping as shown in figure, if all the STRING 1
Widow 2 Widow
STRING 1 ING
S TR
ING 1 R
ST
STRING 1 STRING 4 TRING 1 STRING 4
f e d
Computer Frame Scan Visaport
display buffer conversion transformation
ywmax yvmax
ywmin yvmin
æ1 0 x v min ö æ S x 0 0 ö æ 1 0 – x w min ö
ç ÷ ç ÷ ç ÷
N = ç0 1 y v min ÷ × ç 0 S y 0 ÷ × ç 0 1 – y w min ÷
ç0 0 1 ÷ø çè 0 0 1 ÷ø çè 0 0 1 ÷
è ø
· An example for viewing transformation is shown in Fig. 1.13.3.
Window
ywmax
(xw, yw)
ywmax
ywmin
ywmin
0
xwmin xwmax 0 xvmin xvmax
CAD/CAM
system
Hardware Software
CAD hardware :
CAD hardware consists of a central processing unit, storage devices, one or more
graphic display terminals and other input and output devices as shown in Fig. 1.14.2.
CAD hardware components :
· Central Processing Unit (CPU)
· Memory
· Hard disk, Floppy disk, CD-ROM
· External storage devices
· The monitor
1 - 72 Computer Aided Design and Manufacturing
Introduction
stress-strain, heat transfer or any other characteristics depending upon the type of
application. The interrelating behavior of all the nodes gives the behavior of the
whole object.
· The CAD software has the option of defining the nodes and network structure as
per the designer's requirement.
· The output of the finite element analysis can be observed through the graphical
user interface. If the user finds that the output results are undesirable, they can
change the shape and dimensions of the object and carry out FEA again.
· Some of the common FEA packages in CAD for carrying out engineering
analysis are ANSYS, ABAQUS, NASTRAN etc.
· CAD also has provision for kinematic analysis of the design. ADAMS is the
commonly used CAD package for kinematic analysis.
c) Design Review and Evaluation
· Review and evaluation is checking whether the designed part has been designed
properly or not and if they will fail in practical situations.
· CAD software makes the process of design review and evaluation has become
much faster and convenient.
· Design review and evaluation features offered by CAD software are zoom in and
out, layering, checking interference, animation capability.
d) Automated drafting
· Drafting is the process of making the drawings of the designed parts.
· After designing of the object its assembly and detail parts drawings have to be
made which includes specifications of various materials also called as bill of
materials used for the manufacturing the components of the object.
· Automated drafting is one of the most important applications of the CAD
software.
Reasons for Implementing CAD or Advantages or Benefits of CAD
i. Increase in the productivity of the designer : The CAD software helps designer
in visualizing the final product that is to be made, it subassemblies and the
constituent parts. The product can also be given animation and see how the actual
product will work, thus helping the designer to immediately make the modifications
if required. CAD software helps designer in synthesizing, analyzing, and
documenting the design. All these factors help in drastically improving the
productivity of the designer that translates into fast designing, lower designing cost
and shorter project completion times.
ii. Improve the quality of the design : With the CAD software the designing
professionals are offered large number of tools that help in carrying out thorough
engineering analysis of the proposed design. The tools also help designers to
consider large number of investigations. Since the CAD systems offer greater
accuracy, the errors are reduced drastically in the designed product leading to better
design. Eventually, better design helps carrying out manufacturing faster and
reducing the wastages that could have occurred because of the faulty design.
iii.Flexibility in design : It is easy to change and alter the design in CAD as per the
user's requirement. For example, a building plan might contain separate overlays for
its structural, electrical, and plumbing components. In CAD layers can be used for
this purpose. The user could display, edit, and print layers separately or in
combination. Also, the layers could be named to track content, and layers could be
locked so that they can't be altered. Assigning settings such as color, linetype, or
lineweight to layers helps to comply with industry standards. Assigning a plot style
to a layer makes all the objects drawn on that layer plot in a similar manner.
iv. Improved design analysis : CAD helps in performing advanced engineering
analysis of the design with the aid of CAD packages such as ANSYS, ABAQUS
for FEA and ADAMS for kinematic analysis.
v. Better communications : The next important part after designing is making the
drawings. With CAD software better and standardized drawings can be made easily.
The CAD software helps in better documentation of the design, fewer drawing
errors, and greater legibility.
vi. Creating documentation of the designing : Creating the documentation of
designing is one of the most important parts of designing and this can be made
very conveniently by the CAD software. The documentation of designing includes
geometries and dimensions of the product, its subassemblies and its components,
material specifications for the components, bill of materials for the components etc.
vii. Creating the database for manufacturing : When the creating the data for the
documentation of the designing most of the data for manufacturing is also created
like products and component drawings, material required for the components, their
dimensions, shape etc.
viii. Saving of design data and drawings for future reference : All the data used for
designing can easily be saved and used for the future reference, thus certain
components don't have to be designed again and again. Similarly, the drawings can
also be saved and any number of copies can be printed whenever required. Some of
the component drawings can be standardized and be used whenever required in any
future drawings.
ix. Better design accuracy
x. Better visualization of drawing : CAD has provision for rendering and 3D
visualization. Rendering helps in the visualization of design in required
environment.
Material
selection
Determination Assembly
of dimensions method
Conceptual Part
design drawing
Thickness Part
determination Database arrangement
Simulation Automatic
cutting
Material Automatic
handling Jigs assembly
and
fixtures
CAM
Production/Operations volume
(i) Job Production
Mass production
· Under this method peculiar,
special or non-standardized
Batch production
products are produced in
accordance with the orders Job-shop
production
received from the customers.
· As each product is non-
standardized varying in size and
nature, it requires separate job for Output/Product variety
production.
Fig. 1.16.1 Classification of production system
· The machines and equipment's are
adjusted in such a manner so as to suit the requirements of a particular job.
· Job production involves intermittent process as the work is carried as and when
the order is received.
· It consists of bringing together of material, parts and components in order to
assemble and commission a single piece of equipment or product.
· Ship building, dam construction, bridge building, book printing are some of the
examples of job production. Third method of plant layout viz., stationery material
layout is suitable for job production.
Characteristics
The job production possesses the following characteristics :
· A large number of general purpose machines are required.
· A large number of workers conversant with different jobs will have to be
employed.
· There can be some variations in production.
· Some flexibility in financing is required because of variations in work load.
· A large inventory of materials, parts and tools will be required.
· The machines and equipment setting will have to be adjusted and readjusted to
the manufacturing requirements.
· The movement of materials through the process is intermittent.
Limitations
Job production has the following limitations :
· The economies of large scale production may not be attained because production
is done in short-runs.
· The demand is irregular for some products.
· The use of labour and equipment may be inefficient.
· The scientific assessment of costs is difficult.
(ii) Batch Production
· Batch production pertains to repetitive production.
· It refers to the production of goods, the quantity of which is known in advance.
· It is that form of production where identical products are produced in batches on
the basis of demand of customers' or of expected demand for products.
· This method is generally similar to job production except the quantity of
production.
· Instead of making one single product as in case of job production, a batch or
group of products are produced at one time.
· It should be remembered here that one batch of products may not resemble with
the next batch.
· Under batch system of production, the work is divided into operations and one
operation is done at a time.
· After completing the work on one operation it is passed on to the second
operation and so on till the product is completed.
· Batch production can be explained with the help of an example.
An enterprise wants to manufacture 20 electric motors. The work will be
divided into different operations. The first operation on all the motors will be
completed in the first batch and then it will pass on to the next operation. The
second group of operators will complete the second operation before the next
and so on. Under job production the same operators will manufacture full
machine and not one operation only.
· Batch production can fetch the benefits of repetitive production to a large extent,
if the batch is of a sufficient quantity.
· Thus, batch production may be defined as the manufacture of a product in small
or large batches or lots by series of operations, each operation being carried on
the whole batch before any subsequent operation is operated.
· This method is generally adopted in case of biscuit and confectionery and motor
manufacturing, medicines, tinned food and hardware's like nuts and bolts etc.
Characteristics
The batch production method possesses the following characteristics,
· The work is of repetitive nature.
· There is a functional layout of various manufacturing processes.
· One operation is carried out on whole batch and then is passed on to the next
operation and so on.
· Same type of machines is arranged at one place.
· It is generally chosen where trade is seasonal or there is a need to produce great
variety of goods.
(iii) Mass or Flow Production
· This method involves a continuous production of standardized products on a large
scale.
· Under this method, production remains continuous in anticipation of future
demand. Standardization is the basis of mass production.
· Standardized products are produced under this method by using standardized
materials and equipment.
· There is a continuous or uninterrupted flow of production obtained by arranging
the machines in a proper sequence of operations.
· Process layout is best suited method for mass production units.
· Flow production is the manufacture of a product by a series of operations, each
article going on to a succeeding operation as soon as possible.
· The manufacturing process is broken into separate operations.
· The product completed at one operation is automatically passed on to the next till
its completion.
· There is no time gap between the work done at one process and the starting at
the next.
· The flow of production is continuous and progressive.
Characteristics
The mass or flow production possesses the following characteristics :
· The unit's flow from one operation point to another throughout the whole process.
· There will be one type of machine for each process.
· The products, tools, materials and methods are standardized.
· Production is done in anticipation of demand.
· Production volume is usually high.
· Machine set ups remain unchanged for a considerable long period.
1) Batch production :
· In batch production, the time to process one batch consisting of 'Q' work units is
the sum of set up time and processing time.
Batch processing time = Tb (min)
Set up time = Tsu (min batch)
Q = Batch quantity (Pc )
Tc = Cycle time (min Pc )
\ Tb = Tsu + Q ´ Tc
\ Tb
Tp =
Q
· The average production rate for the machine is simply the reciprocal of average
production time expressed in hourly rate.
60
Rp = Pc hr
Tp
Tp = Tsu + Tc min Pc
3) Mass production :
· For mass production setup time could be neglected (Tsu ~ 0) and Q = 1
· Then average production time per work unit,
Tp = 0 + Tc
· Therefore Tp = Tc
60 60
Rp = = Pc hr
Tp Tc
Example 1.17.1 : The Turret lathe section has six machines, all devoted to the
production of the same part. The section operates 10 shifts/week. The number of hours
per shift averages 8.0. Average production rate of each machine is 17 units/hr.
Determine the weekly production capacity of the turret lathe section.
Solution :
Pc = 8160 unit/week
Example 1.17.2 : A production facility has 5 works centers, all devoted to the
production of the same part. The facility operates 8 hr/shift, 2 shifts/day and
5 days/week. Average production rate for each machine is 15 units/hr. Compute the
weekly production capacity of the production facility.
Production capacity = n S w H sh R P
Pc =
no
\ Pc = 6000 units/week
Q
\ u=
Pc
Where,
Q = Actual quantity produced by the facility during a given time period (Pc / week).
Pc = Production capacity for same period (Pc / week).
Note :
i) Utilization can be assessed for an entire plant, a single machine in the plant or
any other productive resources such as labour.
ii) Utilization is often defined as the proportion of time that the facility is operating
relative to the time available.
iii) Utilization is usually expressed as percentage.
iv) If utilization is high, that means the facility is being operated to its full capacity.
B) Availability (A)
· Availability is defined using two other reliability measure terms.
· MTBF = Mean Time Between Failures
· MTTR = Mean Time To Repair.
MTBF - MTTR
A =
MTBF
Breakdown
Repairs completed
Equipment
operating
TIme
MTBF
Fig. 1.17.1 Time scale showing MTBF and MTTR used to define availability
(n S w H sh R P )
Pc = U ´ A ´
no
Pc = 1600 units/week
b) Utilization (u)
Q
u =
Pc
\ U = 62.5 %
Pc = 900 units/week
Example 1.17.4 : The mean time between failures for a certain production machine is
200 hours and the mean time to repair is 5 hours. Determine the availability of the
machine.
\ MLT = n o (Tsu + Tc + Tn o )
\ MLT = Tc
Example 1.17.5 : A certain part is produced in a batch size of 100 units. The batch
must be routed through 5 operations to complete the processing of the parts. Average
set up time is 3 hr/operations and average operation time is 6 min (0.1 hour). Average
non operation time due to handling, delays, inspection etc. Is 7 hours for each
operation. Determine how many days it will take to complete the batch, assuming that
the plant runs for 8 hr shift / day.
Example 1.17.6 : A certain part is routed through six machines in a batch production
plant. The set up and operation times for each machines are given in the table below.
The batch size is 100 and the average non operation time per machine is 12 hours.
Determine.
i) Manufacturing Lead Time (MLT)
ii) Production Rate for operation 3
1 4 5
2 2 3.5
3 8 1.0
4 3 1.9
5 3 4.1
6 4 2.5
Tc = 4.5 min
MLT = 141 hr
\ R P = 4.05 hr
A ´ U ´ Pc ´ MLT
WIP = Sw Hsh
Where,
A = Availability
U = Utilization
Pc = Plant (or) production capacity
MLT = Manufacturing Lead Time
S w = Number of shifts/ week
H sh = Hours/shift
· Work In Process (WIP) is the inventory that is in the state of being transformed
from raw material to finished product.
· WIP represents investment by a firm that cannot be converted to revenue until all
processing is finished.
Example 1.17.7 : The average part produced in a batch manufacturing plant must be
processed subsequentially through six machines on average. Twenty new batches of
parts are launched each week. Average operation time is 6 min, average setup time
= 5 hours, average batch size = 36 parts and average non operation time per batch
= 10 hrs/ machine. There are 18 machines in the plant working in parallel. Each of the
machine in the plant working in parallel. Each of the machine can be set up any type of
job processed in the plant. The plant operates at an average of 70 production hours per
week. Scrap rate is negligible. Determine manufacturing lead time for an average part,
plant capacity, plant utilization and work in process.
105
MLT = = 1.5 week
70
· Production rate, R P
Batch processing time,
TP = Tsu + QTc = 300 + 25 ´ 6 = 450 min = 450 min
Average production Time/week, (TP )
Tb 450
TP = = = 18 min
Q 25
60 60
Production rate, R P = =
TP 18
R P = 3.33 Pc / hr
WIP = 11 parts
Tc = Fc + V c
a) Factory overheads
Some of the typical factory overheads are,
· Plant supervision
· Applicable taxes
· Factory depreciation
· Material handling
· Power for machinery
· Security personnel
· Insurance
· Tool crib attendant
· Clerical support
· Heat and Air conditioning
· Light
· Payroll services
b) Corporate overheads
Some of the typical corporate overheads are,
· Sales and Marketing
· Accounting department
· Research and development
· Office space
· Finance department
· Legal counsel
· Corporate executives
Various components of manufacturing costs,
Various components of manufacturing costs are,
1) Prime cost
2) Factory or Work cost
3) Manufacturing or Production cost
4) Total cost or Ultimate cost
5) Selling prices
6) Market price
1) Prime cost :
It is the direct cost associated with production
Prime cost = Direct labour cost + Direct material cost + Direct expenses
2) Factory (or) work costs :
Factory cost = Prime cost + Factory expenses (Factory on cost)
3) Production (or) Manufacturing cost :
Production cost = Factory + Administrative expenses
4) Total cost (or) ultimate cost :
Total cost = Manufacturing or production cost + Selling expenses
+ Distribution expenses
5) Selling price :
Selling price = Total cost + Profit
6) Market Price :
Market price = Selling price + Discount
Problems based on components of cost
Volume (units)
Fc
Q BEP =
S p - Vc
Where,
Fc = Fixed cost
V c = Variable cost
S p = Selling price/unit
Total revenue = S P ´ Q
Fc
Q BEP =
S p - V c units
Fc
S BEP =
æV ö
1- ç c ÷ in rupees
è SP ø
Example 1.18.1 : The fixed cost for the year 2015-2016 are ` 700000, variable cost
per unit is ` 45.Each unit is sold at ` 200. Determine.
i) Break even point in terms of sales volume.
ii) Break even point in terms of rupees.
iii) If sales volume of 6000 units has been expected, what will be the profit earned ?
iv) If a profit target of ` 150000 has be budgeted, compute the number of units to be
sold.
S BEP = ` 903225.8
Fc + Profit
Also, Q BEP = =Q
S p - Vc
700000 + Profit
6000 = = ` 23000
200 - 45
iv) Number of units to be sold if profit target = ` 150000
Here, Q BEP = Q, since there is profit
Fc + Profit
\ Q =
S p - Vc
700000 + 150000
= = 5483.8
200 - 45
Q = 5484 units
Review Questions
Fig. 1.1
· Window
· When a design package is initiated, the display will have a set of co-ordinate values.
These are called default co-ordinates.
· A user co-ordinate system is one in which the designer can specify his own
coordinates for a specific design application.
· Therefore, the designer may want to view only a portion of the image, enclosed in a
rectangular region called a window.
Window
Original
drawing
Fig. 1.2
Q.9 List out the fundamental reason for implementing a CAD system.
+ [ AU : May 2015, Dec. 2013, Dec. 2011 ]
Ans. : · To Increase in the productivity of the designer
· To Improve the quality of the design
m Manageable portions.
m Recognition of need
m Definition of Problem
m Synthesis
m Analysis and Optimization
m Evaluation
m Presentation
Q.15 Mention any four applications of computer aided design in mechanical
engineering.
Ans. : · Computer-Aided Engineering (CAE) and Finite Element Analysis (FEA)
· Computer-Aided Manufacturing (CAM) including instructions to Computer
Numerical Control (CNC) machines
· Photorealistic rendering and motion simulation.
· Document management and revision control using product data management.
Q.16 List and differentiate the types of 2D geometric transformations.
Ans. : · Translation - Moves an object to a different position on the screen.
· Rotation - Rotate the object at particular angle q (theta) from its origin.
· Scaling - Change the size of an object
· Reflection - Mirror image of original object
· Shear - Slants the shape of an object
Q.17 List the various stages in the life cycle of a product
Ans. : · Developing the product concept
· Evolving the design
· Engineering the Product
· Manufacturing the product
· Marketing
· Servicing
Q.18 Define clipping.
Ans. : Any procedure that identifies those portions of a picture that are either inside or outside
of a specified region or space is known as clipping.
· Types of clipping
· Point clipping
· Line clipping
· Area clipping
· Text clipping
Q.19 What is viewing transformations ?
Ans. : · The mapping of a part of a world-coordinate scene to device coordinates is referred to
as a viewing transformation. Sometimes the two-dimensional viewing transformation is simply
referred to as the window-to-viewport transformation or the windowing transformation.
· A world-coordinate area selected for display is called a window.
· An area on a display device to which a window is mapped is called a viewport.
· The window defines what is to be viewed; the viewport defines where it is to be
displayed.
Q.20 Describe Computer Aided Design.
Ans. : CAD is the function of computer systems to support in the creation, modification,
analysis, or optimization of a design. CAD software is used to raise the productivity of the
designer, progress the quality of design, progress communications through documentation, and to
generate a database for manufacturing.
Q.21 State the importance of Computer Architecture in CAD.
Ans. : In CAD, Computer architecture is a set of disciplines that explains the functionality, the
organization and the introduction of computer systems; that is, it describes the capabilities of a
computer and its programming method in a summary way, and how the internal organization of
the system is designed and executed to meet the specified facilities.
Q.22 What are the steps involved in architecture implementation ?
Ans. : Computer architecture engages different aspects, including instruction set architecture
design, logic design, and implementation. The implementation includes Integrated Circuit
Design, Power, and Cooling. Optimization of the design needs expertise with Compilers,
Operating Systems and Packaging.
écos q - sin q ù
R(q ) = ê
ë sin q cos q úû
é cos q sin q ù
R( -q ) = ê ú
ë - sin q cos q û
Q.24 What is design process ?
Ans. : The Engineering Design process is a multi-step process including the research,
conceptualization, feasibility assessment, establishing design requirements, preliminary design,
detailed design, production planning and tool design, and finally production.
Q.25 What is meant by analysis ?
Ans. : · The analysis begins with an attempt to put the conceptual design into the context of
engineering sciences to evaluate the performance of the expected product.
· This requires design modeling and simulation. An important aspect of analysis is the
questions that helps to eliminate multiple design choices and find the best solution to
each design problem.
· Bodies with symmetries in their geometry and loading are usually analyzed by
considering a portion of the model. Example : Stress analysis pressure vessels,
couplings etc.
Q.26 What are the applications of CAD ?
Ans. : · Structural design of aircraft
· Aircraft simulation
· Real time simulation
· Automobile industries
· Architectural design
· Pipe routing and plan layout design
· Electronic industries
· Dynamic analysis of mechanical systems
· Kinematic analysis
· Mesh data preparation for finite element analysis.
Sequential engineering is the term used to In concurrent engineering, various tasks are
explain the method of production in a linear handled at the same time, and not
system. The various steps are done one essentially in the standard order. This means
after another, with all attention and resources that info found out later in the course can be
focused on that single task. added to earlier parts, improving them, and
also saving time.
Y'
Y
Z P'
P X'
P
Z
Y
X
X
Fig. 1.3
Q.31 Write the features needed to be satisfied for line drawing algorithm.
Ans. : · Lines should appear straight
· Lines should terminate accurately
· Lines should have constant density
· Line density should be independent of length and angle
· Line should be drawn rapidly
Q.32 Differentiate preliminary design and detailed design.
Ans. :
The preliminary design fills the gap between the The next phase of preliminary design
design concept and the detailed design phase. The is the Detailed Design which may
system configuration is defined, and schematics, include procurement also. This phase
diagrams, and layouts of the project will offer early builds on the already developed
project configuration. In detailed design and preliminary design, aiming to further
optimization, the parameters of the part being develop each phase of the project by
produced will change, but the preliminary design total description through drawings,
focuses on creating the common framework to modeling as well as specifications.
construct the project.
· No. of days in the week (or) month that the plant operates.
· Employment levels.
Q.35 Define - Utilization and Availability
Ans. : Utilization (U) is defined as the amount of output of a production facility relative to its
capacity.
· Utilization is expressed as,
Q
U =
Pc
1. Describe various stages of design process with an example. (Refer section 1.3) [8]
2. Explain a line drawing algorithm. (Refer section 1.11) [8]
3. Define clipping. Also explain the working of a simple line clipping algorithm.
(Refer section 1.12) [8]
4. Deduce windowing and viewing transformation parametrically.
(Refer section 1.13) [8]
5. Write in detail about the production performance metrics.
(Refer section 1.17) [8]
6. The average part produced in a batch manufacturing plant must be processed
sequentially through six machines on average. Twenty new batches of parts are
launched each week. Average operation time = 6 min., average set up time
= 5 hours, average batch size = 36 parts, and average non-operation time per
batch=10 hrs/machine. There are 18 machines in the plant working in parallel.
Each of the machines can be set up for any type of job processed in the plant.
The plant operates an average of 70 production hours per week. Scrap rate is
negligible. Determine manufacturing lead time for an average part, plant
capacity and plant utilization.) (Refer example 1.17.7) [16]
May-2017
7. Compare and Contrast sequential and concurrent engineering with suitable
examples. (Refer section 1.4) [16]
8. Explain with block diagram, CAD process with suitable examples.
(Refer section 1.5) [16]
9. The average part produced in a batch manufacturing plant must be processed
sequentially through six machines on average. Twenty new batches of parts are
launched each week. Average operation time = 6 min., average set up time
= 5 hours, average batch size = 36 parts, and average non-operation time per
batch = 10 hrs/ machine. There are 18 machines in the plant working in
parallel. Each of the machines can be set up for any type of job processed in the
plant. The plant operates an average of 70 production hours per week. Scrap
rate is negligible. Determine manufacturing lead time for an average part, plant
capacity and plant utilization. (Refer example 1.17.7) [16]
10. Explain in detail job shop production and mass production.
(Refer section 1.16) [16]
Dec.-2017
11. Explain the different types of 2D transformations with examples.
(Refer section 1.9) [13]
12. Explain the Cohen-Sutherland line-clipping approach with proper sketches.
(Refer section 1.12) [13]
May-2018
13. Explain the various graphic transformations required for manipulating the
geometric transformation. (Refer section 1.13) [13]
14. Describe and Demonstrate DDA line drawing algorithm.
(Refer section 1.11.1 and example 1.11.1) [13]
Dec.-2018
15. Describe the stages in product life cycle and importance of each stage.
(Refer section 1.2) [13]
16. Discuss the significance of concurrent engineering approach in limiting design
changes. (Refer section 1.4) [13]
Notes
Geometric Modeling
2.1 Introduction 2 - 3
2.1 Introduction
It is a branch of computational geometry and applied mathematics under which we
study different algorithm for the description of different shapes. Now a days-geometric
modeling is done with the computers and for computer based applications. 3D models and
2D models are widely used in many technical fields such as mechanical and civil
engineering, architecture, medical image processing.
Following are the requirements of geometric modeling.
· At the time of parts inspection, inter changeable manufacturing tolerance is
required.
· There should be an automatic assembly of the model for checking interference,
modeling, etc.
· Kinematic analysis and finite element analysis is required.
· Properties and geometrical evaluation of area, volume, weight, density, etc are
required.
· There should be a graphical visualization of cross-section, line that are hidden in
the geometry.
· The boundary of the solid should be uniquely identified.
Control
polygon
Control point
2D Model
Fig. 2.2.4
Fig. 2.2.5
V1 E1[1 – 2] Linear
V2 E2[ 2 – 3] Linear
V3 E3[ 3 – 4] Linear
V4 E4[1 – 4] Linear
V5 E5[ 2 – 6] Linear
V6 E6[ 5 – 6] Linear
E7[1 – 5] Linear
E8[ 6 – 7] Linear
E9[ 7 – 8] Linear
E10[ 5 – 8] Linear
E11[ 3 – 7] Linear
E12[ 4 – 8] Linear
1. Analytical curves : The curves which are defined as those that can be described by
analytic equation such as lines, circle and conics.
a) Point : A point is an exact position or location on a plane surface.
b) Circle : It is a set of all points
in a place that are at a given
distance from a given point are
equidistance from the curve. P(x, y)
The parametric equation of the a
y
circle is given as
x2 + y2 = r2 O x Q
where x = a cos q
y = a sin q
c) Ellipse : It is a plane curve
which have two focal points such
that all points on the curve and
the sum of the two distances to Fig. 2.3.1
focal points are constant.
Focus
d) Parabola : It is a curve where
Semi minor axis
any point is at an equal distance
from the fixed point i.e. focus F2 F1
and from the straight line i.e.
Vertex
from directrix. (Refer Fig. 2.3.3)
Center
e) Hyperbola : It is a smooth curve Semi - major
which is defined by its geometric axis
properties or by the solution set Fig. 2.3.2 Ellipse
of the equation. It is an open
Parabola
Axis of symmetry
Focus
Directrix
Vertex
Fig. 2.3.3 Parabola
curve with two branches, the intersection of a plane with both halves of a double
cone. (Refer Fig. 2.3.4)
Vertex
a Focus
F2 F1
b
Center
a : Semi major axis
c : Linear eccentricity
c/a : Eccentricity
Fig. 2.3.4 Hyperbola
2. Synthetic curves : The curves which are described by a set of data points or the
control points such as splines, Bezier curve, B-spline curve, etc.
P(x,y,z) umax
umin P(u)
A P'(u) x'(u)
x 0 u
umin umax
z y
Cartesian form
y'(u)
0 u
u
z'(u)
0 u
u
Fig. 2.4.1
2 - 10 Computer Aided Design and Manufacturing
Geometric Modeling
Thus the derivative of the three coordinate system represent the tangent vector which
is given as
dP(u)
P ¢(u) = = [x ¢ y ¢ z ¢ ]
du
P ¢(u) = [x ¢(u) y ¢ (u) z ¢ (u)]
é dx dy dz ù
P ¢(u) = ê
ë du du du úû
U min £ u £ U max
yC¢¢ 1 (u max ) = yC¢¢ 2 (u min ) Fig. 2.5.3 Second order continuity curve
Fig. 2.6.1
Whereas when it is not necessary to pass through all the control points then the
resulting curve is known as approximated curve.
1. When all the data points are located on When all the data points are not located
the created figure is called interpolation on the created figure is called as
curve segment. approximation curve segment.
3. Not possible to change the shape of the Possible to change the shape of a curve
curve locally. locally.
5. Ferguson cubic curve come under this Bezier cubic, B-spline come under this
category. category.
To define the Hermite cubic spline we need the tangent vectors at the points which
can be found by differentiating equation (2.7.1) w.r.t u
3
\ P ¢(u) = å iC i u i–1
i =0
P ¢(u) = 3C 3 u 2 + 2C 2 u + C 1 …(2.7.3)
where 0 £ u £ 1
Thus to find the coefficients C 3 , C 2 , C 1 and C 0 we need to take two end points
(P0 ,P1 ) and their tangent vector (P0¢ and Pi¢).
Taking u = 0, 1 in the equation (2.7.1) and (2.7.3) we get
P0 = C 0 …(i)
P0¢ = C 1 …(ii)
P1 = C 3 + C 2 + C 1 + C 0 …(iii)
P1¢ = 3C 3 + 2C 2 + C 1 …(iv)
Substituting (i) and (ii) in (iii) and (iv) we get
P1 = C 3 + C 2 + P0¢ + P0 …(v)
P1¢ = 3C 3 + 2C 2 + P0¢ …(vi)
Performing 3(v) – (vi) We get
3P1 – P1¢ = C 2 + 2P0¢ + 3P0
C 2 = 3P1 – P1¢ – 2P0¢ – 3P0
C 2 = 3(P1 – P0 ) – (2P0¢ + P1¢ ) …(vii)
Performing (vi) – 2(v) we get
P1¢ – 2P1 = C 3 + P0¢ – 2P0¢ – 2P0
C 3 = P1¢ – 2P1 + P0¢ + 2P0
C 3 = 2(P0 – P1 ) + P0¢ + P1¢ …(viii)
Substituting (i), (ii), (vii) and (viii) in equation (2.7.1) we get,
P(u) = (2P0 – 2P1 + P0¢ + P1¢ )u 3 +(3P1 – P0 – 2P0¢ – P1¢ )u 2 + P0¢ u + P0
where 0 £ u£1
In matrix form it can be represented as
é2u 3 – 3u 2 + 1ù
ê ú
– 2u 3 + 3u 2 ú
P(u) = [P0 P1 P0¢ P1¢ ] ê 3
ê u – 2u 2 + u ú
ê 3 2 ú
ë u –u û
2 - 14 Computer Aided Design and Manufacturing
Geometric Modeling
é 2 –3 0 1ù éu 3 ù
ê– 2 3 0 0ú ê 2ú
P(u) = [P0 P1 P0¢ P1¢ ] ê ú êu ú
ê 1 –2 1 0ú ê uú
ê 1 –1 0 0úû ê ú
ë ë1û
é 2 –3 0 1ù
ê– 2 3 0 0ú
\ Hermite matrix = ê ú
ê 1 –2 1 0ú
ê 1 –1 0 0úû
ë
Similarly, the equation for tangent vector is found by differentiating equation (2.7.4)
w.r.t
P ¢(u) = (6u 2 – 6u)P0 + (– 6u 2 + 6u)P1
+ (3u 2 – 4u + 1)P0¢ + (3u 2 – 2u)P1¢ …(2.7.5)
where 0 £ u£1
In matrix form it can be written as
é 6u 2 – 6u ù
ê ú
ê – 6u 2 + 6u ú
P ¢(u) = [P0 P1 P0¢ P1¢ ]
ê3u 2 – 4u +1ú
ê 2 ú
ë 3u – 2u û
é0 6 – 6 0ù é u 3 ù
ê0 – 6 6 0ú ê u 2 ú
P ¢(u) = [P0 P1 P0¢ P1¢ ] ê ú ê ú
ê0 3 – 4 1ú ê u ú
ê0 3 – 2 0ú ê 1 ú
ë û ë û
é0 6 – 6 0ù
ê0 – 6 6 0ú
\ Hermite tangent matrix = ê ú
ê0 3 – 4 1ú
ê0 3 – 2 0ú
ë û
Example 2.7.1 : Find the parametric equation of Hermite cubic spline with the end
point P0 (1,1) and P1 (7,4) whose tangent vector for end are given as P2 (5,6) and
P3 (10,7).
é 2 –3 0 1ù éu 3 ù
ê– 2 3 0 0ú ê 2ú
= [1 7 4 3] ê ú êu ú
ê 1 –2 1 0ú ê uú
ê 1 –1 0 0úû ê ú
ë ë1û
éu 3 ù
ê 2ú
u
Px (u) = [– 5 7 4 1] ê ú
ê uú
ê ú
ë1û
P x (u) = – 5u 3 + 7u 2 + 4u + 1 …Ans.
éu 3 ù
ê 2ú
u
Py (u) = [2 –4 5 1] ê ú
ê uú
ê ú
ë1û
P y (u) = 2u 3 – 4u 2 + 5u + 1 …Ans.
Example 2.7.2 : The Hermite cubic spline curve has the end points P0 (1,1) and
P1 (7,4). The tangent vector for end P0 is defined by the line between P0 and another
point P2 (8,7) whereas the tangent vector for end P1 is defined by the line between P1
and point P2 (8,7). Evaluate the value of u = 0, 0.2, 0.4, 0.6, 0.8 and 1.0
é 2 –3 0 1ù éu 3 ù
ê– 2 3 0 0ú ê 2ú
= [1 7 7 – 1] ê ú êu ú
ê 1 –2 1 0ú ê uú
ê 1 –1 0 0úû ê ú
ë ë1û
éu 3 ù
ê 2ú
u
= [– 6 5 7 1] ê ú
ê uú
ê ú
ë1û
2 - 17 Computer Aided Design and Manufacturing
Geometric Modeling
P x (u) = – 6u 3 + 5u 2 + 7u + 1 …Ans.
· Parametric equation for y-coordinate
P0y = 1
P0y
¢ = 7–1=6
P1y
¢ = 4–7=–3
P1y = 4
é 2 –3 0 1ù éu 3 ù
ê– 2 3 0 0ú ê 2ú
Py (u) = [1 4 6 – 3] ê ú êu ú
ê 1 –2 1 0ú ê uú
ê 1 –1 0 0úû ê ú
ë ë1û
éu 3 ù
ê 2ú
u
Py (u) = [– 3 0 6 1] ê ú
ê uú
ê ú
ë1û
P y (u) = – 3u 3 + 6u + 1 …Ans.
· Point on the Hermite cubic spline
¡ The control points define the order, derivative and the shape of the curve. As
the position of control point changes the shape of the curve would change.
P1 P2
Start
point u=0
P0 P3 End
u=1 point
Fig. 2.8.1
¡ Bezier curve is always tangential to the first and the last control point as
shown in Fig. 2.8.2.
P1 P2
P2
P3
P0
P1
P0 P3
(i) (ii)
P1
P1
P2
P0
P3
P0
P3
P2
(iii) (iv)
Fig. 2.8.2
where 0 £ u£1
\ The general equation of Bezier curve is
P(u) = P0 (1 - u)n + P1C (n,1) u(1 - u)n - 1 + P2C (n,2) u 2 (1 - u)n - 2 +...+Pn u n … (2.8.2)
where 0 £ u£1
n!
where C (n,i) =
i(n - i)!
where 0 £ u£1
Example 2.8.1 : Find the parametric equation of the Bezier curve whose end points
are P0 (0,0) and P3 (7,0). The other control points are P1 (7,0) and P2 (7,6).
Solution : Given :
P0 = (0, 0)
P1 = (7, 0)
P2 = (7, 6)
P3 = (7, 0)
To find : Px (u), Py (u)
By using the equation (2.8.3) for the four control points.
Px (u) = P0x (1 – u)3 + 3P1x u(1 – u)2 + 3P2x u 2 (1 – u) + P3x u 3
Py (u) = 18u 2 (1 – u)
Example 2.8.2 : Find the equation of a Bezier curve which is defined by four control
points as (80, 30, 0), (100, 100, 0), (200, 100, 0) and (250, 30, 0).
Since all the coordinates along z are equal to zero therefore we have a parametric
curve along the x and y coordinates.
Parametric curve along X - coordinate.
Px (u) = P0x (1 - u)3 + 3P1x u(1 - u)2 + 3P2x u 2 (1 - u) + P3x u 3
Control point
2.9.1 Difference between Hermite Cubic Spline, Bezier Wave and B-Spline
Curve
Sr. Hermite cubic spline Bezier curve B-spline curve
No.
2. To draw the curve it needs To draw Bezier curve it To draw a curve it require
two data points and two require two data points and two data points and one or
tangent vector. one or more control points more control points in
in between is required. between is required.
4. The shape of the curve The shape is controlled by The shape is controlled by
depends on the tangent the control points. the control points.
vectors at the end.
n
å Pi Wi C i,n ( u)
i= 0
P(u) = n
where u Î [0, 1]
å Wi C i,n ( u)
i= 0
Boundary 1
Boundary 2
3. Edge surfaces : It is an extension to the ruled surface as in this the surface is been
patched between the boundaries as shown in the Fig. 2.11.3.
Boundary 1
Boundary 3
Boundary 4
Boundary 2
Fig. 2.11.3 Edge surfaces
4. Surface of revolution : It is used for axisymmetric object which can be revolved
around the axis to form the surface. The revolution can be controlled by controlling
the angle of revolution as shown in the Fig. 2.11.4.
Axis of
revolution
Generator
curve
Generated
part
Fig. 2.11.4 Surface of revolution
2 - 25 Computer Aided Design and Manufacturing
Geometric Modeling
5. Tabulated surface : It is used to generate the surface by extending the planar curve
in either direction as required in the object. This method is suitable for identical
curved cross-section as shown in the Fig. 2.11.5.
Put, u = 0
P(u)
P(0) = P0
Put, u = 1 P1 P2
r(u,v) = [x y z]
= [x(u,v) y(u,v) z(u,v)]
When u min £ u £ u max
v min £ v £ v max
u=0 u=1
v=1 v=0
Increasing v Increasing u
u = 0, v = 0
(a) (b)
2. If the number of polygon vertices is equal to the order of basis in that direction and
if there are no interior Knot values, then B-spline surface reduces to a Bezier
surface.
ii) Subtract operation : In this process one object get subtracted out from the other to
form the resultant object. It is most frequently used to form holes or remove any
material.
In the above example if subtract operation was done then resulting object will be
H R
x
P
P
H
z W x
D
z
Block Cylinder
y
y
x
P
R
R x
H P
z z
Sphere
Cone
y z
y
R2
H P R1
P x
z
W R1
D R0
x
Wedge Torus
Resulting solids
Fig. 2.17.1
· Consider two solids A and B as shown in the Fig. 2.17.1 on previous page and
the resultant solids after performing the boolean operation.
· By using CSG method it is easy to construct the complex model just by adding,
subtracting, performing intersection operation.
· CSG model is been represented in the form of binary tree which gives the
complete information about the model and the number of boolean operation
required to construct the binary tree as shown the Fig. 2.17.2 on previous page.
2 - 33 Computer Aided Design and Manufacturing
Geometric Modeling
S3 = S2 + D
A B
S2 = S1 + C
D
C
C
S1 = A – B
D
A B
S3 = S1 + S2
S1 = A – B S2 = C + D
A B C D
Directrix
Boundary of point
set to translate
Directrix
Directrix
Gluing area
xC 1 (u max ) = xC 2 (u min )
yC 1 (u max ) = yC 2 (u min )
zC 1 (u max ) = zC 2 (u min )
Q.14 Define first order continuity.
Ans. : First order continuity C1 : Slope of C1 Slope of C2
umax of C1 P2 umax of C2
It ensures that the slope at the end
of the curve C 1 is same as the
C2 Curve
slope at the starting of the curve
C 2 and thus we obtained smoother C1 Curve
umax of C2
curve. P3
The slope can be found by umin of C1
differentiating the parametric P1
equation. Fig. 2.2 First order continuity curve
xC¢ 1 (u max ) = xC¢ 2 (u min )
yC¢ 1 (u max ) = yC¢ 2 (u min )
zC¢ 1 (u max ) = zC¢ 2 (u min )
Q.15 Define second under continuity.
Ans. : Second order continuity Tangent
C2 : When the first order umax of C1 P2 umin of C2
equation are differentiated further
Center of
then the condition of second order curvature C2 Curve
C1 Curve
continuity is obtained i.e. they
satisfy both slope as well as umin of C1
curvature continuity. umax of C2
P1
P3
xC¢¢ 1 (u max ) = xC¢¢ 2 (u min )
Fig. 2.3 Second order continuity curve
yC¢¢ 1 (u max ) = yC¢¢ 2 (u min )
zC¢¢ 1 (u max ) = zC¢¢ 2 (u min )
Q.16 Define Hermite cubic curve.
Ans. : When the curve is defined by the two end points and their slope are termed as
Hermite cubic curve. These types of curve are generally used to interpolate a curve for
a given data points. It is commonly known as splines.
P'1
P1 (u = 1)
P'0
P0 (u = 0) x
0
P1 P2
Start
point u=0
P0 P3 End
u=1 point
Fig. 2.5
1) Plane surface
2) Loafed surface
3) Edge surface
4) Surface of revolution
5) Tabulated surface
6) Coons path
Q.20 What is blending function ?
Ans. : Wire frame modeling has been used in computer aided engineering which helps
in the visualization of a design. It consist of finite sets of points which together form
various pairs of edges which makes the visualization of the object simple. If allows to
calculate the positions of different points quickly and accurately.
Q.21 Enlist the different Boolean operations is solid modeling.
Ans. :There are three Boolean operations which are basically used to form the
complex gemetrics : i) Union ii) Subtract 3) Intersect.
Q.22 Define union operation.
Ans. : Union operation : This operation fuses solids or region together into one object.
It is used when we need to joint mechanical assemblies.
For eg. :
Q.34 List out the various bezier curves based on control points. (Refer section 2.8)
+ {AU : May 18)
Q.35 What is the use of surface patch ? (Refer section 2.12) + {AU : May 18)
Q.36 Distinguish between analytic curve and synthetic curve.
(Refer section 2.3) + {AU : Dec. 18)
Part B : University Questions with Answers
May - 2016
1. What are bezier curves ? Discuss its important properties. (Refer section 2.8) [16]
Dec.-2016
May - 2017
Dec.-2017
May - 2018
6. Briefly discuss about the bezier surface and composite surface. [13]
Ans. : Refer section 2.13.
· It is a collection of connected surfaces i.e. A surface that contains atleast one
composite chain as a boundary or internal curve is a composite surface. The
composite chain consist of different types of curves which satisfies tangent and
curvature continuity. Composite surface are composed of different sets of surfaces
but treated as a single entity.
· The orientation of the composite surface is determined by the orientation of the
first surface. Since all the member of the composite surface are oriented in the
same way with their neighbors.
· For example if there are three or more adjacent surfaces need to be composited,
all the surfaces may not be composited into a single surface then in this case
2 - 44 Computer Aided Design and Manufacturing
Geometric Modeling
different subsets of the surface may be composite as shown in the figure below.
As we have three surface A, B and C adjacent to each other. The common curve
between A and B is AB, the common curve between B and C is BC and
common curve between A and C is CA. Hence, there can be two subsets in
which the composite surface can be forced as shown in the Fig. 2.6.
B
AB BC
A
CA
C
D
B
Composite AB BC
BC
CA Composite
C
D
D
C3 C3
C1 C2
C1 B1 B2 C2
B3 B4
B3 B4
B1 B2
C5 C6
Fig. 2.7
Ans. :
S4 = S1 + S2 + S3
S3 = F + G + H
S1 = A + B + C
S2 = D + E
C G
A
F
H
D E
B
S3 = S1 + S2
S1 = A + B – C S2 = D + E – F
A F D
C
B E
Solid S2
Dec.-2018
8. Write short notes on parametric representation of synthetic surface.
(Refer section 2.12) [13]
9. Discuss the following for B-rep and CSG scheme : i) how to represent surface
normals and neighborhoods ii) how to develop a classification algorithm.
(Refer sections 2.17 and 2.18) [13]
Geometric Modeling ends ...
Notes
Cad standards
Syllabus : Standards for computer graphics-Graphical Kernel System (GKS)- Standards
for exchange of images-Open Graphics Library (Open GL)- Data Exchange
standards-IGES, STEP, CALS etc.- Communication standards
3.1 Introduction 3 - 2
such as Auto CAD and CATIA). The two methods of exchanging the data among the
different CAD/CAM systems are,
Direct Translators
· Direct translators convert data directly in one step.
· The direct translator entails translating the modeling data directly from one
CAD/CAM system format to another usually in one step.
· This solution converts the data (database) format from one native format to
another.
· It requires knowledge of both the native formats.
· Direct translators provide a satisfactory solution when only a small number of
systems are involved, but as this number increases the number of translator
programs that need to be written becomes prohibitive.
Indirect Translators
· It adopts the philosophy of creating a neutral database structure (also called a
neutral file) which is independent of any existing or future CAD/CAM system.
· This structure acts as an intermediary and a focal point of communication among
the dissimilar database structures of CAD/CAM systems.
· This solution converts native formats to a neutral format that all CAD/CAM
systems can interpret and understand.
· Indirect translators utilize some neutral file format, which reflects the neutral
database structure, with each system having its own pair of processors to transfer
data to and from this neutral format.
Comparison between direct and indirect translators
System System
5 5
System System
System System 1 2
1 2
Direct translators run more quickly than the indirect ones, and the data files they
produce are smaller than the neutral files created by indirect translators. Indirect translator
philosophy provides stable communication between CAD/CAM systems, protects against
system obsolescence, and unlike direct translators eliminates dependence on single system
supplier. A side benefit of neutral files is that they can potentially be archived. Some
companies in the aerospace industry for example need to keep CAD/CAM databases for
20 to 50 years. Indirect translators based on a standard neutral file format are now the
common practice, while direct translators are seldom used.
CAD system with and without graphic standard
· Fig. 3.1.2 explains CAD system with and without graphics standards
CAD without graphics standard CAD with graphics standard
Graphics Graphics
data base data base
Application Application
programme programme
Graphics
function Kernel
system
Y
Input/Output
devices Device
driver
Input/Output
devices
Application program
Language-independent layer
i. POLYLINE
· The GKS function for drawing
line segments is called polyline.
· The polyline function takes an
array of X-Y coordinates and
draws line segments connecting Fig. 3.2.2 Polyline (N, XPTS, YPTS)
them.
· An example of polyline primitive is shown in the Fig. 3.2.2.
ii. POLYMARKER
· It is a marker type of polyline primitive.
· It is used for drawing certain set of markers or shapes as shown in Fig.3.2.3.
B
Top
Cap
Character Half
height
Base
Bottom
· OpenGL does not require high performance display hardware to be present, but it
does require a frame buffer - memory that stores the raster display bitmap.
· OpenGL draws directly into the frame buffer but also allows the use of multiple
buffers where, for example one buffer is displayed while second is being updated.
· Fig. 3.3.1 shows a schematic diagram of OpenGL.
Per-vertex
Vertex operations
data Evaluator
Primitive
assembly
Per-
Display Rasteriz- fragment Frame buffer
list ation operations
Pixel Pixel
data operations Texture
memory
Features of OpenGL
i) Based on IRIS GL : OpenGL is supported on Silicon Graphics' Integrated Rater
Imaging System Graphics Library (IRIS GL). Though it would have been potential
to have designed a totally new Application Programmer's Interface (API), practice
with IRIS GL offered insight into what programmers need and don't need in a
Three-Dimensional graphics API. Additional, creation of OpenGL similar to
Integrated Rater Imaging System Graphics Library where feasible builds OpenGL
most likely to be admitted; there are various successful IRIS GL applications, and
programmers of IRIS GL will have a simple time switching to OpenGL.
ii) Low-Level : A critical target of OpenGL is to offer device independence while
still permitting total contact to hardware. Therefore, the API gives permission to
graphics operations at the lowest level that still gives device independence. Hence,
OpenGL does not give a suggestion for modeling complex geometric objects.
iii) Fine-Grained Control : Due to minimize the needs on how an application
utilizing the Application Programmer's Interface must save and present its
information, the API must give a suggestion to state entity parts of geometric
entities and operations on them. This fine-grained control is necessary so that these
mechanism and operations may be defined in any order and so that control of
rendering operations is comfortable to contain the needs of various applications.
iv) Modal : A modal Application Programmer's Interface arises in executions in
which processes function in parallel on different primitives. In that cases, a mode
modify must be transmit to all processors so that all collects the new parameters
before it processes its next primitive. A mode change is thus developed serially,
stopping primitive processing until all processors have collected the modifications,
and decreasing performance accordingly.
v) Frame Buffer : Most of OpenGL needs that the graphics hardware has a frame
buffer. This is a realistic condition since almost all interactive graphics run on
systems with frame buffers. Some actions in OpenGL are attained only during
exposing their execution using a frame buffer. While OpenGL may be applied to
give data for driving such devices as vector displays, such use is minor.
vi) Not Programmable : OpenGL does not give a programming language. Its
function may be organized by turning actions on or off or specifying factors to
operations, but the rendering algorithms are basically fixed. One basis for this
decision is that, for performance basis, graphics hardware is generally designed to
apply particular operations in a defined order; changing these operations with
random algorithms is generally infeasible. Programmability would variance with
maintenance of the API close to the hardware and thus with the objective of
maximum performance.
vii) Geometry and Images : OpenGL gives support for managing both 3D and 2D
geometry. An Application Programmer's Interface for utilize with geometry should
also give guidance for reading, writing, and copying images, because geometry and
3.4 Data Exchange Standards + [AU : Dec.-15, 16, 17, 18, May-16, 17, 18]
· The increase in CAD applications in many parts of the engineering industry has
been accomplished by growth in product variety and broadening of the range of
companies involved in the design of a particular product.
· The easiest way for two companies to exchange data is to use the same CAD
software, operating at the same revision level.
· The transfer of data between the systems has been made possible by the neutral
format of data exchange.
· The software packages will have pre-processors to convert drawing data to neutral
file format and post processors to convert neutral file data to drawing file, as
explained in Fig. 3.4.1.
CAD CAD
software A software B
i. Geometric Entities
· Defines the product shape and include curves, surfaces and solids.
· IGES reserves entity numbers 100 to 199 inclusive for its geometric entities.
· Sample entity type numbers used by IGES are shown in the table.
· Specifications and descriptions or entities, including geometric entities, in IGES
follow one pattern.
· Each entity has two main types of data :
¡ Directory data - Defines the entity type number
Flag section
Start section
Terminate section
i. Flag Section
· The flag section is used only with compressed ASCII and binary format.
· It is a single line that precedes the start section in a IGES file.
· In binary file format, the flag section is called as binary file information section
ii. Start Section
· This section is setup manually by the person initiating the IGES file.
· This contains the information such as the name of the sending and receiving
CAD/CAM systems and a brief description of the product.
iii. Global Section
· This section provides the 24 field parameters necessary to translate the file.
· It includes the delimiter characters (1 and 2), sender's identifier (3), file name
(4), ID of the software which generate file (5), version of IGES processor
(6), precision of integer (7 to 11), receiver's identifier (12), model space (13),
units (14), name of the units (15), maximum number of line thickness (16, 17),
file generated time (18), smallest distance (19), largest coordinate value (20),
person and organization creating file (21 and 22), IGES version (23), drafting
standards (24).
iv. Directory Section (DE)
· Contains attribute information such as color, line type, etc.
· This section is generated by IGES pre-processor.
· This section also contains the entry for each entity in the file comprising a code
representing the entity type and subtype.
v. Parameter Data Section (PD)
· This section contains the entity-specific data such as coordinate values, annotation
text, number of spline data points and etc.
· This section includes the geometric, annotation and structure entities to explain
the specific code for a drawing (Explained in section above).
· The Parameter Data (PD) section contains the data that defines the entity.
· The Directory section organizes and gives structure to the information in the
Parameter Data section.
· There can be only one directory entry for each Parameter Data section entity.
· Directory section entries may reference other Directory section entries. This
happens when we specify a transformation matrix and when we represent
structures.
· The supported parameter data is the data being communicated.
vi. Termination Section
· This section marks the end of the data file.
· This section contains subtotals of records for data transmission check purposes.
· The terminate section consists of one physical card image record.
Error Sources in IGES File Processing
· Program errors in the processor
· Misinterpretation of the IGES standard
Limitations of IGES
· IGES files are not information rich - IGES files were developed to exchange
product definition data instead of product data such as mass property information,
product life cycle information etc.
· IGES files cannot carry Model Based Definition (MBD), Product and
Manufacturing Information (PMI) etc.
· IGES files often needed to be repaired.
· Last updated version of IGES file format was released in 1996, which makes this
file format old.
Layer-3
Application protocols
Conformance testing
Test suites
Layer-2
Resource information
+
models
Layer-1
Implementation methods
(Express design language)
Physical files
· This data exchange standard was produced with an aim of applying computer
technology to the process of specifying, ordering, operating, supporting and
maintaining the weapons systems used by the US armed forces, although it can
be adopted by any industry, not just defense industry.
· The CALS initiative has endorsed IGES and STEP as formats for digital data
CALS includes standards for electronic data interchange, electronic technical
documentation, and guidelines for process improvement.
· The Vision is for all or part of a single enterprise (e.g., an original equipment
manufacturer and its suppliers, or a consortium of public and private groups and
academia), to be able to work from a common digital data base, in real time, on
the design, development, manufacturing, distribution and servicing of products.
· The direct benefits would come through substantial reductions in product-to
market time and costs, along with significant enhancements in quality and
performance.
· CALS has developed a further standard which defines subsets of IGES to be used
for specific applications including technical illustrations, engineering drawings,
electronic engineering data, and geometry for manufacture by numerical control
machines. It is expected that CALS will use the STEP standards for product data,
and will also extend into such areas as electronic hardware description and office
document exchange.
· The Spacecraft Industries CALS is to introduce a exchanging of interface data,
which are applied in the collaborative manufacturing of spacecraft by the space
industry.
· The data is exchanged by way of CALS standard such as Word, Excel, PDF,
TIFF and 3D-CAD etc. through the network.
· Generally, several companies conduct manufacturing of spacecraft simultaneously,
for which control documents named ICD (Interface Control Documentation and
Drawing) with 3D-CAD are utilized to provide information on interface work.
Two CALS systems :
· The interface for users is the JCALS Workbench that provides an environment to
access all of JCAL's functionality transparently to the user.
ii. Joint Engineering Data Management Information and Control System (JEDMICS).
Product Product
data data
Archival
product
data
· Preprocessor enable the user to specify the processor actions from entities of their
own system and entities of PDES.
· The pre-processor acts on the basis of the action of application layer followed by
the logical and physical layer.
HEADER SECTION :
· Contains general information about the drawing.
· The HEADER section of a DXF file contains the settings of variables associated
with the drawing.
· System settings such as dimension style and layers.
· Each variable is specified by a 9 group code giving the variable's name, followed
by groups that supply the variable's value.
CLASSES SECTION
· Holds the information for application-defined classes whose instances appear in
BLOCKS, ENTITIES and OBJECTS sections of the database.
· Generally, does not provide sufficient information to allow interoperability with
other programs.
· It is assumed that a class definition is permanently fixed in the class hierarchy.
TABLES SECTION
· Contains definitions of named items.
· The TABLES section contains several tables, each of which can contain a
variable number of entries.
· These codes are also used by AutoLISP and ObjectARX applications in entity
definition lists.
· It includes line styles and user- coordinate systems.
· More primitives in tables section :
Dimension Style (DIMSTYPE) table
· The format of the entities in this section is identical to those in the ENTITIES
section.
ENTITIES SECTION
· This section presents the group codes that apply to graphical objects.
· It includes entity definition and data.
· eg.: Circle, Ellipse, Leader, Light
OBJECTS SECTION
· This section presents the group codes that apply to nongraphical objects.
· Also used by Auto LISP and Object ARX applications.
THUMB NAIL IMAGE SECTION
· Contains the preview image for the DXF file.
· This section exists only if a preview image has been saved with the DXF file.
· Virtually all user-specified information in a drawing file can be represented in
DXFformat.
Advantages
· The DXF file format is the most compatible vector file type
· DXF files are used to exchange data between different CAD programs
· The DXF file format is easy to parse
· The DXF file specification is publicly available
Limitations
· DXF does not support application specific CAD elements
· Complex DXF files can become large in size
· Some applications cannot deal with line widths in DXF Files
(a) Star
(b) Ring
(c) Bus/Tree
Computer
PSE
site A
Computer
PSE site B
PSE Packet
Switching
Exchange
Computer
PSE
site C
PSE
Computer
site D
CAD systems
IGES Level - 3
CAD database
GKS
Application software
VDI/CGI
Level - 1
Output devices
LEVEL 1 :
· Here the communication of data is between application software and output
devices such as printers, plotters etc.
· Virtual Device Interface (VDI) or Computer Graphics Interface (CGI) is the most
important standard in this category.
· These standards specify the format for transfer of data to application software and
output devices
LEVEL 2 :
· Here communication of data takes place between application software and
graphics utility
· GKS is mainly proposed for this purpose
LEVEL 3 :
· Here the communication of data takes place between CAD systems and also
among CAD systems and CAD database.
· IGES is an example for standard used for such communication.
Review Questions
1. (i) Define graphics Keneral system. Explain briefly with suitable examples.
(ii) Examine IGES data exchange format.
2. Describe the data exchange standard and development in data exchange
format.
3. (i) Write short notes on data base management.
(ii) Identiy the thrust involved in developing CAD standards.
4. (i) Summarize the standards for exchanging images.
(ii) Discuss about open graphics library.
5. (i) Describe (1) Local area network (2) Wide area network.
(ii) Describe Standard for the Exchange of product model Data (STEP) in
detail.
6. (i) Describe the types of graphics standards.
(ii) Discuss the two basic items of GKS such as primitives and attributes.
7. (i) Examine the features of open GL.
(ii) Illustrate (1) Direct CAD system export (2) Direct translation software
(3) Neutral data exchange format.
8. Classify the neutral file formats and explain in detail.
9. Analyze Continuous acquisition and life cycle support (CALS) and elaborate
their types.
10. Explain product data exchange standard and draw the three-layer architecture
of PDES.
11. Infer the different levels of graphics standard communication and elaborate the
each.
12. Compare IGES and STEP
13. Elaborate (i) HTML (ii) VRML (iii) CGM (iv) BITMAPS (v) Computer aided
design interface.
14. Compare various testing methods of IGES processors.
15. Explain STEP architecture with neat sketch.
16. List and explain the basic requirements and principles of communication
protocol.
17. Explain IGES entities.
18. Explain GKS primitives with an example.
Fig. 3.1
Q.10 Write any three CAD standards of exchange of modelling data. (May 2016)
Ans. : IGES, STEP, CALS.
l IGES files tends to be surface models. l Step files tends to be solid models.
l IGES is an older file format since the final l STEP is a newer technology with
version of IGES file was released during periodical updating.
1996.
l Defines the product shape and include l Used to support any industrial application
curves, surfaces and solids. such as mechanical, electric, plant design
and architecture and engineering
construction.
Q.12 List down the various elements of CAD/CAM structure with and without
graphics system.
Ans. :
Graphics Graphics
data base data base
Application Application
programme programme
Graphics
function Kernel
system
Y
Input/Output
devices Device
driver
Input/Output
devices
Fig. 3.2
Application program
Language-independent layer
Fig. 3.3
Per-vertex
Vertex operations
data Evaluator
Primitive
assembly
Per-
Display Rasteriz- Fragment Framebuffer
list ation operations
Pixel Pixel
data operations Texture
memory
Fig. 3.4
Q.17 Explain the limitations of IGES.
Ans. : · IGES files are not information rich- IGES files were developed to exchange product
definition data instead of product data such as mass property information, product life cycle
information etc.
· IGES files cannot carry Model Based Definition (MBD), Product and
Manufacturing Information (PMI) etc.
· IGES files often needed to be repaired.
· Last updated version of IGES file format was released in 1996, which makes
this file format old.
Q.18 Obtain a sketch of the file structure for product data exchange.
Ans. :
Product Product
data data
Archival
product
data
Fig. 3.5
Q.19 Assess the various file section in IGES.
Ans. : · Flag Section
· Start Section
· Global Section
· Directory Entry Section
· Parameter Data Section
· Terminate Data Section
Q.20 Summarize the eight major areas in step documentation.
Ans. : · Introductory section :
mechanisms.
· Conformance testing methodology and frame work
This provides the methods for testing implementations and test suites to be
representation.
3 - 36 Computer Aided Design and Manufacturing
CAD Standards
· Application protocols
This part describes implementations of STEP specific to particular industrial
applications.
· Abstract test suites
This part provides test suites for each of the application protocols.
· Application interpreted construct
This part describes various model entity constructs and specific modeling
approaches.
Q.21 Create the flow diagram to communicate between two CAD systems using
IGES.
Ans. : Flow diagram explaining communication between two CAD system using IGES is
shown below,
System 1 System 2
Archival
database
Fig. 3.6
Q.22 Discuss the advantage of open graphics library.
Ans. : · OpenGL provides a set of commands that allow the specification of geometric
objects in two or three dimensions
· OpenGL makes available to the programmer a small set of geometric
primitives - points, lines, polygons, images and bitmaps.
· It provides a means of drawing and rendering geometric objects like points,
line segments, polygons
· Open GL does not require high performance display hardware to be present.
· Open GL draws directly into the frame buffer but also allows the use of
multiple buffers where, for example one buffer is displayed while second is
being updated.
Q.23 Discuss about Local Area Network (LAN) and Wide Area Network (WAN).
Ans. : · A Local Area Network (LAN) is a network that is restricted to smaller physical
areas e.g. a local office, school, or house.
· Wide area network is a computer network that covers relatively larger
geographical area such as a state, province or country.
(a) Star
(b) Ring
(c) Bus/Tree
Fig. 3.7 LAN topologies
For WAN topology : Refer Fig. 3.4.6
Q.25 List the various levels of communication standard.
Ans. : Refer Fig. 3.4.7.
May-2016
4. Briefly explain any one of the known graphics standards. (Refer section 3.3) [16]
5. Write short notes on Drawing Exchange Format (DXF). (Refer section 3.4.5) [16]
Dec.-2016
May-2017
Dec.-2017
May-2018
Dec.-2018
Notes
4.1 Introduction 4 - 3
4.25 Subroutine 4 - 90
4.28 Micromachining 4 - 99
4.1 Introduction :
· When any machine tool is manually operated, the operator controls the relative
movements of the workpiece and tool.
· The accuracy of these movements is controlled by reference to some form of
measuring device fitted on the machine slide or lead screw.
· The operator has to perform functions like starting and stopping the machine,
turning the coolant on and off, etc.
· With manual control accuracy of final workpiece, quality and time required to
manufacture depends on the skill, concentration and experience of the operator.
· When many batches of identical parts are required, it is preferable to use jigs,
fixtures and templates.
· Automatic machine tools are also used in order to minimize errors and variable
quality of manual operation.
· So, to avoid human errors, minimize production cost and due to many other
reasons, NC i.e. Numerical Control machines comes into the picture.
· On a numerically controlled machine tool the decisions which govern the
operation of the machine are made by a series of numbers in binary code which
are interpreted by an electrical system.
· The electronic system converts these numerical commands into the physical
movement of the machine elements.
· Now a days, these NC machines are modified into different machines as follows :
m Special purpose CNC machine tool with vertical and horizontal machining
centre.
m Flexible Manufacturing System (FMS).
m Gear cutting machines.
m Electro-discharge machines with CNC.
m Co-ordinate Measuring Machines (CMM).
· For preparing this data, part programmer is required which should have the
knowledge of tools, cutting fluids, use of machinability data and process
engineering.
· Fig. 4.2.1 (a) shows the block diagram for the procedure of production through NC.
· Fig. 4.2.1 (b) shows the block diagram for NC machine tool system.
· The tape reader reads this data and passes data to the buffer storage through the
decoding circuits.
· The buffer storage stores the received information, till it is required and transfers
it to the required area.
· This unit is also called as Data Processing Unit (DPU).
· MCU also consists of sub-units like control unit, decoding circuits, feed control
units, etc.
· Almost all the operations like tool movements, tool change, speed and feed
change and many others can be controlled by MCU.
2. Machine tool and NC tooling :
· It is the manufacturing arm of NC machine tool system.
· It receives the raw material and performs different operations like turning,
milling, drilling, grinding, etc.
· For performing these operations, it should receive the information from the MCU.
· As per the information, the desired shape and size is modified.
3. Part program and drawings :
· NC machine operates as per coded information, which is Input Data for the
machine.
· The feeding of this data may be manually or automatic.
· The manual feeding of input data includes operator and hence chances of error
increases.
· Hence, data is fed by automatic means and for this purpose punched tape is
mostly used.
· As punched tape is most widely used hence, it becomes a standard and due to
standardisation, similar tape punchers and tape readers are used in all the systems.
· Punched tape uses a binary coded decimal system for containing operating
information of NC tool.
· Punched tape have eight vertical columns (channels) numbering from 1 to 8 and
one feeding holes column between them.
· Channel 1 to 3 is on one side and 4 to 8 on another side of the punched tape.
· Also, it carries horizontal rows, which represent a code number, letter code or a
word.
· The instructions are marked on the tape in the form of holes in binary codes
format, which is decoded in MCU and electric pulse is generated.
· These pulses are fed further to the servo systems and mechanisms.
· Generally, these tapes are manufactured by paper, which may be oiled or unoiled.
· Punched tapes are cheap but they tear easily. Hence, laminated tapes are also
used.
· Fig. 4.2.2 shows standard EIA (Electronics Industries Association) punched tape.
· The other input media instead of punched tapes are :
m Punched cards m Magnetic tapes m Diskettes, etc.
· Now a days, to enter the program, instead of these media, magnetic cassettes,
floppy discs, compact disc (CD) are used.
· In many machines, MCU carries a keyboard also. This is used directly to
manipulate and feed the part program.
· Due to this method, there is saving in machining time, hence now a days it is the
most popular type of input media to feed part program.
b) Incremental system :
· In this method, the tool positions are indicated with respect to previous point.
· Fig. 4.3.1 (b) shows an example of this system.
1. In this system, all the positions are In this method, the tool positions are
indicated from a reference point, indicated with respect to previous
which is a fixed zero point or set point.
point.
2. The coordinates of each point are The coordinates of each point are
independent of each other. dependent on each other.
3. If an error occurs into the dimensions The main disadvantage of this system
of any location, then the error will be is that if an error occurs into the
restricted to that location only. dimensions of any location, all the
locations marked after that will carry
the same error.
Amplifier
· Then control unit sends correct commands to servo motor (control) and cycle
continues.
b) Digital transducers :
· It converts the rotary motion of machine screw into countable electrical pulses.
· The number of electrical pulses indicates linear distance moved by the machine
table corresponding to the lead screw rotation.
Advantages :
· Control of more than one NC machine.
· Elimination of punched tape and tape reader.
· Convenient storage of NC part programs in computer files.
· Greater computational capability and flexibility.
· The data for tools and cutters can be centrally maintained and updated.
· The data related to manufacturing can be effectively collected and hence,
inventory can be better controlled.
Disadvantages :
· The crucial disadvantage of Direct Numerical Control system is that, if the
central computer goes down, all machines become inactive.
· Initial cost is too high.
a) Bed :
· The bed of CNC machine is generally made of high quality cast iron with heavy
ribbing to provide high stiffness and low weight.
· The cast iron structure provides the necessary damping, to reduce the vibrations
produced due to high speed, large material removal rates and heavy duty
machining.
· Another area of consideration is the design from chip disposal point of view.
Fig. 4.11.1 shows a slant bed structure used in turning centres
· These allows the chips to fall off from the cutting zone. It also provides the
operator easier and better access to the workpiece and tooling.
+
–
+
Z
Slant bed
b) Table :
· The table is mounted on the bed which provides the machining centre with the
z-axis (linear movement).
c) Column :
· Column is mounted on the saddle and designed with high torsional strength, to
prevent distortion and deflection while machining.
4.11.2 Drives
· There are two basic applications where drives are used in CNC machines.
1) Spindle drives 2) Feed drives
1) Spindle drives :
· Spindle drives are used to provide the main spindle power for cutting.
· As large material removal rates are used in CNC, large power motors are used
for spindle drives.
· Also, the speed required during operations is infinitely variable.
· Hence to provide such a speed control for infinitely variable speed DC motors
are used.
· The speed control for DC motors can be achieved by varying the voltage
infinitely.
· The use of AC motors are preffered in the generation of currents in CNC
machine tools. This is achieved by developments in the frequency converter.
2) Feed drives :
· CNC machines are provided with independent axis drive to provide the feed
movements for the slides.
· In order to obtain fast response and positional accuracy a special type of motor
called servomotor is used to power the slides.
· Following are the feed drives that are used in the CNC machine tools :
i) DC servomotors ii) Brushless DC servomotors
iii) AC servomotor iv) Stepper motor
v) Linear motor
i) DC servomotor :
· DC servomotors are characterized by high overload capacity, excellent dynamic
response and low moment of inertia.
· These are made up of permanent magnet type and have high acceleration torque.
· The speed control in DC servomotors is achieved by flux control method, voltage
control method and rheostatic control.
ii) Brushless DC servomotor :
· In brushless DC servomotor, the motoring action achieved by electrical
commutation rather than by mechanical commutation.
· The flux created by current carrying conductor should rotate around the inside of
the stator.
· The speed in this motor is proportional to the frequency of the applied voltage
and number of poles.
iii) AC servomotor :
· AC servomotors are used for low power servomechanisms and have constant
acceleration to maximum speed.
· These motors are highly reliable and have high frequency response.
· The speed control is achieved by controlling the applied controlled voltage.
· Following are some methods to control the speed :
m Supply frequency control
· Either the nut or the screw rotates and causes the rolling of balls through a
helical path, as shown in Fig. 4.11.2.
Ball bearings
Recirculation channel
Nut (shown cutaway)
Sector gear
Circular form
threads Return tube
Ball screw
Balls Nut
Fa
Nut B Spacer Nut A
FB FA
Fig. 4.11.4 : Preloading of the recirculating ball screw and nut arrangement
2. Load carrying capacity It has lower load carrying It has high load carrying
capacity as compared to capacity as compared to
recirculating ball screw. conventional power screw.
For the same load carrying
capacity, recirculating ball
screw is more compact and
light weight.
i) Hydrostatic slideways :
· Fig. 4.11.5 shows the working of hydrostatic slideways.
· The carriage or slides in contact with the slideway are provided with the small
pockets or cavities.
· Air or oil is pumped into small pockets and then flows out from pockets between
slide and slideways.
· These slideways provides almost frictionless condition for slide movement. The
slideways should be kept clean for the efficient operation.
· The only disadvantage is that, it requires very large surface area to provide
proper support.
Oil inlet
Ball
Shaft
Cage
Rollers
· The guiding element prevents the falling of rollers from the shoulders and also
recirculate them with ease.
· While using the rollers the bed should be machined accurately and surface in
contact should be hardened.
iv) Surface coatings :
· In this technique, the guiding surface is coated with low friction material such as
polytetrafluroethylene (PTFE).
· Sometimes, replaceable strips of low friction material are used on guide ways.
(c)
Fig. 4.11.8 : Automatic tool changer
· Generally, machining centres with 16 to 24 tools are used, but now a days
machining centres with 160-200 tools are used.
· MCU receives tool change command and send spindle to its fixed tool change
co-ordinates.
· At that time, tool magazine is indexed to the proper position and tool changer
rotates.
· This tool changer engages the tool in the spindle and tool in the magazine at that
time.
· Both the tools are removed by tool changer from their places and turns by 180º
to swap both tools.
· Thus old tool is returned to magazine and new in the spindle. Hence, completes
the tool changing operation.
i) Linear motion :
· In Fig. 4.11.9 (a) the workpiece is on left side track waiting for completion of
machining operation of earlier workpiece.
· In Fig. 4.11.9 (b) after completion of earlier workpiece, it moves onto the
unloading table and the next component is ready to move onto the machining
table.
· In Fig. 4.11.9 (c) the next component moves onto the machining table and the
system continuous.
ii) Inverted U-path :
· In Fig. 4.11.9 (d) the table is in linear motion but the component is rotated in an
inverted U-path to move onto the machining table and then moves linearly.
Table 1
Table 2 Setting
station 1
(a) (b) (c)
Machine
spindle
ATC
Pallets
Machine
spindle
Pallets
· For the maching purpose of workpieces, the table is moved in rotary motion with
the help of indexing mechanism.
Glass disc
· The lines make and break this photoelectric beam which generates a pulse signal
and this signal is amplified to give a square wave output.
· Number of signals generated per revolution depends on the number of lines on
the disc.
Linear transducer :
· The principle of linear transducer is similar to rotary transducer except that, the
signal directly translates into linear displacements of the slide.
· In linear transducer instead of disc, glass scale with line grating is used, which
have line graduations. Refer Fig. 4.11.12.
Light source
n
Slide motio
Grated
glass
scale
Photocells
· The relative movement between glass scale (fixed to slide) and photocells (fixed
to guide) generates an electric pulse.
· The amount of pulses produced for a given resolution of the gratings decide the
magnitude of the travel.
· Online part programming : The part program can be done online with editing,
if required.
· Flexibility of system : The system is too flexible, as new systems can be added
at low costs.
· Metric conversions : Part program, which is written in inches, can be easily
converted into millimeters i.e. metric conversion is easy.
· Interpolations : In NC system, there is interpolation for straight and circular
path, but in CNC it is available for helical, parabolic and cubic curves also.
· Expanded tool compensations : For the purpose of tool offset and tool wear,
tool compensation is provided.
Disadvantages
Disadvantages of CNC machines are similar to NC machines.
· High initial cost : Initial investment is high.
· High maintenance cost : Maintenance is costly and complicated.
· Costly control system : Control systems are also costly.
· Skilled operator : For part programming well trained and highly skilled operator
is required.
· Unemployment : As only one operator is required, there is increase in
unemployment.
· Computer problem : If there is any problem with computer, then the whole
machine will get stop.
· Costly software : The software required for the operation of CNC machines is
also costly.
4.13 Comparison between NC, CNC and DNC System :
NC machine
Sensors
tool
· These sensors fed this data to adaptive controller along with the process
constraints such as speed, feed rate, etc.
· This performance index is then compared with the set value and maintain it by
continuously changing the process variables.
2. Adaptive Control with Constraints (ACC)
· In this system the various constraints such as torque, cutting forces, motor power,
tool wear, cutting temperature, etc. are specified.
· When the process is in progress, the ACC system manipulate spindle speed, feed
rates to maintain the specified constraints in prescribed limit.
· These constraints are measured with the help of sensors and transducers and
compare with the set value.
· Cermets cutting tools, comprised of titanium carbonitride (TiCN), are hard and
chemically stable, leading to high wear resistance.
· Cermet tools are also effective in dry machining.
· Development in ceramic tool technology enables these tools to move into new
areas of applications. For example, silicon nitride tools offer improved fracture
resistance as compare to other ceramic materials.
Coatings :
· Coatings for tool inserts can be classified as Chemical Vapour Deposition (CVD)
coatings and Physical Vapour Deposition (PVD) coatings.
· These coatings includes titanium carbonited, titanium aluminium nitride which
offers high hardness, increased toughness and wear resistance.
· Recent development in coatings includes soft coatings that are used in dry
machining.
· Diamond coated tools are used for machining hard materials.
· A right hand rule for machine tool axis is as shown in Fig. 4.20.2 (a).
· Machine tool co-ordinate axis is defined for providing a means of locating a tool
in relation to the workpiece.
· According to the machine, a point can be located by several methods. Generally,
that point is at the origin.
· In NC machine, the origin is defined in two ways which are fixed zero and
floating zero.
· In a fixed zero method, the origin is always predefined. It is generally at the
lowermost left hand corner of the worktable. Refer Fig. 4.20.1 (a).
(0, 0)
(0, 0)
(a) Fixed zero (b) Floating zero
+X +Y
+Y
+X
+X +Z
+Z
+Z
+Y
+X
+X +Z
+Y
+X
+Y
Example 4.20.1 : Explain with neat sketch 2, 21/ 2 and 3 axes of CNC machines.
Tool
path
+Z
+Y
XY Plane
+X
+X
Fig. 4.20.5 Axes machine tool
· Various controllers use different syntax during instructing the machine tools.
· But, there are similarities between the codes and by understanding the basics, one
can easily adapt to other controllers with minor changes.
· It is necessary that, the programmer understands the different processes involved
by carefully studying the drawings, fixtures and machine tools.
· A typical block diagram of this process is shown in Fig. 4.21.1.
Machine tool
40 P
30
20
Q
10
X
0,0 10 20 30 40
Fig. 4.21.2 : Linear interpolation
60 60 J = 20
R
A A
50 50
40 J = 30 40
R
30 30
B
20 20
I = – 10 B
10 10 I = – 40
X X
(0, 0) 10 20 30 40 50 60 (0, 0) 10 20 30 40 50 60 70
(a) (b)
60 60
R
A A
50 50
40 40 J = 50
R
30 30
J = 10 B
20 20
B
10 I = – 30 10 I = – 10
X X
(0, 0) 10 20 30 40 50 60 (0, 0) 10 20 30 40 50 60 70
(a) (b)
Note : For XY plane I J values are specified, similarly for YZ plane J K values are
specified.
Tool offset
Tool offset
· The MCU then shifts the Z-axis by the amount stored in the shift register.
Generally, the values of the offset are entered by the operator at the time of
programming. Refer Fig. 4.21.5 for tool length offset.
· Cutter length compensation is given by G43 and cancelled by G49.
v) G40/G41/G42 (Cutter radius compensation)
· During profile cutting operations, an allowance is provided to the cutter radius in
the programmed co-ordinates.
· Consider a component as shown in Fig. 4.21.6 in which the tool path centre line
is decided by the spindle axis centre-line, whereas the workpiece edge is offset
from it by the cutter radius.
Component Tool
profile path
G 41
G 42
(b) Cutter diameter compensation right (G42) : When G42 command is given, the
tool will compensate to the right of the programmed surface when seen in the
direction of the tool movement. Refer Fig. 4.21.7.
(c) Cutter diameter compensation cancel (G40) : G40 command cancels any
compensation as applied previously. The tool will change from a compensated
position to an uncompensated position.
vi) G90/G91 (Absolute and Incremental programming)
G90 (Absolute programming system)
· In this system, all the positions are indicated from a reference point, which is a
fixed zero point or set point.
· Fig. 4.21.8 (a) shows that all positions are marked with a set point.
A
X
Example 4.23.1 : Write a manual part program to finish the stepped shaft in f 40 mm
section as shown in Fig. 4.23.1. Assume spindle speed as 350 rpm and feed rate
0.4 mm/rev.
50
0
40
Fig. 4.23.1
Solution : Given data :
S = 350 rpm and F = 0.4 mm/rev.
Assume that the machine by default is in diameter programming mode.
(Home position)
4
3 2
+X
1 +Z
50
40
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S350 M03; (Spindle speed 350 rpm and in clockwise direction)
N005 G00 X0 Z0 M08; (Rapid tool positioning at point 1 and coolant ON)
N006 G01 X40 F0.4; (Finish the face till point 2 at 0.4 mm/rev.)
N009 G00 G28 U0 W0 M09; (Rapid traverse to home position and coolant OFF)
Example 4.23.2 : Write a manual part program for turning and facing the barstock to
the required dimensions as shown in Fig. 4.23.2. Assume one roughing and one finish
face cut; two roughing and two finish turning cut. Assume spindle speed 450 rpm and
feed 0.5 mm/rev.
50
65
50
Fig. 4.23.2
Solution : Given data :
S = 450 rpm and F = 0.5 mm/rev.
Assume that the machine by default is in diameter programming mode. Refer
Fig. 4.23.2 (a).
2
1 52
1296
50
1
5 4
8 7
11 10
65
72
69
50
+X
32 +Z
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S450 M03; (Spindle speed is 450 rpm and in clockwise direction)
N005 G00 X75 Z2 M08; (Rapid traverse to point 1 and coolant ON)
N006 G01 X0 F0.5; (Rough cut face till point 2 at a feed of 0.5 mm/rev.)
N0019 G00 G28 U0 W0 M09; (Rapid traverse to home position and coolant OFF)
Explanation :
The tool cycles are as follows :
2-3 (Feed for finishing) 4-7-8-9 (Again rough turning of shaft and
shoulder)
4-5-6 (Rough turning of shaft and 4-10-11-12 (Finish turning of shaft and
shoulder) shoulder)
Example 4.23.3 : Write a manual part program for finishing a forged component as
shown in Fig. 4.23.3. Assume speed 300 rpm and feed 0.4 mm/rev. Assume 1 mm
material is to be removed radially from external diameter.
R5
100
50
20 30 30
Fig. 4.23.3
Solution : Given data :
S = 300 rpm and F = 0.4 mm/rev.
Assume that the machine by default is in diameter programming mode.
Refer Fig. 4.23.3 (a).
(Home position)
6
5 25
3 R5
100
4
2 1
60
50
+X
+Z
30
60
80
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N002 G95 G28 U0 W0; (Feed in mm/rev. and go to home position)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S300 M03; (Spindle speed is 300 rpm and in clockwise direction)
N005 G00 X50 Z2 M08; (Rapid traverse to point 1 and coolant ON)
N006 G01 Z – 25 F0.4; (Finish turning upto point 2 with a feed of 0.4 mm/rev.)
N007 G02 X60 Z – 30 R5; (Clockwise interpolation upto point 3 with a radius of 5)
N008 G01 Z – 60; (Finish turning upto point 4)
N009 X100 Z – 80; (Finish turning upto point 5)
N0010 G00 X102; (Rapid traverse to point 6)
N0011 G28 U0 W0 M09; (Return to home position and coolant OFF)
N0012 M05 M30; (Spindle stop and program stop)
Example 4.23.4 : Write a part program for the component as shown Fig. 4.23.4.
Assume that spindle speed 500 rpm and feed is 0.3 mm/rev.
20 30 20
60
20
40
R10
Fig. 4.23.4
Solution : Given data :
S = 500 rpm and Feed = 0.3 mm/rev.
Assume that the machine by default is in diameter programming mode.
Refer Fig. 4.23.4 (a).
8 (Home position)
7 6
R10
60
5 4
40
3
+X
20
2 1
+Z
20
40
50
70
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S500 M03; (Spindle speed 500 rpm and in clockwise direction)
N0010 G02 X60 Z – 50 R10; (Circular interpolation upto point 6 with a radius of 10)
Example 4.23.5 : Write a manual part program to finish the following component
(Refer Fig. 4.23.5). Assume spindle speed 600 rpm and feed 0.45 mm/rev.
R15
Ø 30
Fig. 4.23.5
(Home
4 position)
+X
R15
2 1
Ø 30
+Z
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, Tool no. 01 with offset value 01)
N004 S600 M03; (Spindle speed 600 rpm and in clockwise direction)
N007 G03 X30 Z – 15 R15; (Anticlockwise interpolation upto point 3 with a radius of
15)
Example 4.23.6 : Fig. 4.23.6 shows the finished size of a round bar. The original
diameter of the bar was 28 mm. Make a part program for facing, parting and
reduction of diameter. Take feed = 200 mm/min, spindle speed = 640 rpm and
depth of cut = 2 mm per cut.
X
Ø 24
Ø 28
Ø 20
40
60
Z
Fig. 4.23.6
Home position
12
6 5
11 10 4 3
9 8
X
2 1
Z
40
60
Ø 20
Ø 24
Ø 28
Parting Tool
Example 4.23.7 : Write a part program for that part shown in Fig. 4.23.7.
5
(0, 0)
20 10
10 mm
E D A
5 mm –x
C
B
40 20 –z +z
+x
Fig. 4.23.7
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S500 M03; (Spindle speed 500 rpm and in clockwise direction)
31
R12
Ø 70
Ø 44
Ø 30
Ø 55
20
45
67
15º 95
Fig. 4.23.8
9 8
7 6 31
5 4
3 2
1
R12
Ø 70
Ø 44
Ø 30
Ø 55
20
45
67
15º 95
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N002 G95 G28 U0 W0; (Feed in mm/rev and go to home position)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S500 M03; (Spindle speed 500 rpm and in clockwise direction)
N005 G74 P006 Q015 D2 R1; (Canned cycle starts from line 006 to 015 with depth of
cut 2 mm and relief 1 mm)
N006 G00 X0 Z0 F0.15 M08; (Rapid traverse to origin, coolant ON and feed is
0.15 mm/rev)
N007 G01 X28 Z0; (Linear interpolation upto point 1)
N008 X30 Z – 1; (Linear interpolation upto point 2)
N009 X30 Z – 20; (Linear interpolation upto point 3)
N010 G03 X44 Z – 31 R12; (Circular interpolation upto point 4)
N011 G01 X44 Z – 45; (Linear interpolation upto point 5)
N011 X55 Z – 45; (Linear interpolation upto point 6)
N012 X55 Z – 67; (Linear interpolation upto point 7)
N013 X70 Z – 69; (Linear interpolation upto point 8)
N014 X70 Z – 95; (Linear interpolation upto point 9)
N015 G72 P006 Q014; (Finish facing and turning from line 006 to 014)
N016 G28 U0 W0 M09; (Return to home position and coolant OFF)
N017 M05 M30; (Spindle stop and program stop)
Example 4.23.9 : Write a manual part program to turn the component shown on a
CNC Lathe from 75 mm bar stock. The following data may be assumed :
i) There will be two rough turnings and one finish turning. The first cut is with a depth
of 3 mm for a length of 58 mm, the second with a depth of 3 mm for a length of
59 mm and the third with a depth of 1.5 mm for the full length of 60 mm.
ii) The shoulder of the work-piece is also machined during each cut.
iii) The spindle speed is 400 rpm and the feed rate is 0.5 mm/rev.
Make a free-hand sketch showing relevant points of tool positions for each of the three
turning operations and then write the manual part program. State also what each line
of the program does.
Note : If the exact G-codes and M-codes are not known, the student can use his/her
own code-numbers, but the function of such codes must be clearly stated.
+X
+Z
60
75
60
Fig. 4.23.9
2
1 62
1296
60
1
5 4
8 7
11 10
75
69
63
60
+X
32 +Z
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N003 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N004 S400 M03; (Spindle speed is 400 rpm and in clockwise direction)
N005 G00 X80 Z2 M08; (Rapid traverse to point 1 and coolant ON)
N006 G01 X0 F0.5; (Rough cut face till point 2 at a feed of 0.5 mm/rev.)
N0019 G00 G28 U0 W0 M09; (Rapid traverse to home position and coolant OFF)
Explanation :
The tool cycles are as follows :
1-2 (Rough facing) 6-4 (Rapid traverse)
2-3 (Feed for finishing) 4-7-8-9 (Again rough turning of shaft and
shoulder)
3-4 (Finish facing) 9-4 (Rapid traverse)
4-5-6 (Rough turning of shaft and 4-10-11-12 (Finish turning of shaft and
shoulder) shoulder)
Example 4.23.10 : Write a complete part program using G and M codes for the job
shown in Fig. 4.23.10. Assume suitable speed and feed for machining.
Billet size - Diameter : 60 mm and Length : 90 mm.
Thread : Major Diameter, D0 = 20 mm, Minor Diameter,
Dc = 17 mm and Pitch : 2.5 mm, Groove : Width = 5 mm and depth = 2.5 mm.
R10
Thread
20
40
60
Groove
20 20 10 5 20
Fig. 4.23.10
Solution :
10 9 X
8 7
6 3 2
5 4
Z
1
Program Description
N01 G90 G71 ; Absolute programming mode and data input is in metric mode.
N02 G95 G21 ; Feed in mm/rev ; Metric mode
Facing
N03 M42 T01 ; Tool change, tool number 01
N04 S200 M03 M07 ; Spindle speed 200 rpm, clockwise ON, coolant ON
N05 G00 X0 Z3 ; Rapid to point 1
N06 G01 Z0 F0.5 ; Facing operation begins on the stock
N07 X62 ; Facing ends at point 2
Turning
N08 G71 U2 R1 ; See explanation below
N09 P010 Q015 W0 See explanation below
F0.5 ;
N010 G00 X20 Z0 ; Rapid to point 2
N011 G01 Z–25 ; Turning begins till point 6
N012 G02 X40 Z–35 ; Circular clockwise interpolation upto point 7
N013 G01 X40 Z–45 ; Linear interpolation upto point 8
N014 G01 X60 Z–65 ; Linear interpolation upto point 9
N015 G01 X60 Z–85 ; Linear interpolation upto point 10
Finishing
N016 M42 T02 ; High gear, tool No. 02
N017 G70 P010 Q015 ; See explanation below
N018 G28 U0 V0 W0 Return to home position, coolant off
M09 ;
N019 M05 ; Spindle off
Grooving
N020 M42 T03 ; High gear, tool no. 03
N021 G95 G21 G96 ; Feed per revolution, metric mode, constant surface speed
N022 S400 M03 M07 ; Spindle speed 400 rpm, clockwise ON coolant ON
N023 G00 X30 Z0 ; Rapid to point 2
N024 Z–20 ; Rapid to point 3
N025 X30 ; Rapid to point 3
N026 G75 R0.5 ; See explanation
N027 X15 Z–25 P1000 See explanation
Q500 F0.15 ;
N028 X30 ; Rapid to point 6
Explanation :
N08 G71 U2 R1
Sequence Stock removal Depth of each roughing Tool escape of 1 mm
Number in turning pass in 2 mm
Example 4.23.11 : Write CNC part program for the component shown in Fig. 4.23.11
Mention the assumption made.
150.00
130.00
120.00
65.00
45.00
32.00
R10
Chramfer 3 45º
R8
100.00
54.56
80.00
Fig. 4.23.11
Y
Y
20 P6(0, 50) P5(20, 50)
30
P4(20, 20) P3(50, 20)
20
X X
50 P1(0, 0)
P2(50, 0)
Z P0(–10, –10) Z
X X
10 – 10
Fig. 4.24.1
Programs Description
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input and
feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool no.01.
N04 G41 M03 S500; Cutter radius compensation to left, spindle start in clockwise
direction and spindle speed is 500 r.p.m.
N05 G00 X–10 Y–10 Z5 Rapid travel to position (–10, – 10) and cutter is 5 mm
M08; above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–10 F200; Linear interpolation and move tool 10 mm downward along
Z-axis with feed 200 mm/min to position (0, 0).
N07 X50 Y0; Linear interpolation and tool move to position (50, 0)
N08 X50 Y20; Linear interpolation and tool move to position (50, 20)
N09 X20 Y20; Linear interpolation and tool move to position (20, 20)
N10 X20 Y50; Linear interpolation and tool move to position (20, 50)
N11 X0 Y50; Linear interpolation and tool move to position (0, 50)
N15 G40 M05; Cutter radius compensation cancel and spindle stop.
N16 M09 M30; Coolant off, program end and tape rewind.
R20
40
I=0
and J = 20
X X
50
P1(0, 0)
P2(50, 0)
P0(–10, –10)
Z Z
X X
10 – 10
(a) Workpiece
(b) Tool path
Fig. 4.24.2
Solution : For the tool path refer Fig. 4.24.2 (b).
Program Description
102; Program number
N01 G28 U0 V0 W0; Return to machine reference position.
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input and
feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool no. 01.
N04 G41 M03 S600; Cutter radius compensation to left, spindle ON with speed
600 r.p.m.
N05 G00 X–10 Y–10 Z5 M08; Rapid travel to position (–10, –10) and cutter is 5 mm
above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–10 F150; Linear interpolation and move tool 10 mm downward along
Z-axis with feed 150 mm/min.
N07 X50 Y0; Linear interpolation and tool move to position (50, 0).
N08 G03 X50 Y40 I0 J20; Anticlockwise circular interpolation and tool move to position
(50, 40).
N09 G01 X0 Y40; Linear interpolation and tool move to position (0, 40)
N10 X0 Y0; Linear interpolation and tool move to position (0, 0).
N11 G00 Z5; Rapid travel 5 mm above the workpiece surface.
N12 G28 U0 V0 W0; Return to machine reference position.
N13 G40 M05; Cutter radius compensation cancel and spindle stop.
N16 M09 M30; Coolant off, program end and tape rewind.
R15
20
R15
P6(70, 50)
P5(70, 20)
20
R15
X X
20 20
Fig. 4.24.3
Program Description
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input and
feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool no. 01.
N04 G41 M03 S800; Cutter radius compensation to left, spandle ON with speed
800 r.p.m.
N05 G00 X–10 Y–10 Z5 M08; Rapid travel to position (–10, –10) and cutter is 5 mm
above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–10 F100; Linear interpolation and move tool 10 mm downward along
Z-axis with feed 100 mm/min to position (0, 0).
N07 X20 Y0; Linear interpolation and tool move to position (20, 0).
N08 G02 X50 Y0 I15 J0; Clockwise circular interpolation and tool move to position
(50, 0).
N09 G01 X70 Y0; Linear interpolation and tool move to position (70, 0).
N10 X70 Y20; Linear interpolation and tool move to position (70, 20).
N11 G02 X70 Y50 I0 J15; Clockwise circular interpolation and tool move to position
(70, 50).
N12 G01 X70 Y70; Linear interpolation and tool move to position (70, 70).
N13 X50 Y70; Linear interpolation and tool move to position (50, 70).
N14 G02 X20 Y70 I–15 J0; Clockwise circular interpolation and tool move to position
(20, 70).
N15 G01 X0 Y70; Linear interpolation and tool move to position (0, 70).
N16 X0 Y0; Linear interpolation and tool move to position (0, 0).
N19 G40 M05; Cutter radius compensation cancel and spindle stop.
N20 M09 M30; Coolant off, program end and tape rewind.
Example 4.24.4 : Write the program for the job as shown in Fig. 4.24.4 (a). Use the
following machining data :
Speed = 800 r.p.m., feed = 10 mm/min,
Depth of cut = 3 mm, Thickness of job = 3 mm.
Y
P5(160, 100)
R20
P4(130, 100)
100 P3(110, 80)
(0, 0)
X
110
P1(0, 0)
P2(110, 0)
P0(–10, –10)
(a) Workpiece (b) Tool path
Fig. 4.24.4
Program Description
104; Program number.
N01 G28 U0 V0 W0; Return to machine reference position.
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input
and feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool
no.01.
N04 G41 M03 S800; Cutter radius compensation to left, spindle ON with
speed 800 r.p.m.
N05 G00 X–10, Y–10 Z5 M08; Rapid travel to position (–10, –10) and cutter is
5 mm above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–3 F10; Linear interpolation and move tool 3 mm downward
along Z-axis with feed 10 mm/min to position (0, 0).
N07 X110 Y0; Linear interpolation and tool move to position (110,0).
Example 4.24.5 : Write the program for the job as shown in Fig. 4.24.5 (a).
80
100
P6(80, 20)
P5(0, 20)
(0, 0) 80 A 120 B
Fig. 4.24.5
Program Description
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input
and feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool
no.01.
N04 G41 M03 S500; Cutter radius compensation to left, spindle ON with
speed 500 r.p.m.
N05 G00 X0, Y0 Z5 M08; Rapid travel to position (0, 0) and cutter is 5 mm
above the workpiece surface, coolant ON.
N06 X80 Y0 Z–5 F20; Rapid travel to position (80, 0) and move tool 5 mm
downward along Z-axis with feed 20 mm/min.
N07 G01 X200 Y0; Linear interpolation and tool move to position (200,0).
N09 X0 Y100; Linear interpolation and tool move to position (0, 100).
N10 X0 Y20; Linear interpolation and tool move to position (0, 20).
N11 X80 Y20; Linear interpolation and tool move to position (80, 20).
N12 X80 Y0; Linear interpolation and tool move to position (80, 0).
N15 G40 M05; Cutter radius compensation cancel and spindle stop.
N16 M09 M30; Coolant off, program end and tape rewind.
Example 4.24.6 : Write a part program for the workpiece as shown in Fig. 4.24.6.
Assume cutter diameter 10 mm, depth of workpiece 10 mm, spindle speed 600 r.p.m.
and feed 15 mm/min.
P8(0, 60) P7(35, 60)
35 P5(60, 50)
R10
R15
P6(45, 50)
20
20 15 25
P1(0, 0) P2(20, 0)
P0(–10, –10)
(a) Workpiece (b) Tool path
Fig. 4.24.6
Program Description
107; Program number.
N01 G28 U0 V0 W0; Return to machine reference position.
N02 G90 G71 G94; Absolute programming mode, metric (mm) data
input and feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select
tool no.01.
N04 G41 M03 S600; Cutter radius compensation to left, spindle ON
with speed 600 r.p.m.
N05 G00 X–10, Y–10 Z5 M08; Rapid travel to position (–10, –10) and cutter is
5 mm above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–10 F15; Linear interpolation and move tool 10 mm
downward along Z-axis with feed 15 mm/min to
position (0, 0).
N07 X20 Y0; Linear interpolation and tool move to position
(20, 0).
N08 X35 Y30; Linear interpolation and tool move to position
(35, 30).
Example 4.24.7 : Write a part program for the component as shown in Fig. 4.24.7 (a).
Take feed 30 mm/min; spindle speed 1000 r.p.m. and thickness of component as 10 mm.
Use end mill type cutter of diameter 10 mm.
Y Y P6(20, 90) P5(75, 90)
20 55
P4(90, 75)
55
40
Fig. 4.24.7
Program Description
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input
and feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool
no.01.
N04 G41 M03 S1000; Cutter radius compensation to left, spindle ON with
speed 1000 r.p.m.
N05 G00 X0, Y0 Z5 M08; Rapid travel to position (0, 0) and cutter is 5 mm
above the workpiece surface, coolant ON.
N06 X35 Y20 Z–10 F30; Rapid travel to position (35, 20) and cutter is 10 mm
downward along Z-axis with feed 30 mm/min.
N07 G01 X75 Y20; Linear interpolation and tool move to position
(75, 20).
N08 G02 X90 Y35 I15 J0; Clockwise circular interpolation and tool move to
position (90, 35).
N09 G01 X90 Y75; Linear interpolation and tool move to position
(90, 75).
N16 G40 M05; Cutter radius compensation cancel and spindle stop.
N17 M09 M30; Coolant off, program end and tape rewind.
Example 4.24.8 : Prepare a part program for the given job as shown in
Fig. 4.24.8 (a). By using following data :
Speed = 1000 r.p.m., Feed = 10 mm/min, Depth of cut = 3 mm
Tool position from the surface of the workpiece is 10 mm above. Thickness of
job = 3 mm.
P5(10, 65)
10 55
P6(0, 55) P4(65, 65)
10
55
55
R10
R10 P3(65, 10)
(0, 0)
P1(0, 0)
P2(55, 0)
P0(–10, –10)
(a) Workpiece (b) Tool path
Fig. 4.24.8
Program Description
N02 G90 G71 G94; Absolute programming mode, metric (mm) data input and
feed in mm/min.
N03 G17 M06 T01; Selection of XY plane, tool change and select tool no.01.
N04 G41 M03 S1000; Cutter radius compensation to left, spindle ON with speed
1000 r.p.m.
N05 G00 X–10 Y–10 Z10 Rapid travel to position (–10, –10) and cutter is 10 mm
M08; above the workpiece surface, coolant ON.
N06 G01 X0 Y0 Z–13 F10; Linear interpolation and move tool 13 mm downward along
Z-axis with feed 10 mm/min to position (0, 0).
N07 X55 Y0; Linear interpolation and tool move to position (55, 0).
N08 G03 X65 Y10 I0 J10; Anticlockwise circular interpolation and tool move to position
(65, 10).
N09 G01 X65 Y65; Linear interpolation and tool move to position (65, 65).
N10 X10 Y65; Linear interpolation and tool move to position (10, 65).
N11 X0 Y55; Linear interpolation and tool move to position (0, 55).
N12 X0 Y0; Linear interpolation and tool move to position (0, 0).
N15 G40 M05; Cutter radius compensation cancel and spindle stop.
N16 M09 M30; Coolant off, program end and tape rewind.
60
30
10 Drill (3 Holes) 12
#1
#2
65
55
#3
35
25
75
Fig. 4.24.9
#1
#2
#3
+Y
+X
(Home position)
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N002 M06 T0101; (Tool change, Tool no.1 with offset value 01)
N003 S1200 M03; (Spindle speed 1200 rpm and in clockwise direction)
N004 G00 X12 Y55 M08; (Rapid traverse to point 1 and coolant ON)
N0011 M09 M05 M30; (Coolant OFF, spindle stop and program stop).
Example 4.24.10 : Write a manual part program for drilling two holes of 8 mm
diameter and two holes of 6 mm diameter. Take spindle speed as 1200 rpm for 8 mm
diameter hole and 1600 rpm for 6 mm diameter hole. Refer Fig. 4.24.10.
40
20
8, Drill (2 Holes)
#1
R2.5 6, Drill (2 Holes)
75
60
#3
#2
20
40
30
#4
10
90
100
Fig. 4.24.10
#1
#2 #3
#4
+Y
+X
(Home position)
Program Description
N001 G90 G71; (Absolute programming mode and data input is in metric
mode)
N002 M06 T0101; (Tool change, tool no.1 with offset value 01)
N003 S1200 M03; (Spindle speed 1200 rpm and in clockwise direction)
N004 G00 X20 Y60 M08; (Rapid traverse to point 1 and coolant ON)
N0010 G00 G90 G71; (Rapid traverse, absolute and metric mode)
N0011 S1600 M03; (Spindle speed 1600 rpm and in clockwise direction)
N0017 M09 M05 M30; (Coolant OFF, spindle stop and program stop).
Example 4.24.11 : Write a manual part program for drilling and milling the
machine component as shown in Fig. 4.24.11. Assume 10 mm diameter milling
cutter. Take spindle speed 2000 rpm (for milling) and 3000 rpm (for drilling). Feed
1400 mm/min.
50
30
8 Typ. R5 Typ.
15
60
30
15
15
60
80
90
Fig. 4.24.11
#10
#8 #7
#9
#3 #4
Home
Position
#1 #2
Fig. 4.24.11 (a)
It is assumed that the machine (0, 0) is at the left lower most corner of the workpiece.
Program Description
N001 G90 G71 G94; (Absolute programming mode, data input is in mertic
mode and feed in mm/min)
N004 G01 X65 F1400 M08; (Machining upto point 2 with a feed of 1400 mm/min
and coolant ON)
N0015 G00 G90 G71; (Rapid traverse, absoulte and metric mode)
N0016 X15 Y15 S3000 M03; (Spindle speed 3000 rpm in clockwise direction and
locate point 9)
N0021 M09 M05 M30; (Coolant OFF, spindle stop and program stop)
Example 4.24.12 : Write the part program for the work piece shown in Fig. 4.24.12.
Material : Aluminium, Work piece size : 100 mm ´ 80 mm ´ 15 mm.
y
20
R20
20
60
R20
5
x
5 80
Fig. 4.24.12
2 7 8 3
6 9
10
5 11 4 X
1
Home position
Fig. 4.24.12 (a)
Program Description
N001 G90 G71 G94; (Absolute programming mode,data input is in metric mode
and feed in mm/min)
N002 M06 T0101; (Tool change, Tool no. 1 with offset value 01)
N003 S1000 M03; (Spindle speed 1000 rpm and in clockwise direction)
N004 G00 X10 Y–10 Z–15 (Rapid traverse to point 1 and coolant ON)
M08;
N005 G41 D20; (Tool compensation on RIGHT and cutter diameter is
20 mm)
N006 G01 Y70; (Linear interpolation upto point 2)
N007 X90; (Linear interpolation upto point 3)
Example 4.24.13 : Write a program (manual part program) to drill five holes in the
locations shown in Fig. 4.24.13 and pause at each location where a hole should be
drilled.
3 4
19
2
100
32
1 5
25
25 6 44
25 Start
point 100
25
Drill 5 holes-12.5 DIA
Fig. 4.24.13
3 4
19
2
100
32
1 5
25
X
25 6 44
25
100
25
Home position Start
point
Fig. 4.24.13 (a)
Program Description
N001 G90 G71 G94; (Absolute programming mode and data input is in metric
mode and feed in mm/min)
N002 M06 T0101; (Tool change, tool no. 01 with offset value 01)
N003 M03 S300; (Spindle speed is 300 rpm and in clockwise direction)
N004 G00 X25 Y25 Z10; (Rapid traverse to start point and tool is above the plate)
N005 M08 X25 Y25; (Coolant ON and Rapid traverse to point 1)
N006 G04 X2; (Stoppage of axis motion i.e. pause for 2 sec.)
N007 G01 Z–10 F50; (Linear interpolation, drill the hole with a feed of 50 mm/min.)
N008 G01 Z10; (Move spindle upwards)
N009 G00 X31 Y57 Z10; (Rapid traverse of point 2 and tool is above the plate)
N0010 G04 X2; (Stoppage of axis motion i.e. pause for 2 sec.)
N0011 G01 Z – 10 F50; (Linear interpolation, drill the hole with a feed of 50 mm/min)
N0012 G01 Z10; (Move spindle upwards)
N0013 G00 X31 Y76 Z10; (Rapid traverse to point 3 and tool is above the plate)
Example 4.24.14 : Write a part program for drilling holes in the part shown in
Fig. 4.24.14. The plate thickness is 20 mm.
3
90
1
60
4
25
15
A 25 +Y
50
80
+z
95
+X
–z 20
Fig. 4.24.14
90
60 1
4
25
15
+X
A 25
50
Home 80
position 95
Program Description
N001 G90 G71 G94; (Absolute programming mode and data input is in metric
mode and feed in mm / min)
N002 M06 T0101; (Tool change, tool no. 1 with offset value 01)
N003 M03 S300; (Spindle speed 300 rpm and in clockwise direction)
N004 G00 X25 Y25 Z2 M08; (Rapid traverse to point 1 and coolant ON and tool is
2 mm above the plate)
N017 M09 M05 M30; (Coolant OFF, spindle stop and program stop)
4.25 Subroutine :
· Subroutine is also called as subprograms.
· When a similar machining operation is to be performed repeatedly then the
general programming method will not be used because,
¡ It is very lengthy.
¡ It is tedious.
¡ It is more time consuming.
¡ It consumes more space in the computer memory.
· In such case, subroutine method is used. It is a time saving technique.
· It is an independent program similar to general program and stored in the
computer memory under separate program number.
· It can be called anywhere in the main program and for any number of times.
· To call the subroutine in the main program, the miscellaneous code M98 is used.
The instruction block for subroutine can be written as follows :
N10 M98 P50 L1;
where,
M98 indicates a call to subroutine,
P50 indicates the program number (here 50),
L1 indicates to call subroutine only one time.
· After execution of subroutine return back to the main program and continue it.
· To end the subroutine and return back to the main program M99 code is used.
· It is important to note that, the main program is written in absolute programming
mode (G90) and subroutine is written in incremental programming mode (G91).
· Hence, use code G91 at the start of subroutine and G90 before use of M99.
4 - 90 Computer Aided Design and Manufacturing
Fundamental of CNC and Part Programming
Example 4.25.1 : Write a part program using subroutine for milling a square pocket
of 30 ´ 30 mm and 5 mm depth. Refer Fig.4.25.1. Take diameter of cutter as 5 mm,
speed 500 r.p.m. and feed 100 mm/min.
Solution : Fig. 4.25.1 (b) shows the enlarged view of pocket and corresponding tool path.
From Fig. 4.25.1 (a) coordinates of point P1 = (15, 30) and of point P5 = (60, 30). In this
case we will first write a subroutine program which is then called in the main program.
15
30 PA(0, 20) PB(20, 0)
5
A B
30
1 2
D C
10 15 10
P1 P5 PD(–20, 0) PC(0, –20)
Incremental
25 mode
(b) Enlarged view
of pocket
(a) Workpiece
Fig. 4.25.1
Subroutine program
Program Description
Main program
Program Description
N20 G17 M06 T01; Selection of XY plane, tool change and tool
no. 01 is selected.
N30 G00 X15 Y30 Z5 M08; Rapid travel to position P1 (15, 30) and
cutter is 5 mm above the surface of
workpiece, coolant ON.
N35 M98 P50 L1; Call for subroutine, program number 50 and
for only one time.
N45 M98 P50 L1; Call for subroutine, program number 50 and
only once.
N60 M09 M30; Coolant off, program end and tape rewind.
2. It is used when multiple passes are It is used when multiple passes are
required at different places. required at the same place.
5. It is given in every block of instruction In this cycle, directly final point is given
till the operation is completed. in the instruction block.
6. The path of cutter for every point is The path of cutter for every pass is
mentioned by the programmer. automatically generated.
Peck depth K = 2 mm
P1 P2
40
10 50 End
(a) Workpiece (b) Tool path
Fig. 4.26.2
Solution : Fig. 4.26.2 (b) shows the tool path or peck depth. The starting blocks and end
blocks are similar to all programs hence only the block of slot milling is explained as
follows :
Program Description
N10 G00 X10 Y20 Z5; Rapid travel to initial position i.e. P1 (10, 20)
and cutter is 5 mm above the workpiece
surface.
N15 G74 X60 Y20 Z–10 K2 S50 F100; Slot milling cycle and cutter moves to
P2 (60, 20) and 10 mm downward along
Z-axis with peck feed 50 mm/min and feed
100 mm/min.
R5
Start
40 10 End
20
60
APT
CL Data
Post processor
MCU
NCtapecomnds Machine tool NC Tape commands
· Words in the statement contain maximum six letters. It can contain alphabets or
numbers but no special characters.
· Keywords are the commands in APT to perform a certain function only.
Keywords are of following two types :
i) Major word : This defines type of statement.
ii) Minor word : This defines various parameters.
· Symbols are the words used for geometrical definitions and numerical values.
They must be defined before using in the program.
· Lables are the words used to refer a statement so that control can be passed to it.
They can be defined with all characters.
· Mathematical operations are represented in APT as follows :
Symbol Operation Symbol Operation
+ Addition – Subtraction
* Multiplication / Division
* * Exponential ABS Absolute value
SQRT Square root SIN Sin of angle
COS Cosine of angle TAN Tangent of angle
EXP Value of e to the power LOG Natural log
i) Geometry statement
a) Setup commands
b) Point to point motion command
c) Continuous path motion command
· This crystal is then sliced into individual wafers by using a inner diameter blade
known as wafer machining. (Refer Fig. 4.28.1)
Z
X
10
Solution : Tool path for the given part is shown in Fig. 4.29.1 (b). By using point to
point programming method, the program is written as follows :
(50, 40)
SP (70, 35)
(25, 30) P4
P3 (45, 20)
(15, 10) P2
P1
PARTNO / EXAMPLE 1
MACHIN/MM, 1
PRINT/ON $ $ PRINT GEOMETRY
CLPRINT/ON $$ PRINT CLDATA
SP = POINT/70, 35, 40 $$ (Starting point co-ordinates 70, 35, 40)
P1 = POINT/15, 10, 5 $$ (Co-ordinates of point 1 (P1) 15, 10, 5)
P2 = POINT/45, 20, 5 $$ (Co-ordinates of point 2 (P2) 45, 20, 5)
P3 = POINT/25, 30, 5 $$ (Co-ordinates of point 3 (P3) 25, 30, 5)
P4 = POINT/50, 40, 5 $$ (Co-ordinates of point 4 (P4) 50, 40, 5)
$$ DRILL DIA 6 MM
SPINDL/950, CLW $$ (Spindle speed is 950 rpm clockwise)
SPINDL/ON $$ (Spindle ON)
COOLNT/MIST $$ (Coolant ON and its mist type)
FROM/SP
RAPID, GOTO/P1 $$ (From starting point go to point P1)
$$ DRILLING WITH FEED RATE 0.5 MM/REV
CYCLE/DRILL, – 15, MMPR, 0.5, 2 $$ (Drill 15 mm below origin with feed
of 0.5 mm/rev and 2 mm offset)
GOTO/P2
Example 4.29.2 : Write an APT program for a component shown in Fig.4.29.2 (a). It
is 20 mm thick. Post processor statement is MACHIN/MMPOST, 3. The mill diameter is
10 mm.
60
R5
95
50 70 50
Solution : The tool path for the above geometry is shown in Fig. 4.29.2(b)
PARTNO/EXAMPLE 2
MACHIN / MMPOST, 3
4 - 102 Computer Aided Design and Manufacturing
Fundamental of CNC and Part Programming
3 4
L7
60
L6
2 1 6 5
95
L2 L3 L4 L5
Y
L1
SP X 8 7
50 70 50
PRINT / ON
CLPRINT / ON
SP = POINT / 0, 0, 40 $$ (Starting point co–ordinates 0, 0, 40)
L1 = LINE/XAXIS $$ (Line L1 is along X - axis)
L2 = LINE / Y AXIS $$ (Line L2 is along Y - axis)
L3 = LINE/PARLEL, L2, X LARGE, 50 $$ (Line L3 parallel to L2 at 50 mm)
L4 = LINE/PARLEL, L3, X LARGE 70 $$ (Line L4 parallel to L3 at 70 mm)
L5 = LINE/PARLEL, L4, X LARGE, 50 $$ (Line L5 parallel to L4 at 50 mm)
L6 = LINE/PARLEL, L1, Y LARGE, 95 $$ (Line L6 parallel to L1 at 95 mm)
L7 = LINE/PARLEL, L6, Y LARGE, 60 $$ (Line L7 parallel to L6 at 60 mm)
$$ DEFINE PLANE 2 MM ABOVE THE PART
PL1 = PLANE/0, 0, 1, 2 $$ (Select plane)
$$ = SETUP STATEMENTS
CUTTER/10 $$ (Cutter diameter is 10 mm)
SPINDL/800, CLW $$ (Spindle speed 800 rpm, clockwise)
SPINDL/ON $$ (Spindle ON)
FEDRAT/MMPM, 240 $$ (Feed rate is 240 mm/min)
COOLNT/ON $$ (Coolant ON)
$$ MOTION STATEMENTS
RAPID, GOTO, SP $$ (Goto starting point rapidly)
GO/TO, L6, TO, PL1, TO, L3 $$ (Go from L6 to PL1 and then from PL1 to L3)
GODLTA/ – 18
GOLFT/L6, PAST, L2 $$ (Tool moves from 1 to 2)
GORGT/L2, PAST, L7 $$ (Tool moves from 2 to 3)
GORGT/L7, PAST, L5 $$ (Tool moves from 3 to 4)
GORGT/L5, PAST, L6 $$ (Tool moves from 4 to 5)
GORGT/L6, TO, L4 $$ (Tool moves from 5 to 6)
GOLFT/L4, PAST, L1 $$ (Tool moves from 6 to 7)
GORGT/L1, PAST, L3 $$ (Tool moves from 7 to 8)
GORGT/L3, TO, L6 $$ (Tool moves from 8 to 1)
RAPID, GODLTA/18
RAPID, GOTO/SP $$ (Go to starting point rapidly)
COOLNT/OFF $$ (Coolant OFF)
SPINDL/OFF $$ (Spindle OFF)
REWIND
FINI $$ (Program finish)
Example 4.29.3 : Write an APT program for a part as shown in Fig. 4.29.3(a).
Thickness of plate is 10 mm. End mill diameter is 10 mm. Assume feed rate as 0.3
mm/rev and spindle speed as 1000 rpm.
R20
100
50
R20
150
Solution : The tool path for given part is shown in Fig. 4.29.3 (b)
5
C2
R20
L3
4
100
L4 P0
L2
50
Y C1
3
X L1 R20
1 2
SP
150
Z
X
10
Review Questions
1. What is mean by 'Numerical control' ?
2. What are the types of NC system ?
3. Write note on punch tape.
R5
R6
100 50 30 22 10
20 30 30
15 6 10 5
80
70
R4.5 +X
R9
26
18
24
20
+Z
19
21
49
51
61
+X
R20
50
10 +Z
R40
50
36
40
7
15
22
42
47
Q.13 List the commonly used co-ordinate systems of CNC machine tools.
Ans. : i) Absolute co-ordinate system.
ii) Incremental co-ordinate system.
Q.14 What is point-to-point (PTP) system ?
Ans. : In this system, tool is accurately located at some specified position. The spindle is brought
to the starting point, then moved to the next location i.e. from point 1 to point then point 3 etc.
On that location, operation is performed and then tool moves to next location.
Q.15 What are G-codes and M-codes ? Give examples.
Ans. : G-codes or preparatory function, changes the control mode of the machine. G-codes are
followed by two digit number. It is written as G 01, G 02, etc.
M-codes or miscellaneous function, controls other auxiliary operations. It is also followed by two
digit number. It is written as M 03, M 04, etc.
Q.16 What is the difference between incremental and absolute system ?
Ans. : In absolute system, all the co-ordinates are indicated from a referance point which is a
fixed zero or set point. In incremental system, all the co-ordinates or tool positions are indicated
with respect to previous point.
Q.17 What is the role of computer for CNC machine tool ?
Ans. : The program is entered into the computer directly through keyboard. The program is
stored in computer memory, which can be recalled whenever required. Programs can be easily
edited and modified as per the requirement. These features makes the system flexible.
Q.18 Differentiate between fixed zero and floating zero in CNC terminology.)
Ans. : In a fixed zero method, the origin is always predefined. It is generally at the lowermost
left hand corner of the worktable. All other points are defined from this point.
In a floating zero concept, operator can define his origin, which makes it convenient to develope
programs of symmetrical components by providing the origin at the point of symmetry in the
workpiece.
Q.19 Name the various elements of CNC machines.
Ans. : i) Mini computer
ii) Machine tool and CNC tooling
iii) Part program and drawings.
Q.20 What are the classifications of NC machines ? What are the types of motion
control system used in NC machines ?
Ans. :
1. According to the tool positioning
a) Absolute system b) Incremental system
2. According to the motion control system
a) Point to point system b) Straight line system
c) Continuous path system.
3. According to servo control system
a) Open loop system b) Closed loop system
Q.21 Define NC.
Ans. : NC is a programmable automation in which various actions are controlled by means of
coded numbers, letters and other symbols.
Q.22 Mention the major elements of NC machines.
Ans. : i) Machine Control Unit (MCU)
ii) Machine tool and NC tooling
iii) Part program and drawings.
Q.23 Compare closed loop NC system with open loop NC system.
Ans. : In open loop system, there is no feedback, to ensure whether the obtained slide movement
is same as desired or not and if not, what error is present.
In closed loop system, there is a feedback device to compare the slide movement. It is nothing
but a transducer.
Q.24 Show the axes of a CNC horizontal boring machine ?
Ans. :
+Z
+Y
+X
Q.25 What are the basic assumptions made while programming in APT language?
Ans. : In APT programming, it is assumed that the workpiece remains stationary and cutting tool
does all the movements.
Continuous path system : In this, there is relative motion between the tool and workpiece,
during the whole operation. Due to this relative motion, different curves and profiles can be
cut. Actually, it is a combination of PTP and straight cut system.
(0, 0)
(0, 0)
(a) Fixed zero (b) Floating zero
(a) (b)
Fig 5.2.1
Fig. 5.2.1 shows two parts of similar shape and size but different manufacturing
requirements.
a) 15000 pieces / year , tolerance limit ± 0.0001 mm, material is CR steel
b) 7500 pieces / year , tolerance limit ± 0.01 mm, material is SS
Fig 5.2.2
Fig. 5.2.2 shows the various components that are different in shape but similar in
terms of design and manufacturing.
· Optiz coding scheme consists of 9 digits can be extended for adding 4 more
digits.
1 2 3 4 5 6 7 8 9 A B C D
The first 5 digits (12345) are called form code which describes design attributes of the
part such as external shape and machined features. The next four digits (6789) are called
supplementary code which indicates the code related with manufacturing such as
dimensions, work materials, accuracy, surface finish etc., The additional four digits
(ABCD) depends on the manufacturer.
Basic structure of the Optize system of parts classifiction and coding
Form code
Supplementary
code
Digit 1 Digit 2 Digit 3 Digit 4 Digit 5
Digit
Part class Main shape Rotational Plane surface Additional holes
machining machining teeth and forming 6 7 8 9
0 L/D 0.5
External Internal Machining Other
0.5 < L/D < 3 shape shape of plane holes and
1 element element surfaces teeth
L/D 3
Rotational
2
Original shape of raw materials
With deviation
L/D 2 Machining Other holes,
3 Main Rotational
of plane teeth and
shape machining
surfaces forning
Dimensions
With deviation
Accuracy
4
Material
L/D 2
5 Special Main
shape
A/B 3
6
A/C 4
Main bore and Machining Other holes,
Nonrotational
Main
7 A/B > 3 rotational of plane teeth and
shape
machining surfaces forning
A/B 3
8
A/C < 4
Main
9 Special shape
Fig. 5.5.1
Form code (digits 1-5) for rotational parts in the Optiz coding system
Smooth or stepped
elements elements direction, external circle diameter
to one end
External plane surface
Rotational parts
Axial on pitch
No gear teeth
2 L/D 3 2 Thread 2 Thread 2 related by graduation 2
Or smooth
circle diameter
around the circle
Example 5.5.1 : Interpret the form code if the part code is 2080.
Solution :
· 2 - Parts has L/D ratio >= 3
· 0 - No shape element (external shape elements)
· 8 - Operating thread
· 0 - No surface machining
· 1 - Part is axial
Example 5.5.2 : Prepare the OPTIZ form code for the given part.
1
13 UNC
2
0.500
0.875
1.500
Fig. 5.5.2
Prepare the code using OPTIZ coding system table. (Fig. No 5.5.1)
Solution : · The total length of the part is 1.75, overall diameter 1.25, L/D = 1.4 so the
code is 1.
· External shape - a rotational part that is stepped on both with one thread. So the
code is 5.
· Internal shape - a through hole (code 1)
· By examining the drawing of the part (code 0)
· No auxiliary holes and gear teeth (code 0)
The form code is
1 5 1 0 0
Example 5.5.3 : Develop the OPTIZ form code for the given part.
3.0 wide groove Spur gear
2.0 deep (both ends) 36.0 pitch diameter
26.0 20.0
(Both ends)
26.6
42.0
95.0
121.0
Fig. 5.5.3
Solution :
2 6 0 0 6
Data collection
Sortation of process
routings
PFA chart
Cluster analysis
Fig. 5.6.1
5.6.1.1
Data Collection
·The data needed for the analysis are part number and operation sequence.
·Both are contained in the product route sheets.
·Each operation is usually associated with particular machine so determining the
operation sequence also determines the machine sequence.
· The following image shows the example of process route sheets.
Assy. No
Pcs. per pur size Date supplied
TA 1279
Weight Issued by
Sub. Assy. No.
60 Bore hole 1.33 to 1.138 dia Lathe H & H 3.0 158 1.44 turret
E107 fixture Hartord
Superspacer pl
# 45
holder # L46
FDTW - 100
insert #21 Chk.
fixture
70 Deburr 0.005 to 0.010 both Lathe E162 0.3 175 Collect CR
sides, hand feed to hand stop lathe #179
1327 RPM
80 Broach keyway to remove Drill Mach. 0.4 91 B87 fixture L59
thread burrs 507 drill broach tap
0.875120G-H6
90 Hone thread I.D. 0.822/0.828 Grind Grinder 1.5 120
95 Home 0.7600/0.7625 Grind Grinder 1.5 120
Lathe 01
Milling machine 02
Drilling machine 03
CNC - Milling 04
Grinding machine 05
Example :
Parts
A B C D E F G H I
1 1 1 1
2 1 1
3 1 1 1
Machines 4 1 1
5 1 1
6 1 1
7 1 1 1
3 1 1 1
2 1 1
6 1 1
Machines 1 1 1 1
5 1 1
7 1 1 1
4 1 1
Fig. 5.6.2
Different machine groupings are identified with in blocks. That block considered as a
machine cell.
If the some packs do not fit into logical groupings, these parts must be analyzed using
revised process sequence. If not, these parts must continue with conventional process
layout.
Machines Parts
A B C D E F G H I
1 1 1 1
2 1 1
3 1 1 1
4 1 1
5 1 1
6 1 1
7 1 1 1
= 256 + 32 + 2
= 290
Binary
Values
28 27 26 25 24 23 22 21 20 Decimal Rank
Equivalent
Parts
Machines A B C D E F G H I
1 1 1 1 290 1
2 1 1 17 7
3 1 1 1 81 5
4 1 1 136 4
5 1 1 258 2
6 1 1 65 6
7 1 1 1 140 3
Parts
Machines A B C D E F G H I
1 1 1 1 290 1
5 1 1 258 2
7 1 1 1 140 3
4 1 1 136 4
3 1 1 1 81 5
6 1 1 65 6
2 1 1 17 7
Parts
Machines A B C D E F G H I Binary
Values
1 1 1 1 26
5 1 1 25
7 1 1 1 24
4 1 1 23
3 1 1 1 22
6 1 1 21
2 1 1 20
Decimal 96 24 6 64 5 24 16 96 7
Equivalent
Rank 1 4 8 3 9 5 6 2 7
Parts
Machines A H D B F G I C E
1 1 1 1
5 1 1
7 1 1 1
4 1 1
3 1 1 1
6 1 1
2 1 1
The final solution is above in the table. Block represents machine cell. So the first
machine cell consists of machine number 1 and 5 which can produce parts A, H an D.
Part Family 1 : (A, H, D) and (1 & 5)
Part Family 2 : (B, F, G) and (7 & 4)
Part Family 3 : (I, C, E) and (3,6 & 2)
Example 5.7.1 : Apply the rank order clustering technique to the part-machine
incidence matrix in the following table to identify logical part families and machine
groups. Parts area identified by letters and machines are identified numerically.
Machines A B C D E F
1 1 1
2 1 1
3 1 1
4 1 1
5 1 1
6 1 1 1
Solution :
Step 1 :
Binary 25 24 23 22 21 20
Values
1 1 1 34 2
2 1 1 4 6
3 1 1 48 1
4 1 1 12 4
5 1 1 18 3
6 1 1 1 12 5
Step 2 :
Binary 25 24 23 22 21 20
Values
1 1 1 34 2
2 1 1 4 6
3 1 1 48 1
4 1 1 12 5
5 1 1 18 3
6 1 1 1 12 4
Step 3 :
Binary 25 24 23 22 21 20
Values
3 1 1 48 1
1 1 1 34 2
5 1 1 18 3
6 1 1 1 12 4
4 1 1 12 5
2 1 1 4 6
Step 4 :
Machines 25 24 23 22 21 Binary
Values
A B C D E F
3 1 1 25
1 1 1 24
5 1 1 23
6 1 1 1 22
4 1 1 21
2 1 1 20
Decimal 48 40 6 7 24 5
Equivalent
Rank 1 2 5 4 3 6
Step 5 :
Machines A B E D C F
3 1 1
1 1 1
5 1 1
6 1 1 1
4 1 1
2 1 1
Decimal 48 40 24 7 6 5
Equivalent
Rank 1 2 3 4 5 6
· To reduce work-in process inventory - smaller batch sizes and shorter lead times
reduce work-in process.
· To improve quality.
· To simplify production scheduling.
· To reduce setup times.
The FMS is the most highly automated of the Group Technology (GT) machine cells.
(The following chapter contains more details about FMS).
Work out
Proc Proc
Man Man
Fig. 5.9.1 U-shaped macine cell with manual part handling between machines
Fig. 5.9.2 In-line layout using mechanised work handling between mechines
It occupies more space so it is suitable for when there is adequate space is exist.
Job travelling time is more. Its suitable for assembly sections.
Work in
Proc
Work out Man
Proc Proc
Man Man
Fig. 5.9.3 Loop layout allows variations in part routing between machines
5.9.2.3 Rectangular Layout
Work in
Proc
Work out Man
Proc Proc
Man Man
Fig. 5.9.4 Rectangular layout also allows variations in part routing and allows of return of
work carriers if they are used
Rectangular layout allows variations in part routing and allows for return for work
carriers if they are used.
5 - 22 Computer Aided Design and Manufacturing
Cellular Manufacturing and Flexible Manufacturing System (FMS)
(4) Backtracking
move
Fig. 5.10.1
"proc" = Processing operations, "man" = Manual
Repeat operations : In which a consecutive operation is carried out on the same
machine so that the parts does not actually move.
In sequence moves : In which the part moves forward from the current machine to an
immediate neighbor machine.
By-passing move : In which the part moves forward to another machine that is two or
more machines ahead.
Backtracking move : In which the part moves backward from the current machine to
another machine.
Example : Compute a) the percentage of in-sequence moves b) the percentage eof
bypass moves c) the percentage of back tracking moves for the below
10 15
40 30 25
50 in 3 2 1 4 30 out
5 10
20 out
Fig. 5.10.2
7
5 6
(a) (b)
Fig. 5.12.1
5 - 24 Computer Aided Design and Manufacturing
Cellular Manufacturing and Flexible Manufacturing System (FMS)
The following example shows the composite part consisting of all 7 design and
processing attributes representing a family of rotational parts features defined in the part B.
Associated with each feature is a certain machining operations as summarized in table
below. A machine cell to produce this part family would be designed with the capability
to accomplish all seven operations required to produce the composite part. The number of
design and manufacturing attributes is greater than seven, allowances must be made for
variations in over all size and shape of the parts in the family.
6. Counterbore Counterboring
Part variety test Can the system process different part styles ?
Schedule change test Can system readily accept changes in the production
schedule ?
Error recovery test Can the system recover equipment malfunctions and
breakdown ?
New part test Can new part designs be introduced into the existing product
mix easily ?
If the answer to be yes for all the above questions, then the system can be considered
as flexible.
Mix flexibility Ability to change the product Similarity of parts in the mix
mix while maintaining the machine flexibility .
same total production
quantity.
Product Flexibility Which is related with How close with new part
adaptability of design design matches with exited
change. part family.
FMS
Fig. 5.14.1
CNC machining
center
Tool
storage
Shuttle cart
(with pallet and part)
Spindle
Pallet (empty)
Shuttle cart
(empty) Pallet rack
Shuttle track
Pallet
(with part)
Pallet holder
(empty)
Fig. 5.14.2
· It consists of only one CNC machining center combine with automated material
handling and storage system.
· Raw materials are loaded into the machine and unloaded from the machining
center.
· The cell can operated in batch mode, a flexible mode and even both.
Computer control
system
Loading Unloading
station station
Material handling
system
Fig. 5.14.3
Computer control
system
Loading Unloading
station station
FMC FMS
It has two or three machines. It has four or more.
It does not have any supporting machines. It has supporting machines which do not
directly participate on it.
Needed simple computer control system. Needed larger and more sophisticated
Computer control system.
Limited error recovery. Minimized effect of machine breakdown.
Simple than FMS. More complex.
Investment, production rate,
Flexible
mfg.
system
annual valume
Flexible
mfg.
cell
Single
machine
cell
1 2 or 3 4 or more Number of
machines
The figure depicts three categories of FMS related with production rate and annual
volume. Though FMS investment is high production rate and annual volume and
production rate is also high. Single machine cell suitable only for low production.
Random-
order FMS
Dedicated
FMS
Fig. 5.15.1
· The above image shows dedicated FMS has less flexibility but produce rate and
annual volume is more.
Work stations
Material Computer
handling FMS control system
Human
resources
Fig. 5.16.1
handling system. Should be designed to permit the safe movement of parts and may be
supported by various mechanical devices (e.g. cranes, forklifts). The station includes a data
entry unit and monitor for communication between the operator and computer system,
regarding parts to enter the system, and parts to exit the system. In some FMSs, various
pallet fixtures to accommodate different pallet sizes may have to be put in place at
load/unload stations.
Partially completed
work parts
Part transport system
Load Unld
Man Work flow Man
Completed
Starting
parts
workparts
Mach Mach Mach Mach
Aut Aut Aut Aut
(a)
Completed parts
(b)
Fig. 5.16.2
Loop layout
· Workstations are organized in a loop and it is served by a looped parts handling
system.
· In Fig. 5.16.3 parts usually flow in one direction around the loop with the
capability to stop and be transferred to any station.
· Each station has secondary handling equipment so that part can be brought-to and
transferred from the station work head to the material handling loop.
· Load/unload stations are usually located at one end of the loop.
· Alternative for of loop layout is rectangular layout. In this layout, the returning
pallets reaches the starting point.
Forward loop
Load Unld
Man Man
Starting Completed
workparts Return loop parts
Returning pallets
Fig. 5.16.3
Ladder layout
· This consists of a loop with rungs like ladder upon which workstations are
located.
· The rungs increase the number of possible ways of getting from one machine to
the next and obviates the need for a secondary material handling system.
· It reduces average travel distance and minimizes congestion in the handling
system, thereby reducing transport time between stations.
Mach
Aut
Mach
Aut
Direction of
workflow
Mach
Aut
Mach
Aut
Mach
Aut
Starting Completed
worksparts parts
Fig. 5.16.4
Rechg Rechg
Completed
parts
Load
Insp
unlad
Aut
Man
Starting
work parts
clng
Mach
Aut
Aut
Insp
Insp
Aut
Aut
Fig. 5.16.5
Robot-centered layout
Robot
Machine tool
Machine worktable
Parts carousel
Fig. 5.16.6
· This layout uses one or more robots as the material handling system.
· Robot centered layouts used to process cylindrical or disk-shaped parts.
Computer
control
room
Tools
Machine Machine
Pallet
Load Unload
Finished
Parts Terminal goods
Fig. 5.16.7
metrics, such as : Daily desired production rates, number of raw workparts available,
work-in-progress etc.
Traffic control - Management of the primary handling system is essential so that parts
arrive at the right location at the right time and in the right condition.
Shuttle control - Management of the secondary handling system is also important, to
ensure the correct delivery of the workpart to the station's workhead Workpiece monitoring -
The computer must monitor the status of each cart or pallet in the primary and secondary
handling systems, to ensure that we know the location of every element in the system.
Tool control - This is concerned with managing tool location (keeping track of the
different tools used at different workstations, which can be a determinant on where a part can
be processed), and tool life (keeping track on how much usage the tool has gone through, so
as to determine when it should be replaced). Performance monitoring and reporting -
The computer must collected data on the various operations on-going in the FMS and present
performance findings based on this.
Diagnostics - The computer must be able to diagnose, to a high degree of accuracy,
where a problem may be occurring in the FMS.
High
Stand alone NC
machines
Flexible
Product Medium manufacturing
variety system
Transfer
lines
Low
Low Medium High
Production volume
Issue Description
Physical characteristics of the workparts. Size and weight of workparts determine size
of the machines required to process the
parts. It also determines the size of the
material handling system needed.
Issue Description
Variations in process routings and FMS If part processing variations are minimal, we
layout. may decide to use an in-line flow; if part
processing variations are high, we may
instead opt for a loop flow, or higher still, for
an open field layout.
Issue Description
Scheduling and dispatching. Scheduling must be considered for the FMS, based upon
the master production schedule. Dispatching is concerning
with launching the parts into the system at the appropriate
times.
Part routing Routing decisions involve the choice of a route that should
be followed by a part in the system. Consideration should
be given to other parts travelling in the system, traffic
management etc.
Tool management We must determine when best to change tools, how long
each tool can last before requiring maintenance, and how to
allocate tooling to workstations in the system.
Pallet and fixture allocation How do we allocate specific pallets and fixtures to certain
parts to be launched into the system ? Different parts
require different pallet fixtures, and before a given part style
can be launched into the system, a fixture for that part must
be made available.
WL i = å å t ijk fijk p j
j k
nt = å å å fijk p j - 1
i j k
WL i * WL i s*
Ui = (R p ) = ,
si si WL*
U i = Utilization of station i,
WL i = Workload of station i(min/pc),
S i = Number of servers at workstation i,
and R*p = Overall production rate (pc/min).
A, B and C. The part mixs fractions and process routing for the three parts ae presented in
the table below. The operation frequency fijk = 1.0 for all operations.
Determine :
a) Maximum production rate of the FMC,
b) Corresponding production rates of each product.
c) Utilization of each machine in the system,
d) Number of busy servers at each station.
k t ijk
2 Mill 2 20 min
3 Drill 3 12 min
4 Unload 1 2 min
2 Mill 2 15 min
3 Drill 3 30 min
4 Unload 1 2 min
2 Mill 3 14 min
3 Drill 2 22 min
4 Unload 1 2 min
nt = å å å fijk Pj - 1
i j k
WL n+1 = nt tn+1
Station WL i /s i
s*
R*p =
WL*
Bottleneck is station 2 : R*p = 1/19.5 = 0.05128 pc/min = 3.077 pc/hr. Individual part
production rates can be obtained by multiplying.
S*
R*pj = pj (R*p) = pj
WL*
Q.5 How the machine cells are classified. + (AU : Dec. 17)
Ans. : · Single machine cell
· Group machine cell with manual handling
· Group machine cell with semi-integrated handing
· Flexible manufacturing cell or flexible manufacturing system.
Q.6 What are the components of FMS ? + (AU : Dec. 17)
Ans. : Work stations
· Material handling and storage system
· Computer control system
· Man power
Q.7 How the part families are identified ? + (AU : May 16)
List out the methods of part family formation. + (AU : Dec. 18)
Ans. : Visual inspection method
· Parts classification and coding
· Production flow analysis
Q.8 What are the problems in implementing group technology ? + (AU : May 16)
Ans. : · Creating part family.
· Rearranging the machines into machine cell.
· Resistance to change (from conventional to new).
· Changing roles of operators new responsibilities to supervisor.
· Extensive education and Hands on training required.
Q.9 List out the four test for flexibility in FMS research ? + (AU : May 16)
Ans. : Part variety test
· Schedule change test
· Error recovery test
· New part test
Q.10 What are the production conditions under which group technology and cellular
manufacturing are most applicable ? + (AU : May 18)
Ans. : · The plant currently uses traditional batch production and a process type layout, and
this results in much material handling effort, high in-process inventory and long manufacturing
lead times; and
· The parts can be grouped into part families.
Q.11 What is the application of rank order clustering ? + (AU : May 18)
Ans. : · Rank order clustering technique is used for performing cluster analysis to form a
machine cell.
· Using this technique machines are grouped into machine cell.
Q.12 What are the three capabilities that a manufacturing system must possess in
order to be flexible ? + (AU : May 18)
Ans. : · Can machine can run different part configurations ?
· It allows changes in the production schedule.
· It capable of continuing to operate event though one machine is break down.
Q.13 List the applications of FMS. + (AU : May 18)
Ans. : · Flexible manufacturing systems are typically used for mid-volume, mid-variety
production. If the part or product is made in high quantities with no style variations, then a
transfer line or similar dedicated production system is most appropriate. If the parts are low
volume with high variety, then numerical control or even manual methods would be more
appropriate
Q.14 What are the applications of group technology ? + (AU : Dec. 18)
Ans. : · Informal scheduling and routing of similar parts through selected machines.
· Virtual machine cells
· Formal machine cells
· Process planning, family tooling and numerical control programs etc.,
Q.15 What are the objective of FMS ? + (AU : Dec. 18)
Ans. : · The objective of FMS is to automate the manufacturing system and produce the
component within a short span of time.
Q.16 List any two advantages and disadvantages of FMS implementation.
Q.19 What is the difference between FMC and FMS systems. + (AU : May 19)
Ans. :
FMC FMS
It does not have any supporting machines It has supporting machines which do not
directly participate on it.
Needed simple computer control system Needed larger and more sophisticated
Computer control system
1. Apply rank order clustering technique to the part-machine incidence matrix in the
following table to identify logical part families and machine groups. N parts are
identified by letters and machines are identified numerically.
(Refer example 5.7.1) [16]
Machines
A B C D E
1 1
2 1 1
3 1 1
4 1 1
5 1
May 2017
Machines A B C D E F G
1 1 1
2 1 1
3 1 1 1 1
4 1 1 1
5 1 1 1 1
5. Explain OPTIZ parts classification and coding system. (Refer section 5.5) [16]
Dec. 2017
6. List out the methods of part family formation. (Refer section 5.2.1) [8]
7. List out the various machines used in FMS. (Refer section 5.16.1) [8]
8. Explain OPTIZ parts classification and coding system. (Refer section 5.5) [16]
May 2018
9. Sketch and explain the layout of typical FMS. (Refer section 5.14.1) [13]
10. Explain about machine cell design and layout. (Refer sections 5.17 and 5.18) [13]
Dec. 2018
14. Flexible manufacturing cell has just been created. After considering a number of
designs, the system engineer chose a layout that consists of two machining
workstations plus a load/unload station. In detail, the layout consists of : The
load/unload station is station 1. Station 2 Performs milling operations and
consists of one server (one CNC milling machine) Station 3 has one server that
performs drilling (one CNC drill press). The three stations are connected by a
part handling system, that has one work carrier. The mean transport time in the
system is 4 min. The FMC produces three parts, A, B and C. The part mix
fraction and process routings for the three parts are presented in the table
below. The operation frequency fijk = 1.0 for all operations.
Determine (i) Maximum production rate of the FMC, (ii) Corresponding
production rates of each product, (iii) Utilization of each machine in the system
and (iv) Number of busy servers at each station. (Refer section 5.20) [16]
A 0.4 1 Load 1 3
2 Mill 2 20
3 Drill 3 12
4 Unload 1 2
(M - 1) uring
M -omputer Aided Design and Maufact
Solved Model Question Paper
OR
b) Write a manual part program to finish the stepped shaft in f 40 mm section as
shown in Fig. 1. Assume spindle speed as 350 rpm and feed rate 0.4 mm/rev.
(Refer example 4.23.1) [13]
50
0
40
Fig. 1
A 0.4 1 Load 1 3
2 Mill 2 20
3 Drill 3 12
4 Unload 1 2
20
40
R10
Fig. 2
PART C - (1 ´ 15 = 15 Marks)
Q.16 a) Explain Graphics Kernal System (GKS). (Refer section 3.2.1) [15]
OR
b) Explain OPTIZ parts classification and coding system. (Refer section 5.5) [15]
Solved Model Question Paper ends ...