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(Computer Aided Design and Manufacturing)

(M –S CHE ME )

e. Iadhug;gd;> M.E., M.I.S.T.E.

Kjy;th;
= NuZfhk;ghs; ghypnlf;dpf; fy;Y}hp
Ngh@h; - 606 907.
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(Computer Aided Design and Manufacturing)

Copy right © : K A L P a t hi p pa ga m
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system, transmitted or reproduced in any way, including but not
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without prior agreement and written permission of the publisher.

First Edition : November 2003

Revised Edition : November 2008
Revised Edition : November 2017

Price : 168.00 For Contact :

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Publisher : 96266 26747
KAL PATHIPPAGAM
Vellore – 632 011

Type setting :
Students’ Media Computer Graphics
Vellore – 632 011.
 KfTiu
Ntfkhf tsh;e;J tUk; mwptpay; kw;Wk; njhopy;
El;gj;ij Ghpe;J nfhs;s mjid mtuth; jha; nkhopapy;
gbg;gNj vspjhd topahFk;. ,jid fUj;jpy; nfhz;L
jkpopy; vOjg; gl;Ls;s “fk;g ;A +l;l h; va;l l; bi]d;
md;L NkD/ghf; rhpq;” vd;w ,e;j Gj;jfk; Mwhk;
gUt ,ae;jputpay; khzth;fSf;fhd Gjpa ghlj;
jpl;lj;jpd;gb cUthf;fg; gl;Ls;sJ.

,g;Gj;jfj;jpy; cs;s midj;J gFjpfSk; jFe;j

tpsf;fg; glq;fSld; RUf;fkhfTk;> njspthfTk; vOjg;
gl;Ls;sd. Technical terms Mq;fpyj;jpy; vOjg;gl;Ls;sjhy;
khzth;fs; Fog;gkpd;wp vspjpy; Ghpe;J nfhs;s KbAk;.
xt;nthU njhFjpapd; KbtpYk; cs;s thhpaj; NjHT
tpdhf;fs; khzth;fSf;F kpfTk; gaDs;sjhf ,Uf;Fk;.

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; fj;jhUf;F vdJ ed;wpia njhptpj;Jf;
nfhs;fpNwd;. ,g;Gj;jfj;ij gbf;Fk; Mrphpa ngUkf;fs;
kw;Wk; khzth;fs; jq;fspd; Mf;fg; g+h;tkhd fUj;Jfis
ey;fp vd;id NkYk; Cf;Ftpf;FkhW Ntz;LfpNwd;.
e. Iadhug; g d;
(iyanarvlr1976@gmail.com)
“elg;g it ahTk; ed;wha; mika tho;j ;Jf;fs; ! ... ”
32062 – COMPUTER AIDED DESIGN AND MANUFACTURING

DETAILED SYLLABUS
Unit – I : COMPUTER AIDED DESIGN
Computer Aided Design : Introduction – definition – Shigley’s design process
– Ohsuga Model - CAD activities – benefits of CAD - CAD software packages.
Transformations : 2D & 3D transformations – translation, scaling, rotation
and concatenation.
Geometric modelling : Techniques - Wire frame modelling – applications –
advantages and disadvantages. Surface modelling – types of surfaces –
applications – advantages and disadvantages – Solid modelling – entities –
advantages and disadvantages – Boolean operations - Boundary
representation – Constructive Solid Geometry – Comparison.
Graphics standard : Definition – Need - GKS – OpenGL - IGES – DXF.
Finite Element Analysis : Introduction – Development - Basic steps –
Advantage.

Unit – II : COMPUTER AIDED MANUFACTURING

Computer Aided Manufacturing : Introduction - Definition – functions of CAM
– benefits of CAM.
Group technology : Part families - Parts classification and coding - coding
structure – Opitz system, MICLASS system and CODE System.
Process Planning : Introduction – Computer Assisted Process Planning
(CAPP) – Types of CAPP - Variant type, Generative type – advantages of CAPP.
Production Planning and Control (PPC) : Definition – objectives - Computer
Integrated Production management system – Master Production Schedule
(MPS) – Capacity Planning – Materials Requirement Planning (MRP) –
Manufacturing Resources Planning (MRP-II) – Shop Floor Control system
(SFC) - Just In Time manufacturing philosophy (JIT) - Introduction to Enterprise
Resources Planning (ERP).
Unit – III : CNC PROGRAMMING, RAPID PROTOTYPING
CNC part programming : Manual part programming - coordinate system –
Datum points: machine zero, work zero, tool zero - reference points - NC
dimensioning – G codes and M codes – linear interpolation and circular
interpolation - CNC program procedure - sub-program – canned cycles - stock
removal – thread cutting – mirroring – drilling cycle – pocketing.
Rapid prototyping : Classification – subtractive – additive – advantages and
applications - materials. Types - Stereo lithography (STL) – Fused deposition
model (FDM) – Selective laser sintering SLS) - three dimensional printing (3D)
– Rapid tooling.

Unit – IV : COMPUTER INTEGRATED MANUFACTURING,

FLEXIBLE MANUFACTURING SYSTEMS, AUTOMATIC GUIDED
VEHICLE, ROBOT
CIM : Introduction of CIM – concept of CIM - evolution of CIM – CIM wheel –
Benefits – integrated CAD/CAM.
FMS : Introduction – FMS components – FMS layouts – Types of FMS: Flexible
Manufacturing Cell (FMC) – Flexible Turning Cell (FTC) – Flexible Transfer Line
(FTL) – Flexible Machining System (FMS) – benefits of FMS - introduction to
intelligent manufacturing system.
AGV : Introduction – AGV - working principle – types – benefits.
ROBOT : Definition – robot configurations – basic robot motion – robot
programming method – robotic sensors – end effectors – mechanical
grippers – vacuum grippers - Industrial applications of Robot: Characteristics
- material transfer and loading – welding - spray coating - assembly and
inspection.

Unit – V : CONCURRENT ENGINEERING, QUALITY FUNCTION

DEPLOYMENT, PRODUCT DEVELOPMENT CYCLE, AUGMENTED
REALITY
Concurrent Engineering : Definition – Sequential Vs. Concurrent engineering
– need of CE – benefits of CE.
Quality Function Deployment (QFD) : Definition – House of Quality (HOQ) –
advantages – disadvantages. Steps in Failure Modes and Effects Analysis
(FMEA) – Value Engineering (VE) – types of values – identification of poor
value areas – techniques – benefits. Guide lines of Design for Manufacture
and Assembly (DFMA).
Product Development Cycle : Product Life Cycle - New product development
processes.
Augmented Reality (AR) : Introduction - concept – Applications.
 Contents
Units Page No.

Unit – I : Computer Aided Design …...…...…... 1.1 – 1.43

Unit – II : Computer Aided Manufacturing…..... 2.1 – 2.32

Unit – III : CNC Programming and Rapid

Prototyping……………….............. 3.1 – 3.58

Unit – IV : Computer Integrated Manufacturing,

Flexible Manufacturing Systems,
Automated Guided Vehicle & Robot … 4.1 – 4.30

Unit – V : Concurrent Engineering,

Quality Function Deployment,
Product Development Cycle &
Augmented Reality …...…...…...….. 5.1 – 5.19

 2 & 3 Marks Questions and Answers

 Board Examination Question Papers
 Unit – I
COMPUTER AIDED DESIGN
1.1 Introduction
jw;NghJ nghUl;fspd; juj;ijg; gw;wpa tpopg;Gzh;T>
mijg; gad;gLj;JNthhpilNa mjpfhpj;J tUfpwJ. vdNt
kpFe;j jukhd nghUl;fis> Fiwthd Neuk; kw;Wk; Fiwe;j
nrytpy; jahhpf;f Ntz;baJ mtrpakhfpwJ. Computer Aided
Design kw;Wk; Manufacturing %yk; ntt;NtW tifahd
nghUl;fisAk; kpFe;j juj;Jld; Fiwe;j nrytpy; cw;gj;jp
nra;a KbAk;. Interactive graphics, analysis software, graphic
workstation Mfpatw;wpd; Nkk;ghL kw;Wk; kypthd tpiyapy;
fpilf;Fk; computer Mfpait> rpwpa kw;Wk; eLj;ju
epWtdq;fSk; CAD/CAMI gad;gLj;jp cw;gj;jp nra;tij
rhj;jpakhf;FfpwJ.

1.2 Computer Aided Design (CAD) - Definition

xU nghUspd; designI cUthf;Fjy;> Nkk;gLj;Jjy;>
gFg;gha;jy;> kw;Wk; optimization Mfpatw;wpw;F computerI gad;
gLj;JtNj Computer Aided Design (CAD) MFk;.

1.3 Shigley’s design process

Shigley vd;gtuJ tbtikg;G Kiwg;gb> xU nghUis
tbtikg;gjpy; fPo;f;fz;l MW epiyfs; cs;sd.
1) Recognition of need
,J jw;Nghija designy; jpUj;jg;gl Ntz;ba FiwghLfis
fz;lwpjy; MFk;. NkYk; xU Gjpa nghUs; re;ijapy; ntspaplg;gl
Ntz;Lk; vd;w gadhsh;fspd; Njitia fz;lwpjYk; MFk;.

2) Definition of problem
,J design nra;ag;gl
Ntz;ba nghUspd; KO
tpguq;fisAk; kpfj; njspthf Fwpg;gpLjy; MFk;. nghUspd;
,af;f kw;Wk; ,aw;gpay; gz;Gfs;> tpiy> juk;> ,af;fr;
nray;ghLfs; Mfpait ,jpy; mlq;Fk;.

1.1
 Stages of CAD

Recognition of need

Problem definition

Synthesis

Analysis and
Optimization

Evaluation

Presentation

Fig.1.1 Shigley’s design process

3) Synthesis
,e;j epiyapy;> designerd; fw;gidj;jpwd; kw;Wk;
jw;NghJs;s nghUl;fisg; gw;wpa Ma;T KbTfs; Mfpatw;iwf;
nfhz;L> Njitahd nghUspd; gy;NtW tbtq;fs; cUthf;fg;
gLfpd;wd.

4) Analysis and optimization

Synthesis %yk; cUthf;fg;gl;l design MdJ Njitahd
nray;ghl;bw;F Vw;w tifapy; cs;sjh vd;gij jFe;j analysis
%yk; fz;lwpag; gLfpwJ. Analysis kw;Wk; synthesis jpUk;g jpUk;g
nra;ag;gl;L xU conceptual design ngwg;gLfpwJ. ,e;j conceptual
desing MdJ analyse nra;ag;gl;L> Nkk;gLj;jg;gl;L> kPz;Lk;
design nra;ag;gLfpwJ. xU kpfr;rpwe;j design ngwg;gLk; tiu
,e;j nray;Kiw jpUk;g jpUk;g eilngWfpwJ.

5) Evaluation
,J problem definition
epiyapy; Njhw;Wtpf;fg;gl;l
msTfSld; jw;NghJ ngwg;gl;l msTfs; xj;Jg; Nghfpwjh
vd;gij fz;lwptjhFk;. kpfr;rpwe;j nray;ghl;Lj;jpwd;> juk;>

1.2
ek;gfj; jd;ik Mfpatw;iwg; ngWk; tifapy; ,e;j design
NkYk; Nkk;gLj;jg; gLfpwJ. Evaluation jpUg;jpfukhf
,y;iynadpy;> design nray;Kiw xU kpfr;rpwe;j designI ngWk;
tiu synthesis epiyapypUe;J jpUk;g jpUk;g nra;ag;gLfpwJ.

6) Presentation
,jpy; working drawing jahh; nra;jy;> material specification,
bill of material, part list Nghd;wit mlq;Fk;.

1.4 Ohsuga model

Requirements

Build initial Model

Model 1

Modify and Analyze and

Refine Evaluate

Model
2

Modify and Analyze and

Refine Evaluate

Model Generate data

n for manufacturing

Modify and Analyze and

Refine Evaluate

Fig.1.2 Ohsuga model

ghfq;fis tbtikg;gjpy;> mLj;jLj;j xU njhlh;r;rpahd
Kiw nghJthf gad;gLj;jg;gLk;. Mdhy; Ohsuga modeld;gb>
xU jpUg;jpfukhd ,Wjp model fpilf;Fk; tiu gy;NtW
gbepiyfspy; design MdJ jpUk;g jpUk;g Nkk;gLj;jg; gLfpwJ.
nghUj;jkhd cldb jPh;T ,y;yhj #o;epiyfspy;> ,j;jifa
Kiw nghJthfg; gad;gLj;jg; gLfpwJ.

1.3
 Ohsuga design model MdJ fPo;f;fz;l gbepiyfisf;
nfhz;bUf;Fk; :
1) Njitfisf; fUj;jpy; nfhz;L> xU Kjw;fl;l model
cUthf;fg;gLk;.
2) ,e;j model MdJ gy;NtW Nfhzq;fspy; gFg;gha;T
nra;ag;gl;L kjpg;gPL nra;ag;gLk;.
3) gpd;G> nfhLf;fg;gl;l Njitfis G+h;j;jp nra;Ak; tifapy;
,e;j model MdJ jpUj;jg;gl;L> nkUNfw;wg;gLk;.
4) cWjpahd kw;Wk;
ek;gfkhd topKiwfisf; nfhz;L
gbg;gbahf design NkYk; Nkk;gLj;jg;gLk;.
5) Nkw;nfhz;L ve;j xU Nkk;ghLk; mtrpakpy;iy vd;w
epiyia milAk; tiu> design MdJ jpUk;g jpUk;g
kjpg;gPL nra;ag;gl;L jpUj;jg;gLk;.
6) xU jpUg;jpfukhd ,Wjp model fpilf;Fk; tiu Nkw;fz;l
nray;Kiw vj;jid Kiw Ntz;LkhdhYk; jpUk;g jpUk;g
eilngwyhk;.
7) ,Wjp model fpilj;jTld;> nghUis cw;gj;jp nra;jy;
kw;Wk; NrhjidapLtjw;F Njitahd tpguq;fs;
Njhw;Wtpf;fg;gLk;.

Application of Ohsuga model

Ohsuga model MdJ rpwpa mstpyhd projectf;F kl;LNk
Vw;wJ. Vnddpy;> rpwpa projectfspy; kl;LNk Fiwe;j vz;zpf;if
iterationfisf; nfhz;L ,Wjp modelI tpiuthf mila ,aYk;.

1.5 CAD activities

Computer Aided Designd; gy;NtW nray;ghLfs; fPNo
tpsf;fg;gl;Ls;sd.
1) Geometric modelling
xU nghUspd; Njhw;wj;ijg; gw;wpa fzpj tbt tpsf;fNk
model vdg;gLk;. CAD systemj;jpy; cs;s gy;NtW tiugl
software njhFg;Gfisf; nfhz;L nghUl;fspd; modelfis
cUthf;fyhk;.
Part drawing, working drawing kw;Wk; sectional drawing
Mfpatw;iw cUthf;f 2D modelling Kiw gad;gLj;jg; gLfpwJ.
1.4
Wireframe model, surface model kw;Wk; solid model vd %d;W
tifahd 3D modelfs; cs;sd. ,tw;wpy;> nghUl;fspd;
cz;ikahd Njhw;wj;ij cUthf;f solid model nghpJk;
gad;gLj;jg; gLfpwJ.
Design Process

Recognition of need

Problem definition Role of computers

in CAD

Geometric
Synthesis
modeling

Analysis and Engineering

Optimization analysis

Design review and

Evaluation
evaluation

Automated
Presentation
drafting

Fig.1.3 Activities of CAD

2) Engineering analysis
nghUl;fspd; kpfr;rhpahd msTfisj; jPh;khdpf;f
engineering analysis Nkw;nfhs;sg; gLfpwJ. CAD system MdJ
engineering analysis Nkw;nfhs;sj; Njitahd softwareIf;
nfhz;bUf;Fk;. ,jpy; fPo;f;fz;lit mlq;Fk; :
 Stress-strain analysis
 Heat transfer analysis
 Dynamic analysis
 Finite element analysis (FEA), etc.
3) Design review and evaluation
Design accuracyI Nrhjidapl CAD softwarefspy; gy
rpwg;G mk;rq;fs; cs;sd. mtw;wpy; rpy mk;rq;fs; fPNo
tpsf;fg;gl;Ls;sd.

1.5
  Dimensioning and tolerancing routines: Fwpg;gpl;l
tolerance msTfSld; dimensionfis jhdhfNt cUthf;f
,e;j mk;rk; gad;gLfpwJ. Dimensiony; Vw;gLk; Fiwfs;
,jd; %yk; jtph;f;fg; gLfpwJ.
 Zooming: kpfr;rpwpa msTila ghfj;ijAk; designy;
kpfr;rhpahf ,izg;gjw;F ,e;j mk; rk; nghpJk; cjTfpwJ.
 Layering: ,e;j mk;rj;ijg; gad;gLj;jp> xU tiuglj;jpd;
gy;NtW ghfq;fis ntt;NtW layerfspy; tiuayhk;. gpd;G
Njitf;Nfw;g mtw;iw xd;wpd;kPJ xd;W nghUj;jpf;
nfhs;syhk;.
 Animation: xU nghUspd; khjphp tbt(prototype)j;ij
cw;gj;jp nra;tjw;F Kd;Ng> mjd; ,af;fr; nray;ghLfis
fz;lwpaTk; Nkk;gLj;jTk; ,e;j mk;rk; cjTfpwJ.

4) Automated drafting
tiuglj;jpd; databaseI cUthf;Fjy; kw;Wk; tiuglj;jpd;
hard copyI jahhpj;jy; Mfpait ,jpy; mlq;Fk;. Automatic
dimensioning, cross hatching, sectional view creation Nghd;w CAD
mk;rq;fisg; gad;gLj;jp tiuglq;fis kpf tpiuthf
cUthf;fyhk;.

1.6 Benefits of CAD

nghUl;fis design nra;Ak;NghJ ngwg;gLk; ed;ikfs; :
1) DesignI cUthf;Fk; tPjk; mjpfhpf;fpwJ.
2) Lead time (nkhj;j Neuk;) FiwfpwJ.
3) Design cUthf;Ftjpy; flexibility mjpfhpf;fpwJ.
4) Design error FiwfpwJ.
5) Design gFg;gha;T Nkk;gLfpwJ.
6) Design, documentation kw;Wk; drafting jug;gLj;jg; gLfpwJ.
7) Design cUthf;Fjy; kw;Wk; Nkk;gLj;Jjy; vspjhfpwJ.
8) glq;fis ntt;NtW Nfhzq;fspy; vspjhf fhzyhk;.
9) njspthfg; Ghpe;Jnfhs;sf; $ba kpfr;rhpahd tiuglq;
fis cUthf;fyhk;.

1.6
nghUl;fis cw;gj;jp nra;tjpy; ngwg;gLk; ed;ikfs; :
1) Tool kw;Wk; fixture design.
2) Computer Aided Process Planning (CAPP).
3) Production Planning and Control (PPC).
4) Assembly list kw;Wk; bill of materials jahhpj;jy;.
5) nghUl;fis tifg;gLj;jp ngahpLjy;.
6) Computer aided inspection.
7) NC part programfs; jahhpj;jy;.
8) Assembly sequence planning

1.7 CAD software packages

CADy; gad;gLj;jg;gLk; softwarefspy; fPo;f;fz;lit mlq;Fk;.
1. System softwares or operating system
2. Application softwares
System software
System software vd;gJ computerd; nray;ghLfs;
midj;ijAk; eph;tfpf;Fk; computer programfspd; njhFg;G
MFk;. Computer systemj;jpd; gy;NtW ghfq;fSf;F ,ilNa
jfty; ghpkhw;wj;ij ,e;j programfs; fl;Lg; gLj;Jfpd;wd.
Operating systemj;jpd; Kf;fpa nray;fs; fPo;f;fz;lthW:
1) Inputkw;Wk; output nray;ghLfSf;Fj; Njitahd
jfty;fis computer kw;Wk; ,ju fUtpfSld; ghpkhwpf;
nfhs;Sjy;
2) Computery; cs;s gy;NtW filefis eph;tfpj;jy;
3) Computer programfis memoryy; Nrkpj;J itj;jy; kw;Wk;
program nray;ghLfis fl;Lg;gLj;Jjy;

DOS, Windows, OS/2, UNIX, kw;Wk; Linux Mfpait

ngUk;ghYk; gad;gLj;jg;gLk; operating systemfs; MFk;.

Application software
CADy; gad;gLj;jg;gLk; application softwarefspy;
fPo;f;fz;lit mlq;Fk;.
1) nghUl;fspd; 2D kw;Wk; 3D modelfis cUthf;fj;
Njitahd softwarefs;

1.7
 2) Finite element analysis, heat transfer analysis, stress-strain
analysis Nghd;w gy;NtW gFg;gha;TfSf;F Njitahd
softwarefs;
AutoCAD, Pro/E, IDEAS, UniGrpahics, CADian, SolidWorks,
CADKey, ArchiCAD, Autodesk Inventor kw;Wk; CATIA Mfpait CADy;
ngUk;ghYk; gad;gLj;jg; gLk; application softwarefs; MFk;.
1.7.1 AutoCAD
AutoCAD vd;gJ Autodesk vd;w epWtdj;jhy; cUthf;fg;
gl;l software MFk;. ,J tiuglq;fis vspjhfTk; tpiuthfTk;
tiutjw;Fg; ngUk;ghYk; gad;gLj;jg;gLk; softwarefspy;
xd;whFk;.
Features of AutoCAD
1) Creating basic geometric objects : Line, circle, rectangle Nghd;w
mbg;gil tiugl ghfq;fis ,jpy; vspjhf tiuayhk;. ,jw;Fj;
Njitahd Gs;spfis VNjDk; xU pointing device %ykhfNth
my;yJ command liney; type nra;Njh cs;sPL nra;ayhk;.
2) Modifying the objects : AutoCAD fl;lisfisg; gad;gLj;jp
tiuglj;jpd; msT> tbtk; kw;Wk; glk; tiuag;gl;Ls;s
,lk; Mfpatw;iw vspjpy; khw;wp mikf;fyhk;.
3) Zooming : tiuglj;jpd; Fwpg;gpl;l ghfj;ij nghpjhf;fpg;
ghh;f;fNth my;yJ tiuglj;jpd; NtnwhU Njhw;wj;jpw;F
khwNth ,e;j trjp gad;gLfpwJ.
4) Layering : ,e;j trjpapd; %yk;> tiuglj;jpd; gy;N tW
ghfq;fis ntt;NtW layerfspy; tiue;J> Njitahd
layerfis super-imposing Kiwapy; nghUj;jpf; ghh;f;fyhk;.
5) Dimension and tolerance routines : ,jpy; ntt;NtW
epiyfspYk; tbtq;fspYk; mstPLfisf; Fwpf;f ,aYk;.
NkYk; ,jpy; xt;nthU mstPLf;Fk;> Njitahd toleranceIAk;
,izf;f ,aYk;.
6) Hatching : tiugl ghfq;fspd; gug;ig tiuaWf;fg;gl;l
patternfisf; nfhz;L epug;Gtjw;F ,e;j trjp cjTfpwJ.
NkYk; ekf;F tpUg;gkhd tbtpy; patternIAk; cUthf;fpf;
nfhs;syhk;.

1.8
7) 3D modelling : Wireframe, surface kw;Wk; solide modelling
Nghd;w gy;NtW 3D modelling trjpfs; AutoCADy; cs;sd.
xt;nthU tifapYk; cUthf;Fjy; kw;Wk; khw;wp
mikj;jYf;F ntt;NtW Kiwfs; ifahsg;gLfpd;wd.
8) Rendering : 3D modelfSf;F mjd; nra;nghUis ,izj;J
cz;ikahd cUtj; Njhw;wj;ij Vw;gLj;j rendering trjp
gad;gLfpwJ. Hidden line kw;Wk; shaded imageIAk; cUthf;f
,aYk;.
9) Customization : AutoCADy; cs;s gy;NtW trjpfis ehk;
vspjhfg; gad;gLj;Jtjw;Nfw;g khw;wp mikj;Jf; nfhs;syhk;.

Advantages of AutoCAD
Refer: Benefits of CAD (Section 1.6)

1.8 Transformations
gy;NtW mbg;gil tiugl ghfq;fis ,izj;J
KOikahd tiuglq;fs; cUthf;fg; gLfpd;wd. ,it mtw;wpd;
KbTg; Gs;spfs; %yk; Fwpf;fg; gLfpd;wd. ,e;j KbTg;
Gs;spfspy; rpy fzpj nray;ghLfisr; nra;tjd; %yk; glk;
khw;wp mikf;fg; gLfpwJ. ,e;j nray;Kiw transformations
vdg;gLk;. Translation, scaling kw;Wk; rotation Mfpait xU rpy
mbg;gil transformationfs; MFk;.
1.8.1 Two-dimensional transformations
Two-axes Cartesian systemj;jpy; xU Gs;spia eph;zapf;f
mjd; X kw;Wk; Y mr;Rj; J}uq;fs; Fwpf;fg; gLfpd;wd. ,e;j
mr;Rj; J}uq;fis (X,Y) vd;w 1x2 matrix tbtpy; Fwpf;fyhk;.
cjhuzkhf> (4,2) vd;w matrix MdJ X mr;rpy; 4 myF J}uKk;
Y mr;rpy; 2 myF J}uKk; nfhz;l xU Gs;spiaf; Fwpf;Fk;.

,Nj Nghd;W> xU Nfhl;Lj;Jz;L mjd; ,uz;L KbTg;

Gs;spfspd; mr;Rj; J}uq;fs; mlq;fpa 2x2 matrix %yk; Fwpf;fg;
glyhk;. Line matrixd; FwpaPL fPo;f;fz;lthW:
x1 y1
L =q r
x2 y2
,q;F> (x1, y1), (x2, y2) Mfpait L vd;w Nfhl;Lj;Jz;bd;
KbTg; Gs;spfs; MFk;.

1.9
 Matrix tbtpy; Fwpf;fg;gLk; ve;j xU glKk;
transformationf;F gpwF milAk; Gjpa matrix tbitf; fz;lwpa
matrix algebra tpjpfs; filgpbf;fg; gLfpd;wd. gy;NtW 2D
transformationfs; fPNo tpsf;fg; gl;Ls;sd.

1) Translation
Translation vdgJ glj;jpd; ghfq;fis Xhplj;jpy; ,Ue;J
kw;nwhU ,lj;jpw;F efh;j;Jtijf; Fwpf;Fk;. xU Gs;spia
efh;j;Jk;NghJ fPo;f;fz;l nray; eilngWfpwJ.
x' = x + m, y' = y + n
,q;F> x', y' = efh;j;jg;gl;l Gs;spapd; mr;Rj; J}uq;fs;
x,y = Muk;g epiyapy;> Gs;spapd; mr;Rj; J}uq;fs;
m, n = X kw;Wk; Y jpirapy; efh;j;jg;gl Ntz;ba J}uk;

Nkw;fz;l nray; matrix tbtpy; fPo;f;fz;lthW Fwpf;fg; gLfpwJ.

(x', y') = (x, y) + T
,q;F, T = Translation matrix = (m, n)
xU Nfhl;Lj;Jz;Lf;F> mjd; ,uz;L KbTg;
Gs;spfSf;Fk; ,e;j transformation matrix cgNahfpf;fg; gLfpwJ.

Example:
Y

7 (5,7)

6
Translated line
5

4 (3,4) (4,4)

3
Original line
2

1 (2,1)

1 2 3 4 5 6 7 8 9 X

Fig.1.4 Translation

1.10
 (2,1) kw;Wk; (3,4) Mfpa KbTg;Gs;spfisf; nfhz;l xU
Nfhl;Lj; Jz;bidf; fUJNthk;. ,e;j Nfhl;Lj;Jz;L X jpirapy;
2 myF J}uKk; Y jpirapy; 3 myF J}uKk; efh;j;jg; gLtjhff;
nfhs;Nthk;.

2 1
gpd;G, line matrix, L = q r
3 4
2 3
Translation matrix, T = q r
2 3
Translationf;Fg; gpd;G fpilf;Fk; Gjpa line matrix,
2 1 2 3 4 4
=q r+ q r=q r
3 4 2 3 5 7
,e;j Gjpa Nfhl;Lj; Jz;lhdJ (4,4) kw;Wk; (5,7)
Mfpatw;iw KbTg; Gs;spfshff; nfhz;bUf;Fk;. Translation
%yk; Vw;gLk; khw;wk; glj;jpy; fhl;lg;gl;Ls;sJ.

2) Scaling
tiugl ghfj;jpd; msit rpwpjhfNth my;yJ nghpjhfNth
khw;Wtjw;F scaling vd;W ngah;. glj;jpy; cs;s Gs;spfs; scaling
matrix %yk; fPo;f;fz;lthW khw;wp mikf;fg; gLfpwJ.
(x', y') = (x, y) S
m 0
,q;F, S = Scaling matrix = q r
0 n
,jd; %yk; glj;jpd; msT m klq;F X jpirapYk;> n klq;F
Y jpirapYk; khw;wp mikf;fg;gLk;.

Example:
(2,1) kw;Wk; (3,4) Mfpa KbTg;Gs;spfisf; nfhz;l xU
Nfhl;Lj; Jz;bidf; fUJNthk;. ,e;j Nfhl;Lj;Jz;L X kw;Wk;
Y jpirfspy; 2 klq;F nghpjhf;fg; gLtjhff; nfhs;Nthk;.
2 1
gpd;G, line matrix, L = q r
3 4
2 0
Scaling matrix, S = q r
02

1.11
 Y

8 (6,8)

5 Scaled line
4 (3,4)

2 (4,2)

1 (2,1)

1 2 3 4 5 6 7 8 9 X

Fig.1.5 Scaling

Scalingf;F gpd;G fpilf;Fk; Gjpa line matrix,

2 1 2 0 4 2
=q r q r=q r
3 4 0 2 6 8
,e;j Gjpa Nfhl;Lj; Jz;lhdJ (4,2) kw;Wk;(6,8)
Mfpatw;iw KbTg; Gs;spfshff; nfhz;bUf;Fk;. Scaling %yk;
Vw;gLk; khw;wk; glj;jpy; fhl;lg;gl;Ls;sJ.

3) Rotation
Rotation vd;gJ tiuglj;ij mjd; njhlf;fg; Gs;spiag;
nghWj;J  Nfhzj;jpw;F VNjDk; xU jpirapy; jpUg;Gjy; MFk;.
Positive Nfhz msTfSf;F fbfhu vjph;j;jpirapy; jpUg; gg;gLk;.
jpUg;gg;gLk;NghJ glKk; efUk;.
Matrix tbtpy;> ,e;j epfo;Tf;fhd nray;Kiw fPo;f;fz;lthW:
(x', y') = (x, y) R
cos sin
,q;F, R = Rotation matrix = q r
–sin cos

Example:
(2,1) kw;Wk; (3,4) Mfpa KbTg;Gs;spfisf; nfhz;l xU
Nfhl;Lj; Jz;bidf; fUJNthk;. ,e;j Nfhl;Lj;Jz;lhdJ mjd;
njhlf;fg; Gs;spiag; nghWj;J 30o Nfhzj;jpy; jpUg;gg;
gLtjhff; nfhs;Nthk;.
1.12
 Y

6
(0.598, 4.964)
5
Rotated line
4
(3,4)
3

2
(1.232, 1.866) (2,1)
1

1 2 3 4 5 6 7 8 9 X

Fig.1.6 Rotation

2 1
gpd;G, line matrix, L = q r
3 4
cos 30 sin 30 0.866 0.500
Rotation matrix, R = q r= q r
–sin 30 cos 30 –0.500 0.866

Rotationf;Fg; gpwF fpilf;Fk; Gjpa line matrix,

2 1 0.866 0.500 1.232 1.866
=q r q r=q r
3 4 –0.500 0.866 0.598 4.964
,e;j Gjpa Nfhl;Lj; Jz;lhdJ (1.232, 1.866) kw;Wk;
(0.598, 4.964) Mfpatw;iw KbTg; Gs;spfshff; nfhz;bUf;Fk;.
Rotation %yk; Vw;gLk; khw;wk; glj;jpy; fhl;lg;gl;Ls;sJ.

1.8.2 Three-dimensional transformations

2D transformationfSf;F gad;gLk; matrix Kiw 3D
transformationfSf;Fk; gad;gLfpwJ. nray;KiwfSk; 2D
transformationfSf;F cs;sJ Nghd;wNj MFk;.

1) Translation
3D translation fPo;f;fz;lthW matrix tbtpy; Fwpf;fg; gLfpwJ.
(x', y', z') = (x, y, z) + T
,q;F, x', y', z' = efh;j;jg;gl Ntz;ba Gs;spfspd; mr;Rj;J}uq;fs;
1.13
 x,y, z = Muk;g epiyapy; Gs;spapd; mr;Rj; J}uq;fs;
T = Translation matrix = (m, n, p)

m, n, p = X, Y, kw;Wk; Z jpirfspy; Gs;spfs; efUk; J}uk;.

2) Scaling
3D scaling fPo;f;fz;lthW matrix tbtpy; Fwpf;fg; gLfpwJ.
(x', y', z') = (x, y, z) S
m 0 0
,q;F, S = Scaling matrix = q 0 n 0 r
0 0 p

3) Rotation
X mr;irg; nghWj;J  Nfhzj;jpw;F nra;ag;gLk; 3D
rotation fPo;f;fz;lthW matrix tbtpy; Fwpf;fg; gLfpwJ.
(x', y', z') = (x, y, z) Rx
1 0 0
,q;F, Rx = X mr;irg; nghWj;J rotation matrix=q0 cos sin r
0 –sin cos
mNjNghd;W>
cos 0 sin
Ry = Y mr;irg; nghWj;J rotation matrix = q 0 1 0 r
–sin 0 cos

cos sin0
Rz = Z mr;irg; nghWj;J rotation matrix = q–sin cos0r
0 0 1

4) Concatenation
Concatenation vd;gJ mLj;jLj;J epfOk; gy transfor-
mationfis ,izj;J xNu transformation Mf nra;Ak; nray;
MFk;. ,t;thW Vw;gLj;jg;gl;l transformationfs; concatenated
transformationfs; vdg;gLk;. tiuglq;fis jpUj;jp mikf;Fk;
NghJ ,j;jifa transformationfs; nra;ag;gLfpd;wd.

cjhuzkhf> VNjDk; xU Gs;spiag; nghWj;J xU

tiuglk; jpUg;gg; gLtjhff; nfhs;Nthk;. ,e;j nray;Kiwf;F>
originf;F glj;ij efh;j;Jjy;> originIg; nghWj;J Njitahd
Nfhzk; jpUg;Gjy;> gpd;G kPz;Lk; glj;ij mjd; Ke;ija

1.14
,lj;jpw;F efh;j;Jjy; Mfpa transformationfs; Njitg;gLk;.
,e;j jdpg;gl;l transformation matrixfis ngUf;fpf; fpilg;gJ
concatenation matrix MFk;.

1.9 Geometric modelling techniques or

Types of geometric models
xU nghUspd; mikg;igg; gw;wpa fzpj Kiwapyhd Fwpg;G
model vdg;gLk;. Geometric modelling vd;gJ CAD system
cjtpahy; xU nghUspd; modelI cUthf;Fk; Kiw MFk;.
ngUk;ghYk; fPo;f;fz;l %d;W topKiwfspy; modelfs;
cUthf;fg; gLfpd;wd.
1) Wireframe model or line model
2) Surface model
3) Solid model or volume model

1.9.1 Wireframe modelling

 xU nghUis fzpj Kiwapy; computery; Fwpg;gjw;fhd
vspa Kiw mjd; wireframe modelI cUthf;FtJ MFk;.
,J line model my;yJ edge representation vdTk;
miof;fg;gLk;.
 xU wireframe modely; point, line, arc, circle, conics kw;Wk;
curves mlq;fp ,Uf;Fk;.
 Modeld; tpspk;Gfshf mikAkhW> xU wireI Njitahd
tbtj;jpy; tisf;f ,aYk; vd;w cz;ikapd; mbg;gilapy;
‘wireframe’ vd;w nrhy; ,q;F gad;gLj;jg; gLfpwJ.
 Edge MdJ> line, arc my;yJ ve;j xU tisthd curve
MfTk; ,Uf;fyhk;.
 3D wireframe model vd;gJ tiuaWf;fg;gl;l Gs;spfisAk;
mg;Gs;spfis ,izf;Fk; tpspk;GfisAk; nfhz;ljhf
,Uf;Fk;.

Wireframe model with linear edge

 Neh;f;Nfhl;L tpspk;GfSld; cs;s wireframe model MdJ
,uz;L Gs;spfis ,izj;J tiuag;gLk; gy Nfhl;Lj;
Jz;Lfs; mlq;fpaJ MFk;.

1.15
 Z

V2
E6
Y
E1
E5 V4

E - Edge
E2 E3 V - Vertex
V1

E4

V3
X

Fig.1.7 Linear wireframe model of tetrahedron

Vertex list Edge list Edge type

V1 (0,0,0) E1 (V1,V2) Linear
V2 (0,0,1) E2 (V2,V3) Linear
V3 (1,0,0) E3 (V3,V1) Linear
V4 (0,1,0) E4 (V3,V4) Linear
E5 (V1,V4) Linear
E6 (V4,V2) Linear

 cjhuzkhf> tetrahedron MdJ ehd;F Gs;spfisAk;

mtw;iw ,izj;J tiuag;gLk; MW Neh;f;Nfhl;L
tpspk;GfisAk; nfhz;ljhf ,Uf;Fk;.
 xU tetrahedrond; cUtj; Njhw;wkhdJ> (X,Y,Z) mr;Rj;
J}uq;fs; Fwpf;fg;gl;l xU vertex listIf; nfhz;L
tiuaWf;fg; gLfpwJ.

Wireframe model with curvilinear edges

 ngUk;ghyhd nghUl;fs; tisthd Nkw;gug;igf; nfhz;b
Uf;Fk;. tisthd kw;Wk; Neh;f;Nfhl;L tpspk;Gfs; nfhz;L
cUthf;fg; gl;l wireframe model %yk; ,j;jifa
nghUl;fs; tiuaWf;fg; gLfpd;wd.
 Cone ,j;jifa modelf;fhd xU vspa cjhuzk; MFk;.
,J xU cr;rpg; Gs;spiaAk; tl;l tbt mbg;ghfj;ijAk;
nfhz;lJ.
1.16
 Z
V1

E1 E2

Y
V2
E4

X
E3 V3

Fig.1.8 Curvilinear wireframe model of cone

 Generator vdg;gLk; vz;zpf;ifaw;w Neh;f;Nfhl;L

tpspk;Gfs; %yk; cr;rpg; Gs;sp kw;Wk; mbg;gf;fk;
,izf;fg; gl;bUf;Fk;.
 %d;W Gs;spfs; kw;Wk; ehd;F tpspk;Gfisf; nfhLg;gjd;
%yk; coned; gl cUtj;ij tiuaWf;fyhk;. Gs;spfs;
KiwNa cr;rpg; Gs;sp kw;Wk; tl;lj;jpd; ,uz;L
tpl;lg;Gs;spfs; Mfpait MFk;.
 tpspk;Gfspy;> cr;rpg; Gs;spapypUe;J tl;l mbg;ghfj;jpw;F
tiuag;gLk; ,uz;L Neh;f;Nfhl;L tpspk;Gfs; kw;Wk;
tl;lj;ij cUthf;Fk; ,uz;L miutl;l tpspk;Gfs;
Mfpaiy mlq;Fk;.

Vertex list Edge list Edge type

V1 (0,0,3) E1 (V1,V2) Linear
V2 (-1,0,0) E2 (V1,V3) Linear
V3 (1,0,0) E3 (V2,V3) Semi-circular
E4 (V3,V2) Semi-circular

 tl;l tbt mbg;ghfj;ij gy rk ghfq;fshfg; gphpg;gjd;

%yk; coned; wireframe model Njhw;wj;ij Nkk;gLj;jyhk;.
 ,t;thW ve;j xU nghUspd; wireframe modelIAk;
Neh;f;Nfhl;L kw;Wk; tisT tpspk;Gfs; %yk; Vw;gLj;jyhk;.

1.17
Applications of wireframe modelling
fPo;f;fz;ltw;wpy; wireframe modelling nghJthfg; gad;gLfpwJ.
1) Video gamefspy; 3D tbtq;fis cUthf;Fjy;
2) CNC machinef;fhd tool pathI cUthf;Fjy;
3) Computer aided manufacturingf;F Njitahd inputI
cUthf;Fjy;
4) Orthographic kw;Wk; auxiliary Njhw;wq;fis jhdhfNt
cUthf;Fjy;
5) ,ize;Js;s ,uz;L ghfq;fSf;fpilNa cs;s
interferenceI NrhjidapLjy;
6) Exploded view kw;Wk; perspective viewfis vspjhf
cUthf;Fjy;

Advantages of wireframe modelling

1) ,jid tbtikg;gJ vspJ.
2) ModelI Nrkpj;J itf;f Fiwe;j memory NghJkhdJ.
3) Manipulation Neuk; FiwT.
4) Wireframe model cUthf;f mjpf gapw;rp Njitapy;iy.
5) Orthographic, isometric kw;Wk; perspective Njhw;wq;fis
,jpypUe;J cUthf;FtJ vspJ.
6) Wireframe modelI edit nra;tJ kpfTk; vspJ.

Disadvantages of wireframe modelling

1) Wireframe modelI Ghpe;J nfhs;tJ fbdk;.
2) Wireframe modelI ghh;g;gth;fSf;F epiwa Fog;gq;fs; Vw;gLk;.
3) Mass, volume, moment of inertia Nghd;w gz;Gfisf;
fzf;fpl ,ayhJ.
4) rpf;fyhd tbtk; nfhz;l nghUl;fis Fwpg;gpl Vw;wJ ,y;iy.
5) kiwe;Js;s NfhLfis ePf;FtJ mjpf Neuk gpbf;Fk; nray;
MFk;.
6) Wireframe modelI cUthf;Ftjw;fhd nray;Kiw
rpf;fyhdJ MFk;.
7) Wireframe model cUthf;f topological kw;Wk; geometrical
data ,uz;Lk; Njitg;gLk;.

1.18
1.9.2 Surface modelling

Fig.1.9 Representation of surface modelling

 xU nghUspd; surface model MdJ mjd; wireframe modelI
tpl KOikahdJk; Fiwthd re;Njfj;jpw;F ,lkspg;gjhfTk;
,Uf;Fk;.
 Wireframe modeld; kPJ gug;Gfis tiuaWg;gjd; %yk;
surface modelI cUthf;fyhk;.
 xU nghUspd; vy;iyahdJ gy surfacefshy; tiuaWf;fg;
gl;bUf;fyhk;.
 ,e;j surfacefshdJ Neh;f;NfhLfs; kw;Wk; tisNfhL
fshy; jdpahfNth my;yJ ,ize;Njh cUthf;fg;glyhk;.
gy surfacefs; ,ize;J cUthf;fgl;l xU surface model
glj;jpy; fhl;lg;gl;Ls;sJ.
 fPo;f;fz;ltw;wpd; designI cUthf;Ftjw;F curve kw;Wk;
surfacefis gad;gLj;JtJ mtrpakhfpwJ.
 Body panel of automobiles
 Aircraft structural members
 Marine vehicles
 Consumer products, etc.
Types of surfaces
Surface modelfis cUthf;Ftjw;Fg; gad;gLk; mbg;gil
tiugl cUtq;fs; fPNo tpsf;fg;gl;Ls;sd.
1.19
 Fig.1.10 Plane surface Fig.1.11(a) Ruled surface
1) Plane surface
,J xU vspa rkjskhd 2D surface MFk;. ,ij
cUthf;f Fiwe;j gl;rk;> xNu Nfhl;by; mikahj %d;W
Gs;spfs; Njitg;gLk;.
2) Curved surface
,uz;L tifahd curved surfacefs; cs;sd.
(a) single curved surface (b) double curved surface

Single curved surface: ,it vspa curved surfacefs;

MFk;. ,it Neh;f;NfhLfisf; nfhz;L cUthf;fg; gLfpd;wd.
Cylindrical surface, conical surface, surface of pyramids, prisms
kw;Wk; conics Mfpait single curved surfacefSf;F rpy
cjhuzq;fs; MFk;.
Double curved surface: ,it curvefisf; nfhz;L
cUthf;fg;gLk; rpf;fyhd surfacefs; MFk;. Sphere, ellipsoid,
paraboloid, kw;Wk; torus Mfpait double curved surfacefSf;F rpy
cjhuzq;fs; MFk;.
Double curved surfacefis cUthf;Ftjw;Fg; gad;gLk; rpy
topKiwfs; fPNo tpsf;fg; gl;Ls;sd.
 Ruled surface: ,uz;L my;yJ mjw;F Nkw;gl;l
curvefSf;F ,ilNa linear blending Kiwiaf; nfhz;L
ruled surface cUthf;fg; gLfpwJ. ve;j twistk; ,y;yhj
surfacefis cUthf;f ,e;j Kiw gad;gLfpwJ.
 Surface of revolution: ,J xU ,Ugf;fr; rkr;rPUila
surface MFk;. xU rkjskhd wireframe entityI VNjDk;
xU ika mr;irg; nghWj;J Row;Wtjd; %yk; ,J
ngwg;gLfpwJ.
1.20
Fig.1.11(b) Surface of revolution Fig.1.11(c)Tabulated cylinder
 Tabulated cylinder: xU rkjskhd tisit Fwpg;gpl;l
VNjDk; xU jpirapy; Fwpg;gpl;l J}uj;jpw;F efh;j;Jtjd;
(translating) %yk; ,j;jifa gug;Gfs; cUthf;fg; gLfpd;wd.
 Bezier surface: ,it nfhLf;fg;gLk; input dataf;fSf;F
Vw;g Njhw;Wtpf;fg;gLk; tisTfs; MFk;. ,J xU
synthetic surface MFk;. ,J twist kw;Wk; bendI
mDkjpf;Fk;. ,J bezier tisTfisf; nfhz;L
cUthf;fg; gLfpwJ. ,it jpwe;j vy;iyfspy;
gad;gLj;jg; gLfpd;wd.
 B–spline surface: nfhLf;fg;gLk; input dataf;fSf;F Vw;g
Njhuhakhf my;yJ interpolation %ykhf ,j;jifa
surfacefs; Njhw;Wtpf;fg; gLfpd;wd. ,J xU synthetic
surface MFk;. ,it B-spline tisTfisf; nfhz;L
cUthf;fg; gLfpd;wd. ,it jpwe;j vy;iyfspy;
gad;gLj;jg; gLfpd;wd.
 NURBS: Non–Uniform Rational B–spline Surfacefs; midj;J
CAD systemfspYk; nghJthf gad;gLj;jg;gLtJ MFk;.
,it B-spline surfacefisg; Nghd;wNj MFk;. Mdhy;
$Ljyhf weighing factor ,jw;F cz;L. ,itfisg;
gad;gLj;jp ve;j tbtpy; cs;s gug;GfisAk; cUthf;fyhk;.
 Coons surfaces: ,it ehd;F curvefis vy;iyfshff;
nfhz;L cUthf;fg;gLk; surfacefs; MFk;. xU jdpg;gl;l
patchI mjd; ,uz;L gf;fq;fspYk; $Ljy; patternfis
,izj;J ePl;lyhk;. ,e;j ,izg;ghdJ linear my;yJ cubic
blending nray; %yk; eilngWk;. ,jd; %yk; xU
kpUJthd gug;G fpilf;Fk;.

1.21
Fig.1.11(d) Coons surface Fig.1.11(e) Swept surface

 Swept surface: xU tiuaWf;fg;gl;l curveI VNjDk; xU

spline curved; ghij topahf sweep nra;J ,j;jifa surfae
ngwg;gLfpwJ.
 Sculptured or curved mesh surface: gy;NtW curvefis
FWf;Fk; neLf;Fkhf ,izj;J ,j;jifa surfacefs;
ngwg;gLfpd;wd.

Fig.1.11(f) Sculputured surface Fig.1.11(g) Fillet surface

 Fillet surface: ,it mUfUNf cs;s ,uz;L surfacefis

,izf;Fk; B-spline surfacefs; MFk;. Filletd; NghJ gioa
surfacefs; ntl;lg;glyhk; my;yJ ntl;lg;glhkYk;
,Uf;fyhk;.
 Offset surface: Vw;fdNt cs;s surfacefis Fwpg;gpl;l
J}uj;jpw;F offset nra;J Gjpa msTfSld; ,j;jifa
surfacefs; cUthf;fg; gLfpd;wd. Surface modelI Jhpjg;
gLj;j ,j;jifa surfacefs; nghpJk; cjTfpd;wd.

1.22
Application of surface model
fPo;f;fz;ltw;wpy; surface modelling nghJthfg; gad;gLfpwJ.
1) ,ize;Js;s ,uz;L ghfq;fSf;fpilNa cs;s
interferenceI NrhjidapLjy;
2) FWf;F ntl;Lj; Njhw;wj;ij cUthf;Fjy;
3) Finite element meshfis cUthf;Fjy;
4) NC tool path cUthf;Fjy;

Advantages of surface model

1) Wireframe modelfis tpl surface modelfs; Fiwthd
re;Njfj;jpw;F ,lkspg;gjhf ,Uf;Fk;.
2) kiwe;Js;s NfhLfis ePf;Fjy; %yk; nghUspd; Xustpw;F
cz;ikahd Njhw;wj;ij Vw;gLj;j ,aYk;.
3) Shading KiwAk; ,jpy; cs;sJ.

Disadvantages of surface model

1) Modeld; cl;Gw tpguq;fis ,izg;gJ fbdk;.
2) Designerf;F mjpf fzpjj; jpwikAk; gapw;rpAk; Njit.
3) ModelI cUthf;f mjpf Neuk; Njit.
4) ModelI Nrkpj;J itf;f mjpf memory Njit.
5) Manipulation Neuk; mjpfk;.
6) Wireframe modelIg; Nghd;W vspjhf cUthf;f KbahJ.

1.9.3 Solid modelling

 3D modelI cUthf;Ftjw;F solid modelling KiwNa kpfr;
rpwe;jJ MFk;. ,jd; %yk; modelIg; gw;wpa KO
tpguq;fisAk; njhpe;J nfhs;s KbAk;.
 ,e;j Kiwapy;> modeld; KOj; Njhw;wKk; kpf vspjhf
Ghpe;J nfhs;Sk;gb Njhw;Wtpf;fg;gLk;.
 Modelf;F tz;zj;ij nfhLg;gjd; %yk;> cz;ikahd
nghUisg; Nghd;w Njhw;wj;ij cUthf;fyhk;.
 midj;J solid modelling njhFg;gpYk;> 3D modelfis
cUthf;Fjy;> khw;wp mikj;jy;> mstPLfis
NrhjidapLjy; Nghd;wtw;wpw;fhd mk;rq;fs; ,Uf;Fk;.
1.23
  Solid modelfis cUthf;Ftjw;F fPo;f;fz;l Kiwfs; cs;sd.
1) Constructive solid geometry (CSG)
2) Boundary representation (B–rep)
3) Pure primitive instancing
4) Generalized sweep
5) Cellular decomposition
6) Hybrid scheme
 ,tw;wpy;> constructive solid geometry kw;Wk; boundary
representation technique Mfpait CAD systemfspy; nghpJk;
gad;gLj;jg; gLfpd;wd.

Solid modelling entities or primitives

Y
Y Y
H
P P P
H X X
Z X R R
H
W D Z Z

Block Cylinder Cone

Y Y Y
Z
R2
R
H P R1 X
P P
Z
Z X
W X Ro Ri
D
Sphere Wedge Torus
Fig.1.12 Solid modelling entities

Solid modelfis
cUthf;Ftjw;F gad;gLk; mbg;gil
cUtq;fs; entities vdg;gLk;. ,it primitives vdTk; miof;fg;
gLk;. ,tw;iw Boolean operatorfs; %yk; xd;wpizj;J Njitahd
solid modelI cUthf;fyhk;. Kf;fpa solid entities :

 Block : ,J xU jpz;k ngl;b my;yJ fd rJuk; MFk;.

,jd; tbtikg;G jfty;fs; width (W), height (H) kw;Wk;
depth (D) Mfpait MFk;. Gs;sp PMdJ local coordinate
systemj;jpd; Muk;gj;ij Fwpf;fpwJ. W, H kw;Wk; D
Mfpatw;wpd; kjpg;gpidf; nfhz;L> coordinate systemj;ijg;
nghWj;J block mike;Js;s epiy epu;zapf;fg;gLk;.

1.24
  Cylinder : ,J xU Neh;f;Nfhl;L cylinder MFk;. ,jd;
tbtkhdJ mjd; radius R (my;yJ diameter D) kw;Wk;
Length H Mfpatw;wpd; %yk; Fwpf;fg;gLfpwJ. Lenght H
MdJ nghJthf Z mr;R jpirapy; vLj;Jf; nfhs;sg;gLk;.
,J positive MfNth my;yJ negative MfNth ,Uf;fyhk;.
 Cone : ,J xU Neh;f;Nfhl;L cone my;yJ coned; frustum
MFk;. ,jd; tbtkhdJ mbg;gf;f tpl;lk; D, Nky;gf;f tpl;lk;
d kw;Wk; cauk; H Mfpait %yk; Fwpf;fg;gLk;.
 Sphere : Radius R my;yJ diameter D %yk; ,J
tiuaWf;fg;gLfpwJ. Local coordinate systemj;jpd; Muk;g
Gs;spahdJ ,jd; ikag;Gs;spahf ,Uf;Fk;.
 Wedge : ,J xU nrq;Nfhz Kf;Nfhz wedge MFk;. ,jd;
tbtikg;Gj; jfty;fs; height H, width W kw;Wk; base depth
D Mfpait MFk;.
 Torus : xU tl;lj;ij mjd; kPJs;s xU planeIg; nghWj;J
Row;Wk;NghJ torus fpilf;fpwJ. Torus bodyd; radius R1
kw;Wk; torus bodyd; centre line radius R2 Mfpait %yk; ,jd;
tbtikg;G Fwpf;fg;gLfpwJ. Inner radius RI kw;Wk; outer
radius RO Mfpait %yKk; ,J Fwpf;fg;gLk;.

Solid modelling schemes

1) Constructive solid geometry (CSG) or C–rep
,J building block approach vdTk; miof;fg;gLk;. ,e;j
Kiwapy;> primitives vdg;gLk; mbg;gil solid mikg;Gfs;
cjtpAld; Njitahd model cUthf;fg; gLfpwJ. Block, sphere,
hemi-sphere, cylinder, cone, torus kw;Wk; wedge Mfpait xU rpy
primitivefs; MFk;. ,e;j primitivefs; nghJthf CAD systemfs;
midj;jpYk; Nrkpj;J itf;fg; gl;bUf;Fk;.
CSG using Boolean operators
Boolean operatorfs; %yk; primitivefis xUq;fpizj;J xU
KOikahd solid model cUthf;fg;gLfpwJ. Union ( or +), intersection
() kw;Wk; difference (–) Mfpa Boolean operatorfs; cs;sd.
 Union (): UNION Boolean operator %yk; ,uz;L solidfis
,izf;Fk;NghJ> ,uz;L solidfSk; Nrh;e;J nkhj;jkhf milj;Jf;
nfhs;Sk; ,lk; ,Wjpahd solid Mf fpilf;fpwJ. ,uz;L solidfs;
xd;Wld; xd;W $Ltjhf ,jid vLj;Jf; nfhs;syhk;.
1.25
 A B

AUB A B A-B B-A

U

Fig.1.13 Bollean operations for two - dimensional model

 Difference (–) : DIFFERENCE Boolean operator %yk; ,uz;L
solidfis ,izf;Fk;NghJ> Kjy; solidy; ,Ue;J ,uz;lhtJ
solid milj;Jf;nfhs;Sk; ,lj;ij ePf;fpa gpd;G cs;s ,lk;
,Wjpahd solid Mf fpilf;fpwJ. Kjy; solidy; ,Ue;J
,uz;lhtJ solidI fopg;gjhf ,jid vLj;Jf; nfhs;syhk;.

AUB A B A-B B-A

U

Fig.1.14 Bollean operations for three - dimensional model

 Intersection () : INTERSECTION %yk; ,uz;L solidfis
,izf;Fk;NghJ> ,e;j ,uz;L solidfSf;Fk; nghJthf
cs;s ,lk; ,Wjpahd solid Mf fpilf;fpwJ.
BLOCK kw;Wk; CYLINDER Mfpa vspa primitivefspd; kPJ
Boolean operatorfspd; tpisT 2D kw;Wk; 3D Kiwapy; glj;jpy;
fhl;lg;gl;Ls;sJ.

CSG tree

U 5

2 3 4
U
6

1 1 2
U
5

3 4
Model
CSG tree
Fig.1.15 CSG tree

1.26
 CSGapy;> xU rpf;fyhd modelI cUthf;Ftjw;F> Boolean
operatorfspd; construction tree kw;Wk; primitivefspd;
msT
MfpaitNa Nrkpj;J itf;fg;gl Ntz;ba tpguq;fs; MFk;.
,jd; %yk; Nrkpf;fj; Njitg;gLk; msT FiwfpwJ. NkYk; CSG
treeI khw;wp mikg;gjd; %yk;> xU Gjpa modelI ve;j
Neuj;jpYk; cUthf;fyhk;.
2) Boundary representation (B–Rep)
 ,e;j Kiwapy;> xU solid model MdJ mjd; vy;iyfis
eph;zapf;Fk; mbg;gil gl cUtq;fs; mlq;fpa xU data
structure %yk; Fwpg;gplg; gLfpwJ. ,it topological
elements kw;Wk; geometric elements vdg; gphpf;fg; gLfpd;wd.
 Topological elementfs; xU network my;yJ groupy; xd;Wld;
xd;W ,izf;fg; gl;Ls;sd. Network MdJ elementfSf;F
,ilNaAs;s njhlh;gpid vertex, edge kw;Wk; face
Mfpatw;wpd; topahf Fwpg;gpLfpwJ.

Edge Edge

Vertex

Edge
Face Face

Vertex

Edge Edge

Fig.1.16 Winged edge data representation

 Vertex, edge kw;Wk; face Mfpait topological elements
vdg;gLk;. Point, curve kw;Wk; surface Mfpait geometric
elements vdg;gLk;.
 Topological kw;Wk; geometric elementfs; fPo;f;fz;lthW
xd;Wld; xd;W njhlh;G nfhz;bUf;Fk;.
Face  Surface
Edge  Curve
Vertex  Point

1.27
  B-rep modely; face vd;gJ xU vy;iyf;Fs; tiuaWf;fg;
gl;l surface MFk;. B-repy; gad;gLj;jg;gLk; xU winged
edge data structure glj;jpy; fhl;lg; gl;Ls;sJ.

Model

Input views
Fig.1.17 Boundary representation
 xU solid modelI cUthf;Ftjw;fhd boundary
representation glj;jpy; fhl;lg; gl;Ls;sJ.

Comparison of CSG and B–Rep

CSG B–Rep
1) Primitivefspd; cjtpAld; solid vy;iyfis tiuaWg;gjd; %yk;
model cUthf;fg;gLfpwJ. solid model cUthf;fg; gLfpwJ.
2) kpfr; rhpahd solid modelI cU Solid modelI cUthf;FtJ
thf;FtJ kpfTk; vspJ. vspjy;y.
3) Boolean operatorfs; gad; Topological elementfs; gad;
gLj;jg; gLfpd;wd. gLj;jg; gLfpd;wd.
4) Fiwthd memory NghJkhdJ. mjpf memory Njit.
5) ModelI jpUk;gTk; Njhw;Wtpf;f ModelI jpUk;gTk; Njhw;Wtpf;f
mjpf fzf;fPLfs; Njit. Fiwe;j fzf;fPLfNs Njit.
6) Bezier surface
Nghd;w Bezier surface kw;Wk; rpf;fyhd
tisTfis cUthf;f ,ayhJ. tisTfis cUthf;yhk;.
7) C-repy; ,Ue;J mjw;Fhpa wire B-repy; ,Ue;J mjw;Fhpa
frame modelf;F khw;WtJ wire frame modelf;F
kpfTk; fbdk;. khw;WtJ vspJ.

1.28
3) Hybrid schemes
 ,J C-rep kw;Wk; B-rep ,uz;Lk; ,ize;j Kiw MFk;.
 ,e;j ,uz;L KiwfspYk; cs;s FiwghLfis ePf;fp>
rpwg;G mk;rq;fis ,izj;J Hybrid scheme gad;gLj;jg;
gLfpwJ.
 ,e;j Kiwapy;> xU Fwpg;gpl;l modelI cUthf;f B-rep
kw;Wk; C-rep Kiwfspy; rpwg;ghdJ gad;gLj;jg;gLk;.

Applications of solid modelling

fPo;f;fz;ltw;wpw;F solid modelling gad;gLj;jg; gLfpwJ.
1) Hidden line drawing, section kw;Wk; shaded tiuglq;fis
cUthf;Fjy;
2) Surface area, centre of gravity, moment of inertia, radius of
gyration Nghd;w mass propertyfis fzf;fPL nra;jy;
3) Self-adaptive finite element meshefis cUthf;Fjy;
4) Solid assemblyfSf;fhd kinematics analysis
5) Dynamics interference analysis
6) Process plan cUthf;Fjy;
7) CNC program cUthf;Fjy;
8) CNC tool path cUthf;Fjy;

Advantages of solid modelling

1) Solid modelfs;
KOikahdit kw;Wk; vspjpy; Ghpe;J
nfhs;sf; $bait.
2) Solid modelfis vspjpy; cUthf;fyhk;.
3) cl;Gw tpguq;fis ,jpy; ,izf;f ,aYk;.
4) Part program cUthf;Fjpy; mjpf gq;F tfpf;fpwJ.
5) Modeld; tbtk; kw;Wk; msTfs; gw;wpa epiwa tpguq;fis
Nrkpj;J itf;fpwJ.
6) Mass properties fzf;fpLtjw;F kpfTk; Vw;wJ.

Disadvantages of solid modelling

1) ,jid Nrkpj;J itf;f mjpf memory Njit.
2) mjpf manipulation time Njit.

1.29
 1.9.4 Comparison of wire frame, surface and solid modeling
Detail Wire frame model Surface model Solid model
1. Representation Gs;spfs; kw;Wk; Gs;spfs;> tpspk;Gf; Gs;spfs;> tpspk;Gf;
tpspk;Gf; NfhLfs; kw;Wk; NfhLfs;> gug;Gfs; kw;Wk;
NfhLfspd; gug;Gfspd; njhFg;G cl;Gw fd msT
njhFg;G Mfpatw;wpd; njhFg;G
2. Ghpe;J nfhs;tjpy; rpukk; mjpfk; FiwT ,y;iy
3. Njitahd memory FiwT Wireframe modelI tpl Surface modelI tpl mjpfk;
mjpfk;
4. Manipulation time FiwT mjpfk; FiwT
5. cUthf;fj; Njitahd Neuk; FiwT mjpfk; FiwT
6. cl;Gw tpguq;fis ,izj;jy; KbahJ KbahJ KbAk;
7. jhdhfNt Njhw;wq;fis KbahJ KbahJ KbAk;
cUthf;Fjy;
8. Cross sectioning jhdhfNt jhdhfNt cUthf;f jhdhfNt cUthf;f
cUthf;f KbahJ KbahJ KbAk;
9. kiwe;Js;s NfhLfis jhdhfNt ,ayhJ jhdhfNt ,ayhJ jhdhfNt ,aYk;
ePf;Fjy;
10. Mass properties fzf;fpLjy; KbahJ KbahJ KbAk;
11. NC gad;ghL fbdk; my;yJ jhdhfNt ,aYk; jhdhfNt ,aYk;
KbahJ
1.30
1.10 Graphics standards
gy;NtW epWtdq;fshy; cUthf;fg;gl;l gy;NtW CAD/CAM
softwarefs; gad;gLj;jg; gLfpd;wd. vdNt> ,jpy;
gad;gLj;jg;gLk; midj;J hardware kw;Wk; softwarefis
,izg;gjw;F xU standard cUthf;FtJ mtrpakhfpwJ. NkYk;
computer integrated manufacturingy;> CAD systemj;jpy; ,Ue;J
jfty;fis CAM systemj;jpw;F mDg;g Ntz;baJ
mtrpakhfpwJ. ,t;thW dataf;fis ntt;NtW CAD
systemfSf;F ,ilNa ghpkhwpf; nfhs;s cjTgit graphics
standards MFk;.

Graphics database

DXF, IGES, STEP, SET

Applications
programs
GKS, PHIGS, CORE

Graphics functions

VDI, VDM, NAPLPS

Device driver Device driver

Device Device

Fig.1.18 Various CAD standards

Need or benefits of graphics standards

CADy; fPo;f;fz;l gz;Gfisg; ngWtjw;F Graphics
standards mtrpak; MFk;.

1) Application program portability: CAD systemj;jpy; cs;s

programfshdJ hardwareIr; rhh;e;J ,Uf;ff; $lhJ.
ntt;NtW systemfSf;F ,ilNa gfph;e;J nfhs;sf;
$baitahf programfs; ,Uf;f Ntz;Lk;.
2) Picture data portability: glq;fis Fwpg;gpLk; Kiw kw;Wk;
Nrkpf;Fk; Kiw Mfpait graphic devicefisr; rhh;e;J
,Uf;ff; $lhJ.
3) Text portability: vOj;J cUtq;fs; kw;Wk; mtw;iwf;
Fwpg;gpLk; Kiw hardwareIr; rhh;e;jjhf ,Uf;ff; $lhJ.
1.31
 4) Object database portability: gFg;gha;T kw;Wk; cw;gj;jp
nray;fs;> nghJthd xU CAD databaseI gad;
gLj;Jtjhf ,Uf;f Ntz;Lk;.

CAD/CAM gad;ghLfSf;F fPo;f;fz;l graphics standardfs; cs;sd.

 GKS : Graphical Kernel System
 OpenGL : Open Graphics Library
 IGES : Initial Graphics Exchange Specification
 DXF : Drawing Exchange Format
 PHIGS : Programmer’s Hierarchical Interface for Graphics
 STEP : STandard for the Exchange of Product model data
 DMIS : Dimensional Measurement Interface Specifications
 VDI : Virtual Device Interface
 VDM : Virtual Device Metafile
 GKSM : GKS Metafile
 WMF : Windows Meta File

1.11 Graphical Kernel System (GKS)

IGES file link to
other CAD systems

Application CAD system IGES

software software processor

GKS language
binding

GKS

Metafile Device driver Device driver

driver

Metafile Input
storage device

Fig.1.19 GKS implementation in CAD workstation

1.32
 Fwpg;gpl;l nghJthd nray;ghLfis Nkw;nfhs;tjw;Fg;
gad;gLk; nray;Kiwfspd; njhFg;Ng GKS MFk;. xU rpwe;j 2D
standard Mf GKSI ISO jPh;khdpj;Js;sJ.

Objectives of GKS
1) 2Dapy; glk; tiutjw;fhd midj;J trjpfisAk; mspj;jy;.
2) Plotterfs;> display devicefs; Nghd;w midj;J graphic
devicefisAk; fl;Lg;gLj;Jjy;.
3) gy;NtW programfis cUthf;Ftjw;F Fiwe;j
memoryINa milj;Jf; nfhs;Sjy;.

Features of GKS (Benefits or advantages of GKS)

1) Device independence: ,jpy; ve;j xU mk;rKk;> input
kw;Wk; output devicefisr; rhh;e;J ,Uf;fhJ.
2) Text or annotation: ,jpy; gad;gLj;jg;gLk; vOj;Jf;fs;
kw;Wk; fl;lisfs; Mq;fpyk; Nghd;w ,aw;ifahd
nkhopia xl;b ,Uf;Fk;.
3) Display management: glq;fisj; Njhw;Wtpj;jy;> cursor
control kw;Wk; ,ju mk;rq;fSf;Fj; Njitahd KOikahd
trjpfisf; nfhz;L s;sJ.
4) Graphics functions: Graphics nray;fis 2D kw;Wk; 3Dapy;
tiuaWf;fyhk;.
5) Metafile drivers: Graphic jpwd; ,y;yhj metafile
drivefisAk; ,jDld; ,izj;Jf; nfhs;syhk;.

Input methods
GKS #o;epiyf;F inputfisf; nfhLg;gjpy; fPo;f;fz;l
njhlh;fs; Kf;fpakhdit MFk;.
 Locator :World coordinatey; xU locationI cs;sPL nra;Ak; Kiw
 Valuator:Gs;spfSf;F ,ilNaAs;s cz;ikahd njhiyT
 Choice :0,1,2,3 Nghd;w vz;fspd; Njh;T
 Pick :VNjDk; xU tiugl ghfj;ij Njh;e;njLj;jy;
 String :Characterd; kjpg;G
 Stroke :World coordinatey; location kjpg;ig njhlh;r;rpahf
Fwpg;gpLjy;.

1.33
Graphic primitives
Nfhl;Lj;Jz;Lfis tiutjw;F PEN vd;w fl;lisg; gad;
gLj;jg;gLk;. ,e;j PEN fl;lisapy; colour, thickness, kw;Wk; line
type Nghd;w gz;Gfis khw;wpf;nfhs;Sk; trjp ,Uf;Fk;. GKSy;
fPo;f;fz;l mbg;gil graphic primitivefs; cs;sd.
 Polyline: gy;Nfhl;Lj;Jz;Lfs; tiutjw;F
 Polymarker: Fwpg;gpl;l marker tifia cUthf;f
 Generalised Drawing Primitives (GDP): Arc, circle, ellipse,
spline Nghd;w VNjDk; xU mbg;gil tiugl ghfj;ijf;
Fwpg;gpLtjw;F
 Text: vOj;Jf;fis cUthf;f
 Fillarea: gug;Gfis NfhbLtjw;F kw;Wk; epug;Gtjw;F

1.12 Open Graphics Library (OpenGL)

Open Graphics Library (OpenGL) vd;gJ 2D kw;Wk; 3D
tiuglq;fis rendering nra;tjw;F nghpJk; gad;gLj;jg;gLk; xU
application programming interface (API) MFk;. ,J graphics
processing unit (GPU) cld; ,ize;J nray;gl;L> hardwareI
J}z;Ltjd; %yk; mjpNtf rendering ngwg;gLfpwJ.

OpenGL pipeline process

Vertex Fragment Output Display

Processor Rasterizer Processor Merging

Fig.1.20 OpenGL pipeline process

xU staged; output MdJ mLj;j staged; input Mf

mikAkhW njhlh;r;rpahf eilngWk; nray;Kiw pipeline
vdg;gLk;. OpenGL rendering pipeline MdJ> vertices my;yJ
primitives mlq;fpa Kg;ghpkhz glq;fis mjd; input Mf Vw;Wf;
nfhs;fpwJ. xt;nthU pixelf;Fk; colour-valueI nfhLf;fpwJ.

OpenGL rendering pipeliney; cs;s gbepiyfs; :

 Vertex processing : xt;nthU verticeIAk; process nra;J
khw;WfpwJ.
 Rasterization : xt;nthU primitiveIAk; frangmentfspd;
njhFg;ghf khw;WfpwJ. Fragment vd;gJ 3Dy; xU pixelIf;

1.34
 Fwpf;Fk;. ,jpy; position, color, normal kw;Wk; texture
Mfpait mlq;Fk;.
 Fragment processing : xt;nthU fragmentIAk; process
nra;fpwJ.
 Output merging : 3Dy; cs;s midj;J primitivefspd;
fragmentfisAk; ,izj;J 2D colour pixelfshf fhl;LfpwJ.

Features in OpenGL
The important features of OpenGL includes the following :
 Language independent : OpenGLI ngUk;ghyhd languagefspy;
gad;gLj;j ,aYk;. ,jid Ada, C, C++, Fortran, Python, Perl,
Java Nghd;w ve;J xU programYk; mioj;J gad;gLj;jyhk;.
 Platform independent : Mac OS, OS/2, UNIX, Windows, Linux
Nghd;w ngUk;ghyhd operating systemfspy; OpenGL ,aq;Fk;.
 Open architecture : OpenGLd; extension mechanismj;ij
gad;gLj;jp> hardware jahhpg;ghsh;fs; jq;fSf;F chpa
extensionfis cUthf;fp $Ljyhf Nrh;j;Jf;nfhs;s KbAk;.
 Vertex and fragment shaders : OpenGL Shading LanguageI
gad;gLj;jp> vertex kw;Wk; fragment processorfSf;fhd
program cUthf;fg;gLk;.
 Multi texturing : Texture colour kw;Wk; fragment colourfis
xd;NwhL xd;W fyitahf ,izf;f KbAk;.
 Instanced rendering : tbtikg;G jfty;fis mjptpiuthf
gyKiw rendering nra;Ak; trjp cs;sJ.
 Viewport array : xNu Neuj;jpy; nghUspd; gy;NtW
Njhw;wq;fis fhz;gpf;f viewportfs; trjp cs;sJ.
 Flush Control : xU commandI nray;gLj;Jtjw;F Kd;G>
Vw;fdNt cgNahfj;jpy; cs;s commandI Kbj;Jf;
nfhs;Sk; tifapyhd application cs;sJ.
Advantages of OpenGL
 mjpf visual quality kw;Wk; nray;ghL.
 Open kw;Wk; multiplatform graphics standard.
 epiyahdJ kw;Wk; ek;gfj;jd;ik tha;e;jJ.

1.35
  Extension mechanismj;jpd; %yk; Gjpa hardware cw;gj;jpf;F
toptFf;fpwJ.
 ve;j xU systemj;jpYk; ,jid ,af;fyhk;.
 gad;gLj;JtJ vspJ.

Applications of OpenGL
 Computer Aided Design (CAD)
 Virtual reality
 Scientific visualization
 Information visualization
 Flight simulation
 Video games.

1.13 Initial Graphics Exchange Specification (IGES)

,J xU gue;J tphpe;j standard MFk;. xU nghUisg;
gw;wpa midj;J tpguq;fisAk; ghpkhwpf; nfhs;s ,J
gad;gLfpwJ. CAD systemj;jpypUe;J IGESf;F jfty;fisg;
ghpkhw;Wk; software MdJ pre-processor vdg;gLk;. IGESypUe;J
jfty;fis kw;nwhU CAD systemj;jpw;F ghpkhw;Wk; software
MdJ post-processor vdg;gLk;.

CAD Pre- IGES Post- CAD

system A processor file processor system B

Fig.1.21 CAD data transfer using IGES

IGESy; mbg;gil tiuglq;fs; (entities) %yk; KOikahd

tiuglq;fs; Fwpg;gplg; gLfpd;wd. ,e;j entities fPo;ff
; z;l %d;W
gphpTfshfg; gphpf;fg;gLfpd;wd.
1) Geometry: xU nghUis tiuaWf;f cjTk; line, circle,
surface Nghd;wit.
2) Annotation: Dimension, notes, title block, Nghd;wit.
3) Structure: tiuglq;fis vspjhf cUthf;Ftjw;F>
entitiesfis ,izj;Jg; gad;gLj;Jk; Kiw.
IGESy;, xU 80 column fieldy;> recordfs; mike;jpUf;Fk;.
1 Kjy; 72 column tiu jfty;fSk;> 73 Kjy; 80tJ column
tiu Fwpg;gpl;l recordd; subsection mike;Js;s ,lj;ijf;
Fwpf;Fk; thpir vz;Zk; mike;jpUf;Fk;.

1.36
Sub–sections of IGES
IGES file fPo;f;fz;l Ie;J sub-sectionfisf; nfhz;Ls;sJ.
a) Start section : ,J column 73y;“S” vd;w vOj;J %yk;
fz;lwpag;gLk;. glj;jpd; source file, glj;ijg; gw;wpa
tpguq;fs;> format type Mfpait ,e;j gFjpapy;
Fwpf;fg;glyhk;.
b) Global section : ,J column 73y; “G” vd;w vOj;J %yk;
fz;lwpag;gLk;. ,e;jg; gFjpapy; glj;ijg; gw;wpa tpguq;fs;>
fileI cUthf;fpa egh; gw;wpa tpguq;fs;> Njjp>
gad;gLj;jg;gl;l drafting standard Mfpaitf; Fwpf;fg;
gl;bUf;Fk;.
c) Directory entry section : ,J column 73y; “D” vd;w vOj;J
%yk; fz;lwpag;gLk;. tiuglj;jpy; cs;s midj;J
enenties gw;wpa tpguq;fs; ,jpy; mlq;fp ,Uf;Fk;. xt;nthU
entryk; 8 characterfs; nfhz;l 20 fieldfSld; $ba ,uz;L
thpfisf; nfhz;bUf;Fk;. ,tw;wpy;> colour, linetype, view,
pointerfs; Nghd;wit Fwpf;fg; gl;bUf;Fk;.
d) Parameter data section : ,J column 73y; “P” vd;w vOj;J
%yk; fz;lwpag;gLk;. Entities njhlh;ghd tpguq;fs; ,jpy;
mlq;fp ,Uf;Fk;. Coordinate kjpg;Gfs;> curve kw;Wk; surface
coefficient, kw;w entitiesf;fhd pointerfs;> text character
kw;Wk; ,ju tpguq;fs; Mfpait ,jpy; Fwpg;gplg;
gl;bUf;Fk;.
e) Terminate section : ,J column 73y; “T” vd;w vOj;J %yk;
fz;lwpag;gLk;. xt;nthU sectionYk; mlq;fpAs;s
recordfspd; subtotal ,e;j sectiony; Fwpf;fg; gl;bUf;Fk;.

Disadvantages of IGES
1) IGES rpf;fyhdJ kw;Wk; mjpf thh;j;ijfs; mlq;fpaJ.
2) gad;gLj;jg;gLk; applicationIg;
nghWj;J IGES
rpwe;jjhfNth my;yJ NkhrkhdjhfNth ,Uf;Fk;.
3) IGES fiel MdJ mjd; picture fileI tpl Ie;J klq;F
mstpy; nghpaJ.
4) rpwg;ghd CAD gad;ghLfSf;Fj; Njitahd epiwa entities
,jpy; ,y;iy.

1.37
1.14 Drawing Exchange Format (DXF)
DXF MdJ Autodesk vd;w epWtdj;jhy; cUthf;fg;gl;l
format MFk;. ,J AutoCAD drawing filefis kw;w systemj;jpw;F
khw;Wtjw;F JizGhpfpwJ. AutoCAD mjpf mstpy; gad;gLj;jg;
gLtjhy;> ngUk;ghyhd CAD/CAM gadhsh;fs; ,jid xU
standard Mf Vw;wf; nfhz;Ls;sdh;. DXF file MdJ .DXF vd;w file
extension cld; $ba ASCII text file MFk;.
Organization of DXF file
DXF filed; mikg;G fPo;f;fz;l gFjpfisf; nfhz;bUf;Fk;.
a) HEADER section : glj;ijg; gw;wpa nghJthd tpguq;fis
,e;jg; gFjp nfhz;bUf;Fk;. xt;nthU recordf;Fk; xU
variable name kw;Wk; mjNdhL njhlh;Gila xU msT
Mfpait nfhLf;fg; gl;bUf;Fk;.
b) CLASSES section : Databased; BLOCKS, ENTITIES kw;Wk;
OBJECTS gFjpfspy; fhzg;gLk; classes gw;wpa tiuaiwfs;
,e;jg; gFjpfspy; Fwpf;fg;gLk;.
c) TABLES section : fPo;f;fz;l symbol tablefspd; tiuaiwfs;
,e;j gFjpapy; fhzg;gLk;.
1) Linetype table 2) Layer table
3) Text style table 4) User coordinate system table
5) View table 6) Viewport configuration table
7) Dimension style table 8) Application identification table
9) Block reference table
d) BLOCKS section : tiuglj;jpy; cs;s block refeenceI
cUthf;fg; gad;gLj;jg;gLk; entities gw;wpa tiuaiwfs;
kw;Wk; blocks gw;wpa tiuaiwfs; ,e;j gFjpapy;
fhzg;gLk;.
e) ENTITIES section : Block reference cl;gltiuglj;jpy;
gad;gLj;jg;gLk; midj;J mbg;gil gl cUtq;fisg;
gw;wpa tpguq;fSk; ,jpy; mlq;fp ,Uf;Fk;.
f) OBJECTS section : tiuglj;jpy; glq;fs; my;yhj kw;w
entities gw;wpa tpguq;fs; ,e;jg; gFjpapy; mlq;fp ,Uf;Fk;.
g) END OF FILE

1.38
Group and group codes in DXF
DXF file MdJ gy;NtW groupfisf; nfhz;bUf;Fk;.
xt;nthU groupk; ,uz;L thpfspy; Fwpf;fg;gLk;. Kjy; thp>
group codeIAk; ,uz;lhk; thp> group tifiaAk; Fwpf;Fk;. Filey;
tpthpf;fg;gLk; nghUspd; tifiar; rhh;e;J mjw;F mspf;fg;gLk;
group code khWgLk;. xU groupd; kjpg;G fPo;f;fz;l mbg;gilapy;
ngwg;gLfpwJ.

Group code range Following value

0–9 String
10 – 59 Floating point
60 – 79 Integer
210 – 239 Floating point
999 Comment (string)

Advantages of DXF
1) DXF MdJ kpfg;nghUj;jkhd vector file tif MFk;.
2) gy;NtW CAD programfSf;F ,ilNa jfty;fis ghpkhwpf;
nfhs;s DXF cjTfpwJ.
3) ve;j xU CAD/CAM softwareYk; ,jid edit nra;a ,aYk;.
4) DXF filefis rpWrpW gFjpfshf vspjpy; gphpf;fyhk;.
5) DXF MdJ nghJg;gad;ghl;bw;F ,ytrkhf fpilf;fpwJ.

Disadvantages of DXF
1) xU softwaref;nfd gpuj;jpNafkhf cUthf;fg;gl;l CAD
njhFg;Gfspy; ghpkhw;wk; nra;a DXF gad;glhJ.
2) rpf;fyhd DXF filefs; mstpy; kpfg; nghpajhf ,Uf;Fk;.
3) DXF filefspy; cs;s Nfhl;Lj; jbkd;fis rpy software
Vw;Wf; nfhs;tjpy;iy.

1.15 Finite Element Analysis (FEA)

Finite element analysis (FEA) vd;gJ gy;NtW ,aq;F
epiyfspy; ghfq;fspd; gz;Gfis fz;lwpa Nkw;nfhs;s f; $ba
engineering analysisf;F gad;gLk; xU computer simulation Kiw
MFk;.

1.39
1.15.1 Development of FEA
 Finite element method (FEM) vd;w
Ez;fzpj Kiw FEAy;
gad;gLj;jg; gLfpwJ. ,e;j Kiwapy; xU object my;yJ
system MdJ rpW rpW Ez;zpa gFjpfshf (finite elements)
gphpf;fg; gLfpwJ.
 xt;nthU elementf;Fk; xU rkepiyr; rkd;ghL ngwg;gl;L>
xUq;fpizf;fg; gl;l xU simultaneous equation cUthf;fg;
gLfpwJ. Linear algebra my;yJ non-linear numerical
schemefisf; nfhz;L> ,e;j rkd;ghl;bw;F jPh;T
fhzg;gLfpwJ.
 Finite-element method MdJ> civil kw;Wk; aeronautical Jiwapy;
rpf;fyhd elasticity kw;Wk; structural analysis njhlh;ghd
fzf;fPLfSf;F jPh;T fhz;gjw;nfd cUthf;fg;gl;l Kiw
MFk;.
 1968y;, NASA epWtdk; NASTRAN vd;w FEA softwareI Kjd;
Kjypy; mwpKfk; nra;jJ.
 1970y;, ANSYS vdg;gLk; xUq;fpize;j gy;Nehf;F gad;
nfhz;l FEA software cUthf;fg;gl;lJ.
 1971y;, MARC vd;w FEA software njhFg;G cUthf;fg; gl;lJ.
 1978y;, ABAQUS kw;Wk; DYNA3D Mfpa analysis software
cUthf;fg; gl;ld .
 Computer kw;Wk; hardwarefspd; mjpNtf tsh;r;rpapdhy;> 1990
Kjy; ,d;W tiu mjpf vz;zpf;ifapyhd FEA softwarefs;
njhlh;e;J cUthf;fg; gLfpd;wd.

1.15.2 Basic steps in FEA

Finite element analysis Kiwapy; fPo;f;fz;l %d;W gbfs; cs;sd.
1. Pre-processing
2. Analysis (Computation of solution)
3. Post processing (Visualization)

Pre-processing
 Pre-processing vd;gJ analyse nra;ag;gl Ntz;ba nghUspd;
finite element modelI cUthf;FtJ MFk;.

1.40
  Digital blueprintfs;, design filefs;, CAD modelfs;
Mfpatw;iwg; gad;gLj;jp ,j;jifa modelfis
cUthf;fyhk;.
 Meshing nray;Kiwapy; ,e;j model MdJ rpW rpW
Ez;zpa gFjpfshf gphpf;fg; gLfpwJ. ,e;j mesh model
MdJ elementfs; kw;Wk; nodefisf; nfhz;bUf;Fk;.
 FEA softwarefspy; node numberfis milahsg;
Gs;spfshff; nfhz;L jPh;T fzf;fplg;gLfpwJ.
 Elementfs; mesh number %yk; tiuaWf;fg; gLfpd;wd. xU
Fwpg;gpl;l elementd; deflection my;yJ stressIf;
fzf;fpLk;NghJ ,e;j mesh number mbg;gilahff;
nfhs;sg; gLfpwJ.

Analysis (computation of solution)

 nrYj;jg;gLk; tpir> kw;Wk; xt;nthU elementf;fhd
gz;Gfis mbg;gilahff; nfhz;L xU njhlh;r;rpahd
fzf;fPl;L nray;Kiwia FEA ifahs;fpwJ.
 ,j;jifa analysis %yk;> nrYj;jg;gLk; tpir> mOj;jk;
kw;Wk; gravity Mfpatw;why; Vw;gLk; deformation, strain,
stress Nghd;wtw;iw fzf;fplyhk;.

Post-processing (visualization)
 FEA softwarey; cs;s visualization toolfisg; gad;gLj;jp>
analysis Kbtpy; cUthFk; jPh;Tfis ghh;j;J myrp
Muhayhk;.
 ,jpYs;s numerical kw;Wk; graphical toolfisf; nfhz;L
stress kw;Wk; deflection Nghd;w mstPLfis kpfj;
Jy;ypakhf fz;lwpayhk;.

Applications of FEA
 Stress kw;Wk; displacementfis fz;lwpjy;
 Heat transfer
 Solid state diffusion
 Reactions with moving boundaries
 Fluid dynamics
 Electromagnetism
1.41
Advantages of FEA
 mjpf accuracy
 Nkk;gLj;jg;gl;l design
 kpfg; nghUj;jkhd design parameterfs;
 Virtual prototyping
 Fiwthd hardware prototypefs;
 Ntfkhd kw;Wk; Fiwe;j nryTs;s design cycle
 mjpf productivity
 mjpf tUkhdk;

Review Questions
5 Marks Questions :
1) Explain the activities of CAD in Shiley’s design process.
2) Briefly explain the Ohsuga model.
3) List out the benefits of CAD?
4) Briefly explain about CAD software packages.
5) Define the term AutoCAD. List out the advantages.
6) State the features of AutoCAD.
7) Define concatenation with an example.
8) List out the disadvantages of wire frame modelling .
9) List out the advantages and applications of surface models.
10) What are the various representation schemes available for
creating solid models?
11) State the applications of solid modelling .
12) Explain the boundary representation technique.
13) Give the comparison of CSG and B-Rep.
14) What is a graphic standard? List out the benefits of introducing
standards for computer graphics.
15) List out the common graphics standards used in CAD/CAM
applications.
16) State the features of GKS.
17) State the features of OpenGL.
18) Briefly explain the development of FEA.

1.42
10 Marks Questions :
1) Explain the various activities of CAD.
2) Briefly explain the following transformations with an example:
i) Translation ii) Scaling iii) Rotation
3) Explain 3D rotation and 3D translation.
4) Explain wire frame model with examples. State the applications
and advantages.
5) Explain the various types of surfaces used for constructing surface
models.
6) Discuss in detail the surface modelling technique.
7) Explain the various solid modelling entities.
8) Discuss solid modelling with an example. State its merits and
demerits.
9) Explain with an example how complicated solid objects are
created in solid modelling by performing Boolean operations.
10) Compare the wire frame modelling , solid modelling and surface
modelling techniques.
11) Explain the implementation of GKS in CAD system.
12) Explain the OpenGL pipeline process. State its application and
advantages.
13) Explain the structure of IGES file.
14) Explain the organisation of DXF file. List out its advantages and
disadvantages.
15) What is Finite Elements Analysis(FEA). Explain the basic steps.
16) List out the applications and advantages of FEA.



1.43
 Unit – II
COMPUTER AIDED MANUFACTURING
2.1 Computer Aided Manufacturing (CAM)
Manufacturing, planning kw;Wk; control Mfpa nray;ghLfspy;
computer njhopy;El;gj;ij jpwk;gl gad;gLj;JtNj Computer
Aided Manufacturing MFk;.

Need of CAM
fPo;f;fz;ltw;iwg; ngWtjw;F CAM Njitg;gLfpwJ.
 cw;gj;jp tpfpjj;ij mjpfhpg;gjw;F
 Accuracy kw;Wk; juj;ij mjpfhpg;gjw;F
 nghUl;fs; cw;gj;jpapy; flexibilityI Nkk;gLj;Jtjw;F
 nghUl;fis cw;gj;jp nra;a MFk; nkhj;j Neuj;ij
Fiwg;gjw;F
 ek;gfj;jd;ikia Nkk;gLj;Jtjw;F
 Scrap kw;Wk; reworkI Fiwg;gjw;F
 ,ae;jpuq;fspd; guhkhpg;Gr; nryitf; Fiwg;gjw;F

2.2 Functions of CAM (or) Activities of CAM

CAMd; nray;ghLfs; fPo;f;fz;l ,uz;L ngUk; gphpTfshfg;
gphpf;fg; gLfpd;wd.
1) Manufacturing planning 2) Manufacturing control

1) Manufacturing planning
nghUl;fis cw;gj;jp nra;tjw;F jpwk;gl jpl;lkpLjy; kw;Wk;
cw;gj;jp nray;Kiwfis eph;tfpj;jy; Mfpatw;wpw;Fj; Njitahd
jfty;fisg; ngWtjw;F computer kiwKfkhfg; gad;gLj;jg;
gLfpwJ. cw;gj;jpia jpl;lkpLjypy; fPo;f;fz;l nray;ghLfs;
mlq;fpAs;sd.
 Computer Assisted Process Planning (CAPP): xU nghUis
cw;gj;jp nra;tjw;Fj; Njitahd machinefs; kw;Wk;
nray;Kiwfspd; thpirfs; mlq;fpa route sheet jahhpj;jy;.
 Computer assisted NC part programming: CAM software
fisg; gad;gLj;jp NC part programfis cUthf;Fjy;.
 Computerized machinability data system: ntt;NtW
materialfSf;F jFe;j machinability dataf;fis toq;Fjy;.

2.1
 Development of work standard: Work standardfis
eph;zapj;jy;.
 Cost estimating: xU Gjpa nghUspd; tpiyia eph;zapj;jy;.
 Production and inventory planning: Production scheduling,
material requirement planning kw;Wk; capacity planning
Nghd;wtw;iw eph;tfpj;jy;.
 Computer aided line balancing: Assembly liney; cs;s work
stationfSf;F Ntiyfis Kiwahf gphpj;Jf; nfhLj;jy;.

2) Manufacturing control
Computer systemfisg; gad;gLj;jp njhopw;rhiyapy;
eilngWk; ntspg;gilahd nray;fis fl;Lg;gLj;Jjy; kw;Wk;
eph;tfpj;jy; Mfpait ,jpy; mlq;Fk;. cw;gj;jpia fl;Lg;
gLj;Jjypy; fPo;f;fz;l nray;ghLfs; mlq;Fk;.
 Process monitoring and control: cw;gj;jp ,ae;jpuq;fs; kw;Wk;
cw;gj;jp nray;Kiwfis fz;fhzpj;jy;.
 Quality control: cw;gj;jp nra;ag;gl;l nghUspd; mjpfgl;r
juj;ij cWjp nra;tjy;.
 Shop floor control: cw;gj;jp eilngWk; ,lj;jpypUe;J
jfty;fis Nrfhpj;J> mtw;iwf; nfhz;L computer cjtpAld;
cw;gj;jp nray;Kiw kw;Wk; inventory Mfpatw;iw
fl;Lg;gLj;Jjy;.
 Inventory control: xU epWtdj;jpy; Njitahd rhpahd msT
%yg;nghUl;fspd; ifapUg;ig guhkhpj;jy;.

2.3 Benefits of CAM (or) Advantages of CAM

CAMI gad;gLj;Jtjhy; fPo;f;fz;l gyd;fs; fpilf;fpd;wd.
1) tbtikg;gpy; mjpf flexibility
2) mjpf cw;gj;jpj; jpwd;
3) cw;gj;jp nray;Kiwfspy; mjpf flexibility
4) Fiwthd cw;gj;jp Neuk;
5) mjpf ek;gfj;jd;ik
6) Fiwthd guhkhpg;G
7) Fiwthd scrap kw;Wk; rework
8) rpwe;j eph;thf fl;Lg;ghL

2.2
2.4 Group technology
Group Technology (GT) vd;gJ design kw;Wk; manufacturing
nray;Kiwfspy; ghfq;fSf;F ,ilNaAs;s xw;Wikapd;
mbg;gilapy; mtw;iw tifg;gLj;jp> xl;L nkhj;j cw;gj;jp
nryitf; Fiwf;Fk; xU cw;gj;jp topKiw MFk;.

T T T CG CG

T T T SG SG
T - Turning
M - Milling
D - Drilling
CG - Cylindrical Grinding
M M D D D SG - Surface Grinding

M M D D D

Fig.2.1 Process type layout

T M D SG

T M D CG

T T M CG

M D D

Fig.2.2. Group Technology layout

Process layouty;> xNu khjphpahd operationf;F gad;gLk;

midj;J machine toolfSk; xU department Mf tifg;
gLj;jg;gl;L xNu ,lj;jpy; mikf;fg; gl;bUf;Fk;. xU ghfj;ij
OOikahf nra;J Kbf;f mJ ntt;NtW departmentfs; topahf
nry;y Ntz;bAs;sJ. ,jw;fhf me;j part mjpf J}uk; gazk;
nra;a Ntz;bAs;sJ. ,J tPzhd nray; MFk;.

Product layouty;> xU ghfj;ij cUthf;Ftjw;Fj; Njitahd

operationfspd; thpirg;gb> Njitahd machine toolfs; mikf;fg;

2.3
gl;bUf;Fk;. ,e;j layout %yk; part mjpf J}uk; gazk; nra;tJ
jtph;f;fg; gLfpwJ. Batch size rpwpajhf ,Uf;Fk;NghJ> midj;J
machine toolfisAk; KOtJkhf load nra;a ,ayhJ. ,jdhy;
machine toolfspd; gad;ghl;L tPjk; FiwfpwJ.

Partfis xU family Mf tifg;gLj;jp> xt;nthU

partf;Fkhd cw;gj;jp Njitfis xUq;fpizg;gjd; %yk;> batch
sizeI nghpjhf;fyhk;. ,e;j topKiwNa Group Technology
vdg;gLfpwJ. ,jd; %yk; fpilf;fg; ngWk; layout MdJ Group
Technology layout vdg;gLk;.

fPo;f;fz;l #o;epiyfspy; GT kpfTk; cfe;jjhf ,Uf;Fk;.

 goq;fhy process type layout kw;Wk; batch productionI
ifahSk; njhopw;rhiyfs;
 Part familyfshf tifg;gLj;j Vw;w tifapy; gy;NtW
tifahd partfis jahhpf;Fk; njhopw;rhiyfs;

2.4.1 Concept of part families

Part 1 Part 2
10,000/Yr 100/Yr
Tolerance ±0.05 Tolerance ±0.001
Nickel plate Stainless steel
(a) Similar design attributes but different manufacturing attributes

(b) Similar manufacturing attributes but different design attributes

Fig.2.3 Part families
Part family vd;gJ gy;NtW ghfq;fs; mlq;fpa njhFg;ghFk;.
,jpy; cs;s ghfq;fs; mtw;wpd; tbtk; kw;Wk; mstpy;
xd;Wgl;Nlh> my;yJ mtw;iw jahhpg;gjw;F Nkw;nfhs;sg;gLk;
nray;Kiwfspy; xd;Wgl;Nlh ,Uf;Fk;. xU familyy; cs;s

2.4
ghfq;fs; ntt;Ntwhf ,Uf;fyhk;. Mdhy; ,e;j part familyd;
cWg;gpdh;fshf mtw;iw milahsk; fhZk; tifapy; mtw;wpw;
fpilNa xw;Wikfs; ,Uf;f Ntz;baJ mtrpak; MFk;.

Fig.2.3 (a)y; fhl;lg;gl;Ls;s ,uz;L ghfq;fSk; mtw;wpd;

designIg; nghWj;J xd;Wgl;l gz;Gfisg; ngw;wpUf;fpd;wd.
Mdhy; manufacturingIg; nghWj;j tiuapy; ntt;NtW
gz;Gfisg; ngw;wpUf;Fk;. mNj Nghd;W Fig.2.3(b)y; fhl;;lg;gLs;s
,uz;L ghfq;fSk; manufacturingI nghWj;j tiuapy; xNu
khjphpahd gz;GfisAk;> designIg; nghWj;j tiuapy; NtWgl;l
gz;GfisAk; ngw;wpUf;fpd;wd.
nghJthf ghfq;fis tifg;gLj;Jtjw;F fPo;f;fz;l %d;W
topKiwfs; filg;gpbf;fg; gLfpd;wd.
a) Visual inspection: ,J kpfTk; vspa kw;Wk; nryT Fiwe;j xU
nray;Kiw MFk;. ,jpy; ghfq;fspd; gz;Gfis NeubahfNth
my;yJ photography %yNkh ghh;j;J> mtw;wpw;fpilNa cs;s
xw;Wikapd; mbg;gilapy;> part familyfshf tifg; gLj;jg;
gLfpd;wd. %d;W Kiwfspy;> Fiwthd accuracy nfhz;l Kiw
,JthFk;.
b) Production flow analysis (PFA): ,e;j Kiwapy;> ghfq;fis
jahhpg;gjw;F cUthf;fg;gLk; route sheetfis myrp Muha;e;J>
xNu khjphpahd cw;gj;jp nray;Kiwfspd; thpirfisf; nfhz;l
ghfq;fs; xd;WgLj;jg;gl;L part family Mf tifg;gLj;jg;gLk;.
c) Parts classification and coding: ,J kpfTk; rpf;fyhd kw;Wk;
mjpf Neuk; gpbf;Fk; nray;Kiw MFk;. ,Ug;gpDk;> ,JNt
mjpfkhf gad;gLj;jg;gLtJk; mjpf jpwd; nfhz;l nray;
KiwAk; MFk;. ,e;j Kiwapy; ghfq;fSf;F ,ilNaAs;s
xw;Wikfs; fz;lwpag;gl;L> mit coding Kiwapy;
fhz;gpf;fg;gLk;.

2.4.2 Parts classification and coding

 Parts classification vd;gJ ghfq;fSf;F ,ilNa cs;s gz;G
fspd; xw;Wikia mbg;gilahff; nfhz;L> mtw;iw familyMf
tifg;gLj;Jjy; MFk;. Coding vd;gJ xU componentf;fhd
gpuj;jpNafkhd symbolI toq;FtJ MFk;.

2.5
 Part classification kw;Wk; coding nray;KiwahdJ> xt;nthU
ghfj;jpd; design kw;Wk; manufacturing gz;Gfis Muha;tjpy;
,Ue;J njhlq;FfpwJ.
 mjpf vz;zpf;ifapy; classification kw;Wk; coding systemfSk;>
coding nra;tjw;fhd software packagefSk; ,Uf;fpd;wd.
xt;nthU epWtdj;jpd; gad;ghl;bw;Nfw;g ,it khw;wp
mikf;fg;gl Ntz;Lk;.
 Classification nra;tjw;F nghJthf fUjg;gLk; design kw;Wk;
manufacturing gz;Gfs;:

Part design attributes Manufacturing attributes

Basic external shape Major processes
Basic internal shape Minor operations
Rotational or rectangular shape Operation sequence
Length to diameter ratio (Rotational parts) Major dimension
Aspect ratio (Rectangular parts) Surface finish
Material type Machine tool
Part functions Production cycle time
Major dimensions Batch size
Minor dimensions Annual production
Tolerances Fixture required
Surface finish Cutting tools

Application of parts classification and coding

 Design retrieval: xU Gjpa ghfj;ij cUthf;Fk;NghJ>
Vw;fdNt cs;s ghfj;ij jpUk;gTk; vLj;J gad;gLj;jpf;
nfhs;s mjd;; part code cjTk;.
 Automated process planning: xU Gjpa ghfj;jpd; part codeI
gad;gLj;jp> ,NjNghd;w part code nfhz;l ghfq;fs; Vw;fdNt
cs;sjh vd;gijf; fz;lwpe;J> mjw;fhd process planIAk;
gad;gLj;jpf; nfhs;s KbAk;.
 Machine cell design: xU Fwpg;gpl;l part familyy; cs;s
midj;J ghfq;fisAk; cUthf;Ftjw;F Vw;g machine
cellfis tbtikg;gjw;F part codefs; cjTfpd;wd.

2.6
2.4.3 Coding structure
xU part coding scheme MdJ> ghfq;fspd; design kw;Wk;
manufacturing gz;Gfis milahsk; fhZk; tifapy; thpirahf
mikf;fg;gl;l FwpaPLfisf; nfhz;lJ MFk;. Codey; cs;s
FwpaPLfs; midj;Jk; vz;fshfNth> midj;Jk; vOj;JfshfNth>
my;yJ vz;fs; kw;Wk; vOj;Jfs; fye;jitahfNth ,Uf;fyhk;.
xU part codey; ,e;j FwpaPLfs; mike;Js;s tpjNk coding
structure vdg;gLk;.

Group technology gad;ghLfspy; fPo;f;fz;l %d;W tifahd

coding structurefs; gad;gLj;jg; gLfpd;wd.
1) Hierarchical structure (or) Monocode structure
2) Chain type structure (or) Polycode structure
3) Hybrid structure (or) Mixed mode structure

1) Hierarchical structure
,e;j structurey;> xt;nthU FwpaPl;bw;fhd mh;j;jKk;> mjw;F
Kd;G cs;s FwpaPl;bd; kjpg;ig nghWj;J mikAk;.
Example:
15 my;yJ 25 vd;w ,uz;L ,yf;f code numberIf; nfhz;l
ghfj;ijf; fUJNthk;. Kjy; ,yf;fk; ghfj;jpd; nghJthd
tbtj;ijf; Fwpg;gjhf fUJNthk;. FwpaPL 1 vd;gJ cylinder
tbtj;ijAk;> FwpaPL 2 vd;gJ rectangular tbtj;ijAk; Fwpf;Fk;.
Hierarchical structurey;> code 15y; cs;s 5 vd;w FwpaPL length
kw;Wk; diameterf;F ,ilNaahd aspect ratioIf; Fwpf;Fk;. Mdhy;>
code 25y; cs;s 5 vd;w mNj FwpaPL length kw;Wk; widthf;F
,ilNaahd aspect ratioIf; Fwpf;Fk;.

Advantages
 ,e;j structured; tbtk; vspjhdjhf ,Uf;Fk;.
 ,jpy; Fiwthd ,yf;fq;fisf; nfhz;l code %yk; mjpf
jfty;fis $w KbAk;.
2) Chain type structure
,e;j structurey;> xt;nthU FwpaPl;bw;fhd mh;j;jKk;
vg;nghOJk; khwhky; ,Uf;Fk;. NkYk; mjw;F Kd;G cs;s
FwpaPl;bd; kjpg;ig nghWj;J khwhJ.

2.7
Example:
15 my;yJ 25 vd;w ,uz;L ,yf;f code numberIf; nfhz;l
ghfj;ijf; fUJNthk;. Chain type structurey;> Nkw;fz;l ,uz;L
codeYk; cs;s 5 vd;w FwpaPL mjw;F Kd;G ve;jf; FwpaPL
te;jhYk; xNu mh;j;jj;ijf; nfhz;bUf;Fk;. cjhuzkhf>
ghfj;jpd; xl;Lnkhj;j ePsj;ij mJ Fwpg;gplyhk;.

Advantages
 xU ghfj;jpd; Fwpg;gpl;l gz;Gfis vspjhf milahsk; fhz
KbAk;.
 xNu khjphpahd cw;gj;jpj; Njitfs; nfhz;l ghfq;fis
fz;lwptjw;F ,J cjtpahf ,Uf;Fk;.

3) Hybrid structure
,J hierarchical kw;Wk; chain type structurefs; ,ize;jJ
MFk;. ,uz;L structurefspYk; cs;s gad;fis xUq;fpizj;J
hybrid structure gad;gLj;jpf; nfhs;fpwJ. GT part classification
kw;Wk; coding systemj;jpy; ,e;j structure mjpf mstpy;
gad;gLj;jg; gLfpwJ. FWfpa polycode fis thpirahf mikj;J
hybrid codefs; Njhw;Wtpf;fg; gLfpd;wd. Design kw;Wk;
manufacturing gz;Gfs; ,uz;bw;Fk; ,J rpwe;j structure MFk;.

2.4.4 Parts classification and coding systems

fPo;f;fz;l part classification kw;Wk; coding systemfs;
nghJthfg; gad;gLj;jg; gLfpd;wd.
1) Opitz system 2) MICLASS system 3) The CODE system
4) DCLASS system 5) COFORM system 6) The KK–3 system

1) Opitz classification system

H. Opitz vd;gtuhy; ,e;j system Njhw;Wtpf;fg; gl;lJ. Opitz
system MdJ fPo;f;fz;lthW ,yf;f thpiriaf; nfhz;bUf;Fk;.

12345 6789 ABCD

s

Form code Supplementary Secondary

Code code

2.8
  ,jpy; mbg;gil code MdJ xd;gJ ,yf;fq;fisf;
nfhz;bUf;Fk;. NkYk; ehd;F ,yf;fq;fis ,izj;J
,jid ePl;bf; nfhs;s KbAk;.
 Kjy; Ie;J ,yf;fq;fs; (12345) form code vd miof;fg;gLk;.
ghfq;fspd; Kjd;ikahd design gz;Gfis ,it tiuaWf;
fpd;wd.
 mLj;j ehd;F ,yf;fq;fs; (6789) supplementary code vd
miof;fg;gLk;. ,J rpy manufacturing gz;Gfis Rl;bf;
fhl;Lk;.
 $Ljyhd ehd;F ,yf;fq;fs; (ABCD) secondary code
vdg;gLk;. cw;gj;jp nray;Kiwfspd; tif kw;Wk; thpiria
milahsk; fhz;gjw;fhf> xt;nthU epWtdj;jpd; %yKk;
,e;j ,yf;fq;fs; cUthf;fg;gLk;.

Supplementary
Digit 1 Digit 2 Digit 3 Digit 4 Digit 5 code
Part class Digit
Main shape Rotational Plane surface Additional holes 6 7 8 9
machining machining teeth and forming
0 L/D<0.5
External Internal Machining of Other holes
1 0.5<L/D<3 shape shape plane surfaces and teeth

Original shape of raw material

element element
2 L/D>3
With deviation
3 L/D<2 Other holes,
Rotatiional Machining of teeth and
Main shape
Dimension

With deviation machining plane surfaces

Accuracy
Material

4 forming
L/D>2
5 Special
Main shape
A/B<3
6 A/C>4
Main bore and Other holes,
Main shape rotational Machining of teeth and
7 A/B>3 plane surfaces
machining forming
A/B<3
8 A/C<4
Main shape
9 Special

Fig.2.4 Basic structure of Opitz classification system

Opitz parts classification kw;Wk; coding systemj;jpd; mbg;gil

structure MdJ Fig.2.4y; fhl;;lg;gl;Ls;sJ. nfhLf;fg;gl;l ghfk;
RoYk; tifiar; rhh;e;jjh ,y;iyah vd;gij milahsk; fhz
Kjy; ,yf;fk; gad;gLk;. NkYk; ghfj;ijg; gw;wpa nghJthd
tbtk; kw;wk; tpfpjq;fisAk; ,J tiuaWf;fpwJ. RoYk; tif
ghfq;fSf;fhd form code Fig.2.5y; tpsf;fg;gl;Ls;sJ.

2.9
 Digit 1 Digit 2 Digit 3 Digit 4 Digit 5
External shape, Internal shape,
Part class external shape internal shape Plane surface machining Auxiliary holes and gear teeth
elements elements

Smooth, no Smooth, no shape

0 L/D≤ 0.5 0 0 0 No surface machining 0 No auxiliary hole
shape elements elements

Surface plane and/or

No shape No shape Axial, not on pitch
1 0.5<L/D<3 1 1 1 curves in one direction, 1
Elements Elements circle diameter
external
External plane surface
Axial on pitch
2 L/D≥3 2 Thread 2 Thread 2 related by graduation 2
circle diameter
around the circle

or smooth
or smooth
Functional Functional External groove Radial, not on pitch
3 3 3 3 3

Stepped to one end

Stepped to one end
Groove Groove and/or slot circle diameter

Rotational parts
Rotational parts

Axial, and/or radial

No shape No shape External spline
4 4 4 4 4 and/or other
Elements Elements (polygon)
direction
External plane surface Axial, and/or radial
5 5 Thread 5 Thread 5 and/or slot, external 5 on PCD and/or other

ends
ends
spline direction

Functional Functional Internal plane surface

Stepped to both
Stepped to both
6 6 6 6 6 Spur gear teeth
Groove Groove and/or slot

7 7 Functional cone 7 Functional cone 7 Internal spline (polygon) 7 Bevel gear teeth

Internal and external

8 8 Operating thread 8 Operating thread 8 polygon, groove and/or 8 Other gear teeth
slot

Non rotational parts

Non rotational parts

9 9 All others 9 All others 9 All others 9 All others

Fig.2.5 Form code for rotational parts in Opitz system

2.10
Example

M10

Ø8

20
25

12.5
20
40

Fig.2.6 Example for Opitz system

Fig.2.6y; fhl;;lg;gl;Ls;s RoYk; tif ghfj;jpw;fhd form
codeI eph;zapf;Fk; Kiw fPNo tpsf;fg;gl;Ls;sJ.

Digit 1 Digit 2 Digit 3 Digit 4 Digit 5

Auxiliary
Internal Plane surface
Part class External shape holes and
shape machining
gear teeth
Stepped on both Part No auxiliary
L 40 No plane
Details = = 1.64 ends with screw contains a holes and
D 25 surface
thread on one end through hole gear teeth
Form
1 5 1 0 0
code

Opitz systemj;jpy;> Nkw;fz;l ghfj;jpw;fhd form code 15100 MFk;.

2) MICLASS coding system

 MICLASS vd;gJ Metal Institute CLASsification System
vd;gjd; RUf;fk; MFk;.
 MICLASS code MdJ 12 Kjy; 30 ,yf;fq;fs; nfhz;ljhf
,Uf;Fk;.
 Kjy; 12 ,yf;fq;fs; ve;j xU ghfj;jpw;Fk; nghUe;jf; $ba
universal code MFk;.
 kw;w ,yf;fq;fs;> Fwpg;gpl;l epWtdj;jpd; %yk; cUthf;fg;
gLgit MFk;.
 Kjy; 12 ,yf;fq;fspy; tiuaWf;fg;gLk; ghfj;jpd; gz;Gfs;:

2.11
 Digit Attribute
1st digit Main shape
2nd and 3rd digit Shape elements
4th digit Position of shape elements
5th and 6th digits Main dimension
7th digit Dimension ratio
8th digit Auxiliary dimension
9th and 10th digit Tolerance codes
11th and 12th digit Material codes

 ghfq;fis coding nra;tjpy; computerIg; gad;gLj;JtNj

MICLASS sysmtej;jpd; Kf;fpa mk;rkhFk;.
 xU ghfj;ij coding nra;tjw;F> computer %yk; Nfl;fg;gLk;
thpirahd Nfs;tpfSf;F user gjpyspf;f Ntz;Lk;.
ngUk;ghyhd Nfs;tpfs; ‘Yes’ my;yJ ‘No’ tif gjpy;fisf;
nfhz;ljhf ,Uf;Fk;.

Example :
60

Ø6 Ø11

Ø75
Material
50 CC15
40
9.5
50
27

Fig.2.7 Example for MICLASS system

2.12
 Fig.2.7y; fhl;lg;gl;Ls;s ghfj;jpw;F> MICLASS coding
systemj;ij mbg;gilahff; nfhz;L computer %yk; ngwg;gl;;l
universal part code 1271 3231 3144 MFk;.

3) The CODE system of part classification

 Part design dataf;fis jpUk;gg; ngWtJ> process planning,
purchasing, tool design kw;Wk; inventory control Mfpa nray;
ghLfSf;F ,e;j system cjtpahf ,Uf;Fk;.

 ,jd; part code number MdJ vl;L ,yf;fq;fisf;

nfhz;ljhf ,Uf;Fk;. xt;nthU ,yf;fKk; 16 ntt;Ntwhd
kjpg;Gfis (0 - 9 and A - F) ngwyhk;. ,e;j ,yf;fq;fs;
ghfq;fspd; design kw;Wk; manufacturing gz;Gfis
tpsf;Ftjhf ,Uf;Fk;.
 Kjy; ,yf;fk; major division vd miof;fg;gLk;. Cylinder,
flat piece, block my;yJ gpw tbtk; Mfpa nghUspd;
tbtj;ijf; Fwpg;gpl Kjy; ,yf;fk; gad;gLj;jg;gLk;.

 mLj;J tUk; 7 ,yf;fq;fSk; kjpg;GfSk;> Kjy; ,yf;fj;jpd;

kjpg;ig nghWj;J mikAk;. Mdhy;; ,e;j VO ,yf;fq;fSk;
chain type structurI cUthf;Fk;. vdNt CODE system xU
hybrid structure MFk;;.

 CODE systemj;jpy; ,yf;fq;fs; fPo;f;fz;lthW Fwpg;gplg;

gLfpd;wd.

Digit Attribute
1 External shape
2 - 3 nghUspd; mbg;gil tbtk; gw;wpa $Ljy; tpguq;fs;
kw;Wk; manufacturing njhlh;ghd Kf;fpa tpguq;fs;
4 - 6 Thread, groove. slot Nghd;w secondacy manufacturing
nray;Kiwfs;
7 - 8 Partd; xl;Lnkhj;j msT (Diameter, overall length, etc.)

2.13
Example

Fig.2.8 Example for CODE classification system

CODE classification systemj;jpy;> Fig.2.8y; fhl;lg;gl;Ls;s

ghfj;jpw;fhd part code 1388D75 MFk;.

2.4.5 Benefits of Group Technology

1) Vw;fdNt cs;s designI databasey; ,Ue;J vspjhf jpUk;g
ngw KbAk;.
2) Design standardizationf;Fg; gad;gLfpwJ.
3) Process planfis Nkk;gLj;Jtjw;Fk; standardize nra;tjw;Fk;
cjtp nra;fpwJ.
4) Set up time Fiwf;fg;gLfpwJ.
5) Production rate mjpfhpf;fpwJ.
6) Work-in-process kw;Wk; inventory Fiwf;fg; gLfpwJ.
7) Material handling kw;Wk; efh;Tfs; Fiwf;fg; gLfpwJ.
8) nghUspd; juk; Nkk;gLj;jg; gLfpwJ.
9) Scrap Fiwf;fg; gLfpwJ.
10) Machined; gad;ghl;L tPjk; mjpfhpf;fpwJ.
11) vQ;rpAs;s shop floor area mjpfhpf;fg; gLfpwJ.
12) njhopw;rhiyapd; xl;Lnkhj;j efficiency mjpfhpf;fpwJ.

Limitations
1) GTI epWTtjw;F mjpf nrythFk;.
2) kpf mjpf vz;zpf;ifapy; khWgl;l nghUl;fis jahhpf;Fk;
njhopw;rhiyfSf;F ,J Vw;wjy;y.

2.14
 3) xU epWtdj;jpd; nkhj;j cw;gj;jpiaAk; GT %yk; Nkw;nfhs;s
KbahJ.
4) gutyhf Vw;Wf;nfhs;sf; $ba part classification kw;Wk;
coding system vJTk; ,y;iy.
5) Product familyy;
Vw;gLk; khw;wj;jpw;F Vw;g GT cell khw;wp
mikf;fg;gl Ntz;Lk;.

2.5 Process planning

xU nghUis Fwpg;gpl;l msTfSld; cw;gj;jp nra;tjw;F
gpd;gw;wg;gl Ntz;ba kpfg; nghUj;jkhd cw;gj;jp nray;Kiwfs;>
assembly nray;Kiwfs; kw;Wk; nray;Kiwfspd; thpir
Mfpatw;iwf; fz;lwptNj process planning MFk;.

Process planning cUthf;Fk; nray;Kiwapy; fPo;f;fz;lit

mlq;fpAs;sd.
 Interpretation of design drawing: cw;gj;jp nra;ag;gl
Ntz;ba nghUSf;fhd material, dimension, tolerance,
surface finish Nghd;w design tpguq;fs; Kjypy; Muhag;gl
Ntz;Lk;.

 Selection of process and sequence: nghUis cw;gj;jp

nra;tjw;F kpfTk; nghUj;jkhd nray;Kiwfs; kw;Wk; mjd;
thpiriaj; Njh;T nra;a Ntz;Lk;.

 Selection of equipment: epWtdj;jpy; jw;NghJs;s ,ae;jpuq;

fisg; gad;gLj;Jk; tifapy; process plan cUthf;fg;gl
Ntz;Lk;.

 Selection of tools, dies, moulds, fixtures and gauges:

xt;nthU cw;gj;jp nray;Kiwf;Fk; Njitahd fUtpfis
Njh;T nra;a Ntz;Lk;.

 Setting work standards: xt;nthU Fwpg;gpl;l

nray;Kiwf;Fk; Njitahd Neuj;ijf; fzf;fpl;L work
standardfis cUthf;f Ntz;Lk;.

 Selection of cutting tools and cutting condition: Hand

bookI mbg;gilahff; nfhz;L> xt;nthU nray;Kiwf;Fk;
Njitahd mbg;gil tpguq;fis Fwpg;gpl Ntz;Lk;.

2.15
Route sheet
xt;nthU Fwpg;gpl;l ghfj;ijAk; cw;gj;jp nra;tjw;F
gpd;gw;w Ntz;ba nray;Kiwfspd; thpir kw;Wk; mJ njhlh;ghd
tpguq;fs; Fwpf;fg;gl;l gbtk; route sheet vdg;gLk;.

Route sheet ABC Machine Shop Pvt. Limited.

PartNo. PartName Planner Checked by Date: Page:
05879 Generator shaft 1/1
Material Stock Size Comments:
1050 H18 60mm dia. 206 mm
Al length
No. Operation description Dept. Machine Tooling Setup Std.
10 Rough turn to 52mm dia. and Lathe L38 G098 60 min. 5 min.
finish turn to 50mm dia.
20 Drill 4 radial holes 7.5mm Drill D07 J333 30 min. 3 min.
dia.
30 Mill 6 mm deep x 5 mm wide Mill M05 F765 80 min. 5 min.
slot

Fig.2.9 Typical route sheet

xU route sheet fPo;f;fz;l tpguq;fs; mlq;fpajhf ,Uf;Fk;.

1) xU ghfj;ij cw;gj;jp nra;aj; Njitahd midj;J nray;
KiwfSk; mJ mLj;jLj;J nra;ag;gl Ntz;ba thpirapy;
nfhLf;fg;gl;bUf;Fk;.
2) xt;nthU nray; Kiwf;Fkhd Kf;fpa msTfs;> tolerance
Mfpait gw;wpa rpwpa Fwpg;G.
3) xt;nthU nray;KiwAk; nra;ag;gl Ntz;ba machine.
4) Die, mould, cutting tool, jig, fixture kw;Wk; gauge Nghd;w
VNjDk; gpw rpwg;G fUtpfs;.
5) Setup time, standard cycle time, kw;Wk; ,ju tpguq;fs;.

2.5.1 Requirements for process planning

1) cw;gj;jp nra;ag;gl Ntz;ba nghUspd; vz;zpf;if.
2) nghUspd; gy;NtW ghfq;fspd; gl;bay;.
3) jw;NghJs;s %yg;nghUl;fspd; msTfs;.
4) jw;NghJ epWtdj;jpy; cs;s ,ae;jpuq;fisg; gw;wpa tpguq;fs;.

2.16
 5) Njitahd tool, die, mould, fixture kw;Wk; gauge gw;wpa
tpguq;fs;.
6) Njitg;gLk; accuracy kw;Wk; surface finish.
7) Speed, feed, depth of cut kw;Wk; number of passes Nghd;w
jfty;fs;.

2.6 Computer Assisted Process Planning (CAPP)

Computer programfspd; cjtpAld; process planI jhdhfNt
cUthf;Fk; Kiw Computer Assited Process Planning vdg;gLk;.
Geometric Inspection Machine
input feature tool tool Material
based database database database

Fixture Cutting
Pocket Database tool
identification database editor database

Setup Standard Cutting process

Tool time parameter
identification planning optimization
estimator

Process
sequencing

Process
sheet
generation

Fig.2.10 Structure of CAPP

Structure of CAPP
 xU ghfj;jpd; geometric model MdJ process planning
systemj;Jf;fhd input Mf mikfpwJ.
 nfhLf;fg;gl;l ghfj;jpd; gz;Gfisg; nghWj;J> me;jg;
ghfj;ij cw;gj;jp nra;aj; Njitg;gLk; nray;Kiwfspd;
thpiria computer program jhdhfNt cUthf;fp
nfhLf;fpwJ.
 Part design, manufacturing trjpfs; Mfpatw;iw xd;Wf;
nfhd;W njhlh;Gila FOf;fshf tifg;gLj;Jjy; CAPPd;
Kf;fpa nray; MFk;.
2.17
  ,t;thW tifg;gLj;jg;gl;L> CAD database, machine
database, tool database, material database, fixture database
Nghd;wit cUthf;fg;gLfpd;wd.
 CAPP systemj;jpy; cs;s modulefs; ,e;j database cjtpAld;
Muha;e;J xU kpfr; rpwe;j process planI cUthf;Fk;.

Approaches to CAPP

1) Variant approach
 ,J retrieval approach vdTk; miof;fg;gLk;. ,jpy;>
xt;nthU part familyf;Fkhd Group Technology (GT) codeI
gad;gLj;jp> Vw;fdNt cs;s master process plany; ,Ue;J
jFe;j process plan Njh;T nra;ag;gLfpwJ. gpd;G Njitg;gLk;
ghfj;ij cw;gj;jp nra;a Vw;wthW me;j process plan jpUj;jp
mikf;fg; gLfpwJ.

2) Generative approach
 ,e;j topKiwapy;> xt;nthU ghfj;jpw;Fkhd process plan
Gjpjhf njhlf;fj;jpypUe;J jahhpf;fg; gLfpwJ.
 ,e;j topKiwapy;> manufacturing database kw;Wk; part
description schemefspd; cjtpAld; xU Fwpg;gpl;l
ghfj;jpw;fhd process plan cUthf;fg; gLfpwJ.
 ngUk;ghyhd CAPP systemfs; ,e;j topKiwiaNa gpd;
gw;Wfpd;wd.

2.6.1 Operation of Variant type CAPP system

Part Process plan Process

Description GT code Retrieve/Edit plan

Master
plans

Fig.2.11 Variant type to CAPP

2.18
 xU CAPP system ,aq;Ftjpy; fPo;f;fz;l gbepiyfisf;
nfhz;Ls;sJ.
1) Preparatory stage
2) Process planning stage
3) Report generation

1) Preparatory stage
,jpy; fPo;f;fz;lit mlq;Fk;.
 Group TechnologyIg; gad;gLj;jp> jFe;j classification kw;Wk;
coding Kiwiaj; Njh;T nra;a Ntz;Lk;.
 nghUl;fis tifg;gLj;jp part familyfis cUthf;f
Ntz;Lk;.
 xt;nthU part familyf;Fk; jFe;j master process planI
cUthf;f Ntz;Lk;.
2) Process planning stage
 Gjpa ghfj;jpw;fhd code MdJ CAPP systemj;jpy; cs;sPL
nra;ag;gLk;. nfhLf;fg;gl;l codef;F Vw;w process plan
,Ue;jhy;> Gjpa ghfj;jpw;Nfw;g Njitahd jpUj;jq;fs;
nra;ag;gl;L mJ gad;gLj;jg;gLk;.
 nfhLf;fg;gl;l codef;F jFe;j process plan ,y;iynadpy;>
me;j codef;F neUq;fpa process plan Njlg;gLk;. ,e;j
process plany; jpUj;jk; nra;J Gjpa ghfj;jpw;fhd route
sheetI ngwyhk;.

3) Report generation
 Process plan formatter MdJ jFe;j gbtj;jpy; route sheet I
print out vLj;Jf; nfhLf;Fk;.
 ,e;j report MdJ route sheet, process picture,
nray;Kiwfis tpsf;Fk; simulation my;yJ NC part
program Mf ,Uf;fyhk;.

2.6.2 Operation of generative CAPP system

 Expert system vdg;gLk; artificial intelligenced; xU gphpit
generative CAPP system gad;gLj;JfpwJ. Expert system
vd;gJ rpf;fyhd gpur;rpidfis jPh;f;f cjTk; computer
programfs; MFk;

2.19
  Expert systemj;ijg; gad;gLj;jp gpur;rpidfis jPh;f;Fk;
nray;Kiw inference engine vdg;gLk;.
 kpfr; rpwe;j process plannerfspd; njhopy;El;g mwpT kw;Wk;
jpwik Mfpait xUq;fpizf;fg;gl;L computer programfs;
cUthf;fg; gLfpd;wd. ,e;j programfs; knowledge base
vdg;gLk;.
 ,e;j knowledge base kw;Wk; inference engineIg; gad;gLj;jp>
xt;nthU ghfj;jpw;Fkhd process planI CAPP system
njhlf;fj;jpypUe;J cUthf;FfpwJ.
Part Process plan
descriptive Process
system logic plan

Knowledge base

Machine Cutting Jigs

tool tool Materials

Fig.2.12 Generative type CAPP

Generative CAPP systemj;jpy; fPo;f;fz;l nray;Kiw

filgpbf;fg; gLfpwJ.

1) Blanky; ,Ue;J ePf;fg;gl Ntz;ba material (pocket)d; fd

msT fz;lwpag;gLfpwJ.
2) xt;nthU pocketf;Fk; Njitahd machine Njh;T nra;ag;
gLfpwJ.
3) xt;nthU pocketIAk; ePf;Ftjw;F Njitahd operationfspd;
thpir fz;lwpag; gLfpwJ.
4) xt;nthU pocketf;Fk; Njitahd cutting tool Njh;T nra;ag;
gLfpwJ.
5) xt;nthU ghfj;jpw;Fkhd kpfr;rpwe;j speed, feed, depth of cut
kw;Wk; number of passes Mfpait Njh;e;njLf;fg; gLfpwJ.
6) Machine kw;Wk; cutting toolfspd; ,Ug;Gf;F Vw;g operationfs;
thpirg;gLj;jg; gLfpd;wd.
2.20
 7) ghfj;ij cw;gj;jp nra;tjw;F MFk; machining time kw;Wk;
idle time Mfpait fzf;fplg; gLfpwJ.
8) Fiwthd nrytpy; nghUis cw;gj;jp nra;Ak; tifapy;>
,Wjpahd process plan Njh;T nra;ag; gLfpwJ.
9) ,e;j process plan MdJ process sheet, process pictures,
my;yJ CNC part program Nghd;w tbtpy; mspf;fg;gLfpwJ.
2.6.3 Benefits of CAPP
1) kpfr;rpwe;j kw;Wk; Fiwe;j nrytpyhd process plan fpilf;Fk;.
2) mjpf juk; tha;e;j nghUl;fis cw;gj;jp nra;a ,aYk;.
3) Process plannerd; productivity mjpfhpf;fpwJ.
4) Process planning cUthf;Ftjw;F MFk; nkhj;j Neuk;
FiwfpwJ.
5) Computer %yk; cUthf;fg;gLk; route sheetfs; njspthf
,Ug;gjhy; Fog;gkpd;wp vspjpy; Ghpe;J nfhs;s KbAk;.

2.7 Production Planning and Control (PPC)

Production planning and control vd;gJ kdpj tsk;>
%yg;nghUl;fs; kw;Wk; ,ae;jpuq;fs; Mfpatw;iw jpwk;gl
gad;gLj;Jtjw;fhf Kd;$l;bNa jpl;lkpLk; nray;Kiw MFk;.
rhpahd ,lj;jpy;> rhpahd Neuj;jpy; kpfr;rhpahd Kbtpid vLj;J
mjpfgl;r efficiencyI miltjw;F PPC cjTfpwJ.

Objectives of PPC
1) ghJfhg;ghd kw;Wk; rpf;fdkhd cw;gj;jp nray;Kiwia
cWjp nra;jy;
2) tsq;fis jpwk;gl gad;gLj;Jjy;
3) nghUl;fis rhpahd Neuj;jpy; delivery nra;jy;
4) Fiwe;jgl;r inventoryI cWjp nra;jy;
5) cw;gj;jp Neuj;ij Fiwj;jy;
6) nghUl;fspd; juj;ij Nkk;gLj;Jjy;
7) %yg;nghUl;fs; tPzhtij fl;Lg;gLj;Jjy;
8) cw;gj;jp nryit Fiwj;jy;

2.21
2.8 Computer integrated production management system
 PPCy; mlq;fpAs;s nray;ghLfis xU computer cjtpAld;
jfty;fis eph;tfpj;J jpwk;gl ifahs Kbak;. ,JNt
computer integrated production management system
MFk;.
 Planning kw;Wk; control nray;ghLfs; epWtdj;jpy; cs;s ,ju
nray;ghLfSld; xUq;fpizf;fg;gl Ntz;Lk;.

Production planning
Production planningy; fPo;f;fz;lit mlq;Fk;.
 ve;j nghUis cw;gj;jp nra;a Ntz;Lk;> vt;tsT cw;gj;jp
nra;a Ntz;Lk; kw;Wk; vg;nghOJ mit Kbf;fg;gl
Ntz;Lk; vd;gij jPh;khdpj;jy;.
 nghUl;fis tpepNahfpj;jy; kw;Wk; cw;gj;jp nra;jy;
Mfpatw;iw ml;ltizg; gLj;Jjy;.
 Production plangb nghUis cw;gj;jp nra;tjw;F
Njitg;gLk; Ml;fs; kw;Wk; ,ae;jpuq;fis jpl;lkpLjy;.
Sales and
marketing

Aggregate
production Product
planning design

Aggregate Sales Sales

planning orders forecasts

Master
production
schedule

Inventory Capacity
records planning
Detailed
planning Material Engineering &
requirements Manufacturing
planning database

Production Purchasing Shop floor

control department control

Operations Supplier Factory Customer

base base

Fig.2.13 Computer integrated production management system

2.22
  Production planningd; nray;ghLfs; fPo;f;fz;lthW:
1) Aggregate production planning
2) Master production planning
3) Material requirements planning (MRP)
4) Capacity planning

Production control
 ,J production planI epiwNtw;Wtjw;F Njitahd trjpfs;
mspf;fg;gl;Ls;sjh ,y;iyah vd;gij jPh;khdpf;Fk;
nray;Kiw MFk;.
 gy;NtW system kw;Wk; njhopy; EZf;fk; %yk; cw;gj;jp
nray;Kiw kw;Wk; inventory fl;Lg;gLj;jg; gLfpwJ.
 Production controld; nray;ghLfs; fPo;f;fz;lthW:
1) Shop floor control
2) Inventory control
3) Manufacturing resource planning (MRP II)
4) Just–in–time (JIT) production system

2.9 Master production schedule (MPS)

 xU epWtdj;jpd; xt;nthU nghpa product lineYk; cw;gj;jp
nra;ag;gl Ntz;ba nghUl;fspd; vz;zpf;ifia aggregate
production plan Fwpf;Fk;.
 Master production schedule MdJ> aggretate plany; cs;s
xt;nthU nghUisAk; jahhpg;gJ gw;wpa ml;ltiz MFk;.
 ,jpy; jahhpf;fg;gl Ntz;ba nghUspd; tpguk;> vj;jid
nghUl;fs; jahhpf;fg;gl Ntz;Lk;> vg;nghOJ Kbf;fg;gl
Ntz;Lk; vd;gd Nghd;w tpguq;fs; mlq;fp ,Uf;Fk;.

Week
Product line 1 2 3 4 5 6 7 8 9 10
M model line 200 200 200 150 150 120 120 100 100 100
N model line 80 60 50 40 30 20 10
P model line 70 130 25 100
(a) Aggregate production plan

2.23
 Week
Product line models 1 2 3 4 5 6 7 8 9 10
Model M1 120 120 120 100 100 80 80 70 70 70
Model M2 80 80 80 50 50 40 40 30 30 30
Model N1 80 60 50 40 30 20 10
Model P1 50 100
Model P2 70 80 25
(b) Master production schedule

Fig.2.14 Aggregate production plan and MPS

 Master production scheduleI cUthf;Ftjw;F fPo;f;fz;l
jfty;fs; Njitg;gLfpd;wd :
1) Kjd;ik eph;thfj;jpy; ,Ue;J mDg;gg;gLk; production plan
2) xt;nthU nghUspd; Njitiag; gw;wpa njhiyNehf;F
fzpg;G
3) thbf;ifahsh;fsplk; ,Ue;J ngwg;gl;l orderfs;
4) jw;NghJs;s xt;nthU nghUspd; ifapUg;G

Objectives of MPS
1) epWtdj;jpy; cs;s ,ae;jpuq;fs;> %yg;nghUl;fs; kw;Wk;
Ml;fis jpwk;gl gad;gLj;Jjy;.
2) Fiwe;j gl;r inventoryI guhkhpj;jy;.
3) nghUl;fis Fwpg;gpl;l Neuj;jpy; jahhpj;J mDg;Gjy;.

2.10 Capacity planning

Master production scheduley; cs;sJ Nghd;W nghUl;fis
cw;gj;jp nra;tjw;Fj; Njitg;gLk; Ml;fs; kw;Wk; ,ae;jpuq;fspd;
Njitia fz;lwpjNy capacity planning MFk;. Long-term
cw;gj;jpf;F NghJkhd Njitfis fz;lwpjYk; ,jpy; mlq;Fk;.
fPo;f;fz;l ,uz;L epiyfspy; capacity planning Nkw;nfhs;sg;
gLfpwJ.

 Rough–Cut Capacity Planning (RCCP): Master production

schedule jahhpf;Fk;NghJ ,J Nkw;nfhs;sg;gLfpwJ. MPSy;
Fwpg;gplg; gl;Ls;s nghUl;fspd; vz;zpf;ifapy; VNjDk;
khw;wk; cs;sjh vd;gij ,J Rl;bf; fhl;Lk;.

2.24
  Capacity Requirements Planning (CRP): MRP jahhpf;Fk;
NghJ ,J Nkw;nfhs;sg; gLfpwJ. MRPy; Fwpf;fg;gl;Ls;sJ
Nghd;W> midj;J nghUl;fisAk; cw;gj;jp nra;ag;
NghJkhd capacity xt;nthU departmentYk; cs;sjh vd;gJ
,jd; %yk; jPh;khdpf;fg; gLfpwJ. Capacity NghJkhd msT
,y;iynadpy;> plant capacity my;yJ MPS jFe;jthW rhp
nra;ag;gLfpwJ.

Short-term adjustments
1) Ntiyahl;fspd; vz;zpf;ifia khw;Wjy;.
2) Work shiftfspd; vz;zpf;ifia khw;Wjy;.
3) xt;nthU work shiftf;Fkhd labour hourI khw;Wjy;.
4) kw;w rpwpa epWtdq;fSf;F sub-contracting tpLjy;.

Long-term adjustments
1) Njitahd msT ,ae;jpuq;fis thq;Fjy;.
2) Gjpa njhopw;rhiyfis mikj;jy;.
3) kw;w epWtdq;fspy; ,Ue;J njhopw;rhiyfis thq;Fjy;.
4) gpw;fhyj;jpy; Njitg;glhj njhopw;rhiyfis %b tpLjy;.

2.11 Material Requirements Planning (MRP)

Sales orders
Master
production Sales forecasts
schedule Spare parts requirements

Capacity
planning
Material
Inventory requirements
record file planning Product design
BOM, design and
manufacturing
data Manufacturing
engineering
Planned order
releases for
purchasing,
manufacturing
and other
output reports

Fig.2.15 Structure of MRP system

2.25
 Master production scheduleI mbg;gilahff; nfhz;L>
nghUl;fis jahhpf;fj; Njitahd %yg;nghUl;fs; kw;Wk;
Njitg;gLk; ,ju ghfq;fs; mlq;fpa njspthd ml;ltizia
cUthf;Fjy; material requirement planning vdg;gLk;.
Objectives of MRP
1) Inventory kw;Wk; mjw;fhd nryTfisf; Fiwg;gJ
2) cw;gj;jp nra;jy; kw;Wk; %yg;nghUl;fis thq;Fjy; Mfpa
nray;ghLfSf;fpilNa xUq;fpizg;ig Vw;gLj;Jjy;
3) xU nghUis Fwpj;j ehspy; Kbj;J jUtjhf cWjp
mspj;jy;
Inputs to the MRP system
1) Master Production Schedule: xU Fwpg;gpl;l fhy ,ilntspapy;
jahhpj;J Kbf;fg;gl Ntz;ba nghUl;fspd; gl;bay;.
2) Bill Of Materials: xt;nthUnghUisAk; jahhpg;gjw;Fj;
Njitahd %yg;nghUl;fs; kw;Wk; ghfq;fs;.
3) Inventory record file: Kbf;fg;gl;l nghUl;fs;> ghfq;fs;
kw;Wk; %yg;nghUl;fspd; ifapUg;G gw;wpa tpguq;fs;.

Working of MRP system

 xU Fwpg;gpl;l fhy ,ilntspfspy; nra;J Kbf;fg;gl Ntz;ba
nghUl;fspd; vz;zpf;iff;F Vw;g> Njitg;gLk; %yg;
nghUl;fs; kw;Wk; ghfq;fspd; vz;zpf;ifia MRP processor
fzf;fpl;L mspf;fpwJ.
 Njitg;gLk; xt;nthU nghUspd; nkhj;j vz;zpf;ifapypUe;J>
epWtdj;jpy; Vw;fdNt cs;s me;j nghUspd; vz;zpf;ifia
fopj;J tpl;L> NkYk; Njitahd nghUl;fSf;fhd order
receiptI ,J jahh; nra;Ak;.
 ghfq;fs; kw;Wk; %yg;nghUl;fs; te;J NrUtjw;F MFk;
Neuj;ij fzf;fpy; vLj;Jf; nfhz;L> orderI vg;nghOJ
release nra;a Ntz;Lk; vd;gijAk; fzf;fpLfpwJ.

MRP outputs
1) Planned order releases
2) nghUl;fspd; ifapUg;G gw;wpa jfty; mwpf;if
3) Rescheduling notices
4) Cancellation notices
2.26
Benefits of MRP system
1) Inventory Fiwf;fg;gLfpwJ.
2) DemandfSf;F Vw;g vspjpy; khw;wp mikj;Jf; nfhs;syhk;.
3) Nkk;gLj;jg;gl;l thbf;ifahsh; Nrit.
4) Setup Neuk; kw;Wk; cw;gj;jp nryT FiwfpwJ.
5) ,ae;jpuq;fspd; gad;ghL Nkk;gLj;jg;gLfpwJ.

2.12 Manufacturing Resources Planning (MRP–II)

Market
demand

Production
plan

Capacity
planning
Adjust
production
plans Any
Yes Problems?
No
Master Resource
procduction requirement
schedule planning

Material No Any Yes

requirement Problems?
planning

Capacity
requirement
planning
Adjust master
production
Schedule Any
Yes Problems?
No
Schedule
shop
orders

Fig.2.16 MRP– II System

 Manufacturing resources planning (MRP–II) vd;gJ MRPd;
Nkk;gLj;jg;gl;l nray;Kiw MFk;. MRPapy; purchase orderfs;
kw;Wk; work orderfis jpl;lkpLjy; Mfpait kl;LNk mlq;Fk;.
Capacity planning kw;Wk; shop floor controly; ,Ue;J tUk; feed
back Mfpatw;iw MRP fzf;fpy; vLj;Jf; nfhs;tJ ,y;iy.

2.27
  MRP–II vd;gJ computerI mbg;gilahff; nfhz;L ,aq;Fk;
xU system MFk;. ,J MPSy; Fwpg;gplg;gl;Ls;sJ Nghd;W
nghUl;fis cw;gj;jp nra;tjw;Nfw;g planning, scheduling
kw;Wk; %yg; nghUl;fs;> njhopw;rhiyapd; tsq;fs; kw;Wk;
,ju nray;ghLfisf; fl;Lg;gLj;Jjy; Nghd;wtw;iw
Nkw;nfhs;Sk;.
 ,J xU closed loop system MFk;. ,J rpwe;j nghUl;fis
Fwpj;j Neuj;jpy; jahhpg;gjw;F Vw;g epWtdj;jpd; midj;J
Kf;fpa nray;ghLfisAk; xUq;fpizj;J fl;Lg;gLj;Jk;.

 MRP-II systemj;jpy; cs;s Kf;fpa modulefs; :

1) Management planning 2) Customer service
3) Operations planning 4) Financial functions

 MRP-II software njhFg;gpd; Gjpa ngah;fs; :

 Enterprise resource planning (ERP)
 Manufacturing execution systems (MES)
 Customer–oriented management systems (COMS)

2.13 Shop floor control (SFC) system

Production orderfis toq;Fjy;> cw;gj;jp eilngWtij
fz;fhzpj;J fl;Lg;gLj;Jjy;> orderfspd; jw;Nghija epytuk;
gw;wpa jfty;fis Nrfhpj;jy; Mfpait shop floor controly;
mlq;Fk;. ,jpy; fPo;f;fz;l %d;W Kf;fpa nray;ghLfs; cs;sd.
1) Order release 2) Order scheduling 3) Order progress

1) Order release
cw;gj;jp eilngWk; ,lj;jpw;Fj; Njitahd documentfis
mspg;gJ ,jpy; mlq;Fk;. ,e;j documentfspd; njhFg;G shop
packet vdg;gLk;. ,jpy; fPo;f;fz;lit mlq;Fk;.
 Route sheet  Job cards  Move tickets
 Parts list  Material requisition
2) Order scheduling
,J njhopw;rhiyapy; cs;s ntt;NtW work centrefSf;F
production orderI gfph;e;jspf;Fk; nray; MFk;. ntt;NtW work
centrefspy; Nkw;nfhs;sg;gl Ntz;ba production order gw;wpa
tpguq;fs; mlq;fpa dispatch listI ,e;j module jahhpj;J mspf;Fk;.
fPo;f;fz;l ,uz;L gpur;rpidfis order scheduling jPh;f;fpwJ.
2.28
  Machine loading : Work centrefSf;F orderfis
gfph;e;jspj;jy;.
 Job sequencing : xt;nthU work centreYk; mLj;jLj;J
nra;ag;gl Ntz;ba job gw;wp jPh;khdpf;fg;gl;L mjd;
mbg;gilapy; thpirg; gLj;jg;gLfpwJ.

Master
production
schedule

Engineering & Material

manufacturing requirements Priority
database planning control

Order Order Order Management

release scheduling progress reports

Factory
Shop Dispatch Factory data
packet list collection
system

Raw materials Finished

and components products

Work centres Work-in-progress

Fig.2.17 Shop floor control system

3) Order progress
njhopw;rhiyapy; eilngw;Wf; nfhz;bUf;Fk; gy;NtW
Ntiyfs;> work-in-progress (WIP) kw;Wk; cw;gj;jpapy; eilngWk;
Kd;Ndw;wj;ijf; Fwpg;gpLk; gz;Gfs; Mfpatw;iwf; fz;fhzpg;gNj
order progress MFk;. ,jw;F factory data collection (FDC) system
gad;gLj;jg; gLfpwJ. ,J fPo;f;fz;l gbtq;fspy; jfty;fis
Nrfhpj;J mspf;fpwJ.
 Work order status reports
 Progress reports
 Exception reports

2.29
2.14 Just–In–Time (JIT) manufacturing system
Just-In-Time (JIT) vd;gJ nghUl;fs; tPzhtij jpl;lkpl;L
jtph;j;jy; kw;Wk; cw;gj;jp tpfpjj;ij njhlh;e;J mjpfhpj;jy;
Mfpatw;iw mbg;gilahff; nfhz;L nray;gLk; xU cw;gj;jp
nray;Kiw MFk;. ,e;j Kiwapy;> xt;nthU nghUSk; mJ
Njitg;gLk; Neuj;jpw;F rw;W Kd;djhf> Njitg;gLk;
vz;zpf;ifapy; kl;Lk; jahhpf;fg;gl;L mDg;gg;gLk;.
fPo;f;fz;lit tPzhtij jtph;g;gNj JITd; Kf;fpa
Nehf;fkhFk;.
 Waste of over production  Waste of waiting
 Waste of transportation  Waste of processing
 Waste of stocks  Waste of motion
JITI eilKiwg;gLj;Jtjw;fhd ,yf;Ffs; :
 Zero defects  Zero set–up time
 Lot size of one  Zero handling
 Zero breakdowns  Zero lead time
JIT miltjw;fhd Kf;fpa nray;ghLfs; :
 Pull system of production control: xU work centref;F
Njitahd ghfq;fs; jPh;e;J tpLtjw;F rw;W Kd;ghf> mjw;F
Nky; cs;s work centrey; ,Ue;J nghUl;fis jahhpj;J
mDg;GkhW work order toq;fg;gLk;.
 High quality: JIT nray;Kiwapy; midj;J tPzhd
nray;KiwfSk; jtph;f;fg; gLtjhy;> scrap kw;Wk; rework
jtph;f;fg; gLfpwJ.
 Small batch sizes and reduced setup time: WIP inventoryI
Fiwg;gjw;F batch size kw;Wk; setup time Fiwf;fg;gl Ntz;Lk;.

2.15 Enterprises Resources Planning (ERP)

Enterprise resource planning vd;gJ nghUl;fis kpfr;rpwe;j
Kiwapy; cw;gj;jp nra;tjw;F jpl;lkplg; gad;gLk; xU MRP-II
software MFk;. xU ERP softwarey; cs;s Kf;fpa modulefs; :
 Finance module : Sales kw;Wk; manufacturing Jiwfspy;
,Ue;J epjp ghpkhw;wj;ijf; fz;fhzpj;J> general ledgerI
jhdhfNt update nra;J nfhs;Sk;.

2.30
  Distribution module : ,e;j module MdJ> nra;J
Kbf;fg;gl;l nghUl;fs;> raw materialfs;> kw;Wk; service
Mfpatw;iw fz;fhzpj;Jf; nfhs;fpwJ. Sales orders
management, inventory control, distribution planning Mfpait
,e;j moduled; rpy nray;ghLfs; MFk;.
 Manufacturing module : ,e;j module MdJ manufacturing
njhlh;ghd midj;J nray;ghLfisAk; fl;Lg;gLj;JfpwJ.
Bill of materials, routing, MPS, MRP, shop floor control, project
control Mfpait Kf;fpa nray;ghLfs; MFk;.
 Project module : Estimating, budget, planning, monitoring,
invoicing Mfpait ,e;j moduley; mlq;Fk;.
 Tools module : Software customization, documentation kw;Wk;
database management Mfpait ,e;j moduley; mlq;Fk;.
 Other modules : Material management, supply chain
management, quality management, human resource
management, plant maintenance kw;Wk; treasury Mfpait
ERP softwarey; cs;s gpw Kf;fpa modulefs; MFk;.

Review Questions
5 Marks Questions :
1) What is CAM? What are its functions?
2) What is the need of CAM?
3) What are the benefits of CAM?
4) Explain the term Group technology.
5) What are the various design and manufacturing attributes used
as a basis for parts classification and coding in GT.
6) Name some parts classification and coding systems.
7) What are the benefits of group technology?
8) Briefly explain the process planning procedure.
9) State the important requirements for process planning.
10) What are the benefits of CAPP?
11) What are the objectives of PPC?

2.31
12) What are the objectives of MPS?
13) Write short note on capacity planning.
14) Briefly explain Just–In–Time manufacturing philosophy.
15) Describe Enterprise Resources Planning.

10 Marks Questions :
1) Explain the various functions of CAM.
2) Explain the concept of part families.
3) Explain the various coding structures used in parts classification
and coding.
4) Explain OPITZ classification system.
5) Explain the MICLASS system with an example.
6) Explain the CODE system.
7) Explain with a neat diagram the structure of a CAPP system.
8) Explain with neat sketch the Variant type CAPP system.
9) Explain the generative type CAPP.
10) Explain the computer integrated production management system.
11) Explain the structure and working of MRP system.
12) Explain MRP-II.
13) Explain shop floor control system.



2.32
 Unit – III
CNC PROGRAMMING AND
RAPID PROTOTYPING
3.1 NC Part program
xU ghfj;jpd; ,Wjpahd tbtj;ij ngWtjw;F machine
control unit (MCU) %yk; epiwNtw;wg;gl Ntz;ba fl;lisfs;
mlq;fpa tpgug; gl;bay; NC part program vdg;gLk;. nfhLf;fg;gl;l
ghfj;ij jahhpg;gjw;F filgpbf;f Ntz;ba mLj;jLj;j nray;
Kiwfis rpWrpW gFjpfshf cilj;J> MCU Ghpe;J nfhs;Sk;
tifapy; Fwpg;gpl;l formaty; program vOjg;gLfpwJ.

3.2 Manual part programming

,e;j Kiwapy;> part program manuscript vdg;gLk; rpwg;G
gbtj;jpy;> machining fl;lisfs; programmer %yk; vOjg;gLk;.
CNC machine toold; tool path MdJ xU Fwpg;gpl;l format cld;
$ba machine codefshy; tiuaWf;fg; gLfpwJ. ,e;j program
MdJ computer systemj;jpy; ,Ue;J machine control unitf;F
download nra;ag;gLk;.

3.2.1 Data required for manual part program

1) Coordinate system specification
2) Axes specification
3) Machine specification
4) Machine kw;Wk; workpiecefspd; reference point specification
5) Tool specification
6) Workpiecefis nghUj;Jk; Kiw
7) Speed, feed, depth of cut Nghd;w process parameterfs;
mlq;fpa data tablefs; kw;Wk; Gj;jfq;fs;
8) Operationfspd; thpir

3.3 Coordinates system

ngUk;ghyhd NC machine toolfs; vspjhf gad;gLj;j Vw;w
Cartesian coordinate systemj;ijNa gpd;gw;Wfpd;wd. mr;Rfis
tiuaWg;gjw;F right-hand coordinate system gpd;gw;wg; gLfpwJ.

3.1
 Fig.3.1 Right hand coordinate system
Designation of axes
Z-axis
 Z-mr;rpd; efh;thdJ spindle mr;R jpirapNyh my;yJ spindle
mr;Rf;F ,izahfNth ,Uf;Fk;.
 Milling, drilling kw;Wk; lathe Nghd;w machinefspy;> toolI
workpiecew;Fs; nrYj;Jtjw;F> tool MdJ –ve Z jpirapy;
efh;j;jg;gl Ntz;Lk;. +ve Z jpirapy;> workpiece kw;Wk; tool
holderf;F ,ilNaahd clearance mjpfhpj;Jf; nfhz;Nl nry;Yk;.
+z
Workpiece +c

-x +b +y Workpiece
-z

+x
+a

-y +x

Worktable -x +z
-z
(a) For flat workpieces (b) For rotational workpieces

Fig.3.2 Designation of axes

X-axis
 Cutting tool my;yJ workpiece efUk; jpir X mr;rhf
Fwpf;fg;gLk;. ,J Z- mr;Rf;F nrq;Fj;jhf ,Uf;Fk;.
X-mr;rhdJ workpieceIg; nghUj;Jk; gug;Gf;F ,izahf
,Uf;Fk;.
3.2
  Kf;fpa spindley; ,Ue;J columnj;ij Nehf;fp ghh;f;Fk;NghJ>
+ve X mr;rhdJ tyg;gf;fj;jpy; mikAk;. Turning
machinefspy;> X-mr;rhdJ Muj;jpirapy; cross slidef;F
,izahfTk; mikAk;.
Y-axis
 ,J X kw;Wk; Z mr;R ,uz;bw;Fk; nrq;Fj;jhf mikAk;.
,jd; jpirahdJ right hand Cartesian coordinate systemj;ij
mbg;gilahff; nfhz;L jPhkhdpf;fg;gLk;.

Rotary motions
 A, B kw;Wk; C Mfpait Kjd;ikahd rotary motionfshf
tiuaWf;fg; gLfpd;wd. ,e;j efh;Tfs; KiwNa X, Y kw;Wk;
Z mr;RfSf;F ,izahf mikAk;.
 +Ve X, Y kw;Wk; Z jpirfspy; xU right hand screwit
Row;Wk;NghJ mJ Kd;Ndhf;fp efUkhW mikAk; jpirNa
+ve A, B kw;Wk; C Mf fUjg;gLk;.

3.4 Datum points and reference points

Zero point
 Coordinate systemj;jpd; Mjpg;Gs;spahdJ zero point Mf
fUjg;gLfpwJ.
 rpy CNC machinefspy;> khw;wp mikf;f ,ayhj tifapy; xU
epiyahd ,lj;jpy; zero point Fwpf;fg; gl;bUf;Fk;. ,J fixed
zero point vdg;gLk;.
 NtW rpy machinefspy;> machine slided; cjtpahy; cutting
toolI efh;j;jp Gjpa zero pointI Njhw;Wtpf;f KbAk;. ,J
floating zero point vdg;gLk;.

Machine zero point or machine datum (M)

Fig.3.3 Machine zero point

3.3
  ,J machine cw;gj;jpahsh; %yk; tiuaWf;fg;gLk; epiyahd
point MFk;. ,JNt machine controllerd; coordinate
systemj;Jf;fhd zero point MFk;.

 Turning centrey;> spindle nose faced; ikag; Gs;spNa

ngUk;ghYk; machine zero point Mf fUjg;gLk;.

 Machining centrefspy;> tabled; ikag;Gs;sp my;yJ

FWf;Fthf;fpy; cs;s tpspk;gpy; VNjDk; xU Gs;spahdJ
machine zero point Mf fUjg;gLk;.

Work piece zero point (W)

+x
Workpiece zero point Workpiece zero point +x

M W +Z -Z M W

Fig.3.4 Work piece zero point

 ,e;j point MdJ machine zero pointIg; nghWj;J workpiece

coordinate systemj;ij jPh;khdpf;fpwJ. ,e;j point MdJ part
program %yk; Njh;e;njLf;fg;gl;L> machine controllerf;F
input Mf nfhLf;fg;gLk;.

 Turning nra;ag;gl Ntz;ba ghfq;fSf;F> ,e;j Gs;spahdJ

workpieced; tyJ my;yJ ,lJ Kidapy;> spindle mr;rpd;
kPJ ,Uf;FkhW vLj;Jf; nfhs;sg;gLk;. ,J program zero
point vdTk; miof;fg;gLk;.

Tool zero point (T)

 WorkpieceI machining nra;Ak;NghJ> machining nra;ag;gl
Ntz;ba ghijapy; tool nry;YkhW kpfj;Jy;ypakhf
fl;Lg;gLj;jg;gl Ntz;Lk;.

 ,jw;F tool turrety; cs;s xU Gs;sp reference point Mf

vLj;Jf; nfhs;sg;gl Ntz;Lk;. ,JNt tool zero point
vdg;gLk;.

3.4
Machine reference point (R)

XMR
M
ZMR

Fig.3.5 Machine reference point (XMR, ZMR)

 ,e;j Gs;sp home position vdTk; miof;fg;gLk;. Machine

slidefs; kw;Wk; toold; efh;Tfis mstpLk; systemj;ijf;
fl;Lg;gLj;JtjpYk; callibration nra;tjpYk; ,e;j Gs;sp
gad;gLfpwJ.

 ,J cw;gj;jpahsh; %yk; jPh;khdpf;fg;gLfpwJ. Machine

reference coordinate (XMR, ZMR) kjpg;Gfis khw;w KbahJ.

3.5 NC dimensioning
1) Absolute dimensioning: ,e;j Kiwapy;> workpiecey; cs;s
xU Gs;spapd; mr;Rj; J}uq;fs; vg;nghOJk; xU Mjpg;
Gs;spiag; nghWj;Njh my;yJ programming %yk;
Njh;e;njLf;fg;gl;l xU nghJthd datumj;ij nghWj;Njh
Fwpf;fg;gLk;. ,k;Kiwapy;> tool efUk; ghij vJthf
,Ug;gp;Dk;> xt;nthU Gs;spapd; X kw;Wk; Y kjpg;Gfs; khwhky;
,Uf;Fk;.
2) Incremental dimensioning: ,e;j Kiwapy;> workpiecey;
cs;s xU Gs;spapd; mr;Rj;J}uq;fs; vg;nghOJk;> me;jg;
Gs;spf;F Kd;ghf cs;s kw;nwhU Gs;spia mbg;gilahff;
nfhz;L Fwpf;fg;gLk;. Tool efUk; ghijapy; khw;wk;
Vw;gl;lhy;> xt;nthU Gs;spapd; X kw;Wk Y kjpg;Gfs; khWk;.

3.5
Example :
100

(20,80) (40,80) (80,80)

F E D

100
60

(20,20) (60,20) (80,20)

A B C
20

(0,0)
20 40 20

Tool MdJ (0,0) vd;w Gs;spapy; ,Ug;gjhf fUJNthk;.

Programming from A-B-C-D-E-F-A :

Absolute Method Incremental Method

Point
X Y U V
A 20 20 20 20
B 60 20 40 0
C 80 20 20 0
D 80 80 0 60
E 40 80 - 40 0
F 20 80 - 20 0
A 20 20 0 -60

3.6 CNC program procedure

xU part programI cUthf;Ftjpy; fPo;f;fz;l gbepiyfs;
mlq;fpAs;sd.
1) Process planning: cUthf;fg;gl Ntz;ba ghfj;jpd; part
drawingI ftdkhf Muha;e;J process plan jahhpf;f Ntz;Lk;.
2) Axes selection: Workpiecey; coordinate kjpg;Gfis vspjpy;
fzf;fpLtjw;F jFe;jthW reference mr;Rfs; Njh;e;njLf;fg;
gl Ntz;Lk;.

3.6
 Study part drawing

Identify
Machine tool
machine tool
database

Identify operations
Capability of
& tooling
cutting tools Cutting tool
database
Determine feeds,
speeds & depths

Machinability
Prepare database
process sheet

Develop
part program

Simulate
tool path

Dry run

Cut the first part

Inspect the part Proven part

Fig.3.6 CNC program procedure

3) Tool selection: kpfTk; gadspf;fj;jf;f toolI Njh;T nra;a

Ntz;Lk;.
4) Cutting process parameters planning: jFe;j speed, feed
kw;Wk; depth of cut Nghd;wtw;iw ftdkhf Njh;T nra;a
Ntz;Lk;.
5) Job and tool setup planning: Job kw;Wk; toold; Muk;g
epiyfs; ftdkhf tiuaWf;fg;gl Ntz;Lk;.
6) Tool path planning: Fiwthd nrytpy; ghfj;ij cw;gj;jp
nra;tjw;F Vw;g> tool efUk; ghij ftdkhf jpl;lkplg;gl
Ntz;Lk;.

3.7
 7) Part program writing: Fwpg;gpl;l format kw;Wk; syntaxI
fzf;fpy; vLj;Jf; nfhz;L part program vOjg;gl Ntz;Lk;.
8) Part program proving: Part programI machine controllery;
load nra;ag;gLtjw;F Kd;G rhpghh;f;f Ntz;Lk;. xU trial run
Nkw;nfhs;sg;gl Ntz;Lk;.

3.7 Definition of character, word and block

 Bit : Binary digit vd;gNj bit vdg;gLk;. ,jpy; 0 kw;Wk; 1 mlq;Fk;.
 Character: gy bitfs; mlq;fpa row %yk; xU characterI
cUthf;fyhk;. Character vd;gJ vz;zhfNth (0–9), xU
vOj;jhfNth (A–Z kw;Wk; a–z) my;yJ xU FwpaPlhfNth
,Uf;fyhk;.
 Word: gy characterfs; mlq;fpa njhFg;G word MFk;. xU
word MdJ xU operation gw;wpa tpguq;fis mspf;fpwJ.
 Block: gy wordfspd; njhFg;G block MFk;. Block vd;gJ xU
KOikahd NC fl;lis MFk;.

3.7.1 Block format

xU blocky; ,lk;ngw Ntz;ba gy wordfspd; tiuaWf;fg;
gl;l thpiria Fwpg;gJ format vdg;gLk;. NC programingy;
fPo;f;fz;l gy;NtW formatfs; gad;gLj;jg; gLfpd;wd.
 Fixed sequential format: xt;nthU blockYk; vz;fis
kl;LNk nfhz;l Ie;J wordfs; khwhj thpirapy; mikf;fg;
gl;bUf;Fk;.
Example: 00100703003
00200706003
 Fixed sequential format with tab ignored: vspjpy;
gbg;gjw;F Vw;g xt;nthU wordf;Fk; ,ilapy; TAB code
gad;gLj;jg; gl;bUf;Fk;.
Example: 001 00 70 30 03
002 00 70 60 03
 Tab sequential format: Ke;ija blocky; cs;s mNj
kjpg;igf; nfhz;l wordfs; mLj;J tUk; blocky;
Fwpg;gplg;gLtJ ,y;iy.
Example: 001 00 70 30 03
002 00 60

3.8
  Word address format: xt;nthU tifahd wordIAk;
gphpj;jwptjw;F xU vOj;J nfhz;l prefix gad;gLj;jg;
gLfpwJ. xNu khjphpahf jpUk;g tUk; wordfs; tpyf;fg;
gLfpd;wd. ,jpy; wordfs; ,ilntsp ,y;yhky;
njhlh;r;rpahf ,Ug;gjhy;> gbg;gjw;F fbdkhf ,Uf;Fk;.
Example: N001G00X70Y30M03
N002Y60
 Word address format with TAB separation and variable
word order: xt;nthU wordk; TAB %yk; gphpf;fg; gl;bUf;Fk;.
xU Blocky; cs;s wordfis ve;j orderYk; khw;wp vOjyhk;.
jw;Nghija etPd CNC controllerfspy; ngUk;ghYk; ,e;j
format gad;gLj;jg; gLfpwJ.
Example: N001 G00 X70 Y30 M03
N002 Y60

3.8 Structure (or) format of a part program

xU part program MdJ % vd;w FwpaPL nfhz;L njhlq;fg;
gLk;. xU part program gy blockfisf; nfhz;ljhf ,Uf;Fk;.
xt;nthU blockk;> machining nra;ag;gl Ntz;ba ghfj;jpy;
Nkw;nfhs;sg;gl Ntz;ba xU operationIf; Fwpg;gjhf ,Uf;Fk;.
xt;nthU blockYk; cs;s wordfs; nghJthf fPo;f;fz;l thpirapy;
nfhLf;fg;gLk;.
 Sequence number (N – word)
 Preparatory word (G – word)
 Coordinates (X–, Y–, Z– words for linear axes)
 Feed rate (F – word)
 Spindle speed (S – word)
 Tool selection (T – word)
 Miscellaneous command (M – word)
 End–of–block (EOB symbol)
Fanuc controllery; gad;gLj;jg;gLk; part programd; structure :
%; (Program start)
O3642 (Program number)

N010 . . . . .
..........
Blocks s N100 M02; (Program end)

3.9
  Program number : O vd;w word address cld; $ba
program number Mf ,e;j milahsk; Fwpf;fg;gLfpwJ.
,e;j number mjpf gl;rkhf ehd;F ,yf;fq;fs; nfhz;ljhf
,Uf;Fk;.
 Sequence number (N–word) : xt;nthU blockk; xU block
number cld; njhlq;;fg;gLk;. ,J me;j blockd;
milahskhf mikAk;.
 Coordinate function : X, Y, Z, U, V, W, I, J, K, Nghd;w word
address %yk; coordinate kjpg;Gfs; Fwpg;gplg; gLfpd;wd.
 Comments : Programy; Njitg;gLk; ,lj;jpy; Fwpg;Gfis
,izg;gjw;F milg;Gf; Fwpfs; gad;gLj;jg; gLfpd;wd.

Table 3.1 Common word addresses used in word address format

Address Function
N xU blockd; milahsk; fhz;gjw;fhd sequence number
G xU blocky; nfhLf;fg;gLk; preparatory word
X, Y, Z %d;W mr;RfSf;;fhd coordinate data
U, V, W X, Y, kw;Wk; Z jpirfspy; incremental efh;Tfspd;
coordinate data
A, B, C X, Y, kw;Wk; Z mr;Rfisg; nghWj;J RoYk; %d;W
mr;Rfspd; coordiante data
R Arc radius (Circular interpolationy; gad;gLj;jg;gLk;)
I, J, K X, Y, kw;Wk; Z mr;Rfspy; KiwNa arcd; ikag; Gs;spapd;
coordinat value
F Inch my;yJ millimetery; feed per minute my;yJ
revolution
S Spindle rotation speed
T Tool selection
D ToolI offset nra;tjw;F gad;gLj;jg;gLk; tool diameter
P Canned cyclefspy; Kjy; contour blockI tiuaWf;fg;
gad;gLfpwJ.
Q Canned cyclefspy; filrp contour blockI tiuaWf;fg;
gad;gLfpwJ.
M Miscellaneous function.

3.10
3.9 Preparatory functions (G – words)
,it machine mr;Rfspd; efh;T kw;Wk; mjNdhL njhlh;
Gila nray;ghLfis Nkw;nfhs;tjw;fhf ifahsg;gLk; preset
functionfs; MFk;. xU blocky; nfhLf;fg;gLk; fl;lisfis
Vw;gjw;F jFe;jhw;Nghy; machine controllerI ,e;j functionfs;
jahh; nra;fpd;wd.

Modal and Non–modal G–codes

 xU rpy G-codefs; modal Mf fUjg;gLk;. mjhtJ ,j;jifa
G-codefs; controllerf;F settingfshf nray;gLk;. ,e;j G-
codefs; xUKiw nfhLf;fg;gl;L tpl;lhy;> mNj groupIr;
rhh;e;j kw;nwhU G-code %yk; ePf;fg;gLk; tiu njhlh;e;J
,af;fj;jpy; ,Uf;Fk;.
 NtW rpy G-codefs; Non-modal Mf ,Uf;Fk;. ,j;jifa G-
codefs;> mJ ,lk;ngw;Ws;s blocky; kl;LNk ,af;fj;jpy;
,Uf;Fk;.
cjhuzk; : G20 (Inch input) xU modal command MFk;.
,J G21 (Metric input) command %yNk ePf;fg;gLk;.
Table 3.2 Common G–codes

G Function
Code Turning Center Machining Center
G00 Rapid positioning
G01 Linear interpolation
C02 Circular interpolation (Clockwise)
G03 Circular interpolation (Anticlockwise)
G04 Dwell
G10 Setting offset amount
G17 Selection of XY plane
G18 Selection of ZX plane
G19 Selection of YZ plane
G20 Inch input system
G21 Metric input system
G27 Zero return check
G28 Return to zero
3.11
 G Function
Code Turning Center Machining Center
G33 Thread cutting, block by block
G40 Tool nose radius compensation cancel Cutter radius compensation cancel
G41 Tool nose radius compensation Left Cutter radius compensation Left
G42 Tool nose radius compensation Right Cutter radius compensation Right
G50 Maximum spindle speed setting
G65 Call of user macro
G70 Finishing turning cycle
G71 Multiple turning cycle
G72 Multiple facing cycle
G73 Pattern repeating cycle
G74 Peck drilling cycle
G75 Grooving cycle
G76 Multiple thread cutting cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring
G82 Drilling cycle, counter boring
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G90 Box turning cycle Absolute mode of positioning
G91 Incremental mode of positioning
G92 Thread cutting cycle Preset program zero point
G94 Box facing cycle Feed per minute
G95 Feed per revolution
G96 Constant surface speed (m/min)
G97 Constant RPM
G98 Feed per minute
G99 Feed per revolution

3.12
3.10 Miscellaneous functions or Auxiliary functions (M – codes)
,e;j functionfs; machining toold; rpy controlfis ,af;fp>
machined; ,af;fj;ij fl;Lg;gLj;JfpwJ. Miscellaneous
commanfs; tof;fkhf blockd; ,Wjpapy; Fwpf;fg;gLk;.

Table 3.3 Common M – codes

M–code Function
M00 Program stop
M01 Optional stop
M02 End of program
M03 Spindle ON, clockwise
M04 Spindle ON, counter–clockwise
M05 Spindle stop
M06 Tool change
M07 Coolant supply No.1 ON
M08 Coolant supply No.2 ON
M09 Coolant OFF
M10 Automatic clamping
M11 Automatic unclamping
M13 Spindle ON, clockwise + coolant ON
M14 Spindle ON, counter–clockwise + coolant ON
M30 Program END and rewind
M70 X axis mirror ON
M71 Y axis mirror ON
M80 X axis mirror OFF
M81 Y axis mirror OFF
M98 Subprogram call
M99 Subprogram end

[Note: ,e;j Gj;jfj;jpy; gad;gLj;jg; gl;Ls;s

G-codefs;> M-codefs; kw;Wk; programming method
Mfpait Fanuc CNC controller systemj;ij
mbg;gilahff; nfhz;lit MFk;.]

3.13
3.11 Part programming for turning centres
Diameter programming
 Turning %yk; cUthf;fg;gLk; ghfq;fspd; msTfs;
nghJthf mjd; diameterIf; nfhz;Nl Fwpf;fg;gLk;.
Turning operationd;NghJ tool MdJ workpieceI Nehf;fp
Muj;jpirapy; efh;e;J machining nra;fpwJ. vdNt>
gpd;gw;Wtjw;F vspjhf ,Uf;FkhW> ngUk;ghyhd turning
centrefspy; diameter programming trjp ,Uf;Fk;.
 mjhtJ> ,e;j programing Kiwapy;> Mu msTfis
Fwpg;gjw;F gjpyhf> tpl;l (diameter) msTfis Fwpf;FkhW>
X-mr;R jpirapy; midj;J efh;TfSk; ,uz;L klq;fhf
Fwpf;fg;gLk;.

Axes system
Tool datum Tool turret

Machine datum
+X
Work datum

-Z M W

Chuck

Fig.3.7 Axes system used in turning centres

 Turning centrefspy;> spindle mr;rhdJ Z-mr;rhff;
fUjg;gLk;. Kjd;ikahd tool posty; ,Ue;J tpyfpr;
nry;YkhW Z-mr;Rf;F nrq;Fj;jhf Muj;jpirapy; cs;s
mr;R X-mr;R MFk;.
 Spindle mr;R kw;Wk; clamping plane ntl;bf;nfhs;Sk; Gs;sp
home position my;yJ machine datum vdg;gLk;.
 Part programI vspjhf cUthf;Ftjw;F Vw;g workpiece
datum MdJ programmer %yk; Fwpf;fg;gLk;. Tool tip
position kw;Wk; turret datum Mfpatw;wpw;F ,ilNaAs;s
J}uk; tool offset vdg;gLk;.

3.14
3.11.1 Tool function (T–word)
ToolI Njhe;njLg;gjw;F programy; T-word gad;gLj;jg;
gLfpwJ. ,e;j T-word MdJ indexing nra;ag;gl Ntz;ba turret
stationI Njh;T nra;tJld;> tool offset register numberIAk;
activate nra;fpwJ. Tool offset register number MdJ tool-offset
filey; ,Ue;J fPo;f;fz;l tpguq;fis Njhe;njLf;fpwJ.
 X kw;Wk; Z mr;Rfspy; tool offset njhiyT
 Tool nose radiusd; kjpg;Gfs;.
 Tool nose orientation number

T-word MdJ Tmmnn vd;w formatIf; nfhz;bUf;Fk;. ,jpy;

Kjy; ,uz;L ,yf;fq;fs; (mm) turret stationIAk;> filrp ,uz;L
,yf;fq;fs; (nn) tool offset cs;s ,lj;ijAk; Fwpf;fpwJ. Offset
register number 00 vdf; Fwpg;gpl;L offsetI jtph;f;fyhk;.

Example: N050 M06 T0616

Nkw;fz;l block MdJ turret station 6I indexing nra;AkhW
mioj;J> tool offset register number 16Ij; Njh;T nra;Ak;.
3.11.2 Speed function
Spindle speed fPo;ffz;l ,uz;L topfspy; Fwpf;fg; gLfpwJ.
a) Constant surface speed (G96)
Lathey; cutting speed MdJ RoYk; workpieced; diameterIf;
nfhz;L Fwpf;fg;gLfpwJ. ,e;j diameter MdJ step turning, taper
turning, facing Nghd;w ntt;NtW operationd; NghJk; khWgLfpwJ.
vdNt khwhj cutting force kw;Wk; rPuhd surface finishI ngWtjw;F>
workpieced; diameterf;F jFe;jthW spindle speedI khw;WtJ
mtrpakhfpwJ. Constant surface speed %yk; ,J rhj;jpakhfpwJ.
b) Constant RPM (G97)
,JNt default option MFk;. Turning operationd; NghJ
spindle speed njhlh;e;J khw;wg;gLtjhy;> xU Fwpg;gpl;l mjpfgl;r
msitj; jhz;b mjd; rpm nry;y Nehplyhk;. mj;jifa
#o;epiyfspy;> G50 commandI gad;gLj;jp mjpfgl;r spindle
speedI tiuaWf;fyhk;.

Example:
N080 G50 S4000 (Maximum spindle rpm is 4000)
N070 G96 S200 (Spindle speed is set at 200 m/min)
N090 G97 S2500 (Spindle speed is set at 2500 rpm)
3.15
3.11.3 Feed specification
G98 – Feed in mm/min; G99 – Feed in mm/rev.
G98 MdJ default mode MFk;. jpUk;gTk; khw;Wk; tiu feed
rate MdJ khwhky; ,Uf;Fk;;. G99I gad;gLj;Jk;NghJ decimal
point Fwpg;gplg;gl Ntz;Lk;. Control panely; cs;s feed rate over
ride switch MdJ progamy;
Fwpg;gplg;gl;bUf;Fk; feedI 0%y;
,Ue;J 150% f;F khw;wp mikf;Fk;.

Example:

G98 F2.5 (2.5 mm / minute)

G99 F1 (0.01 mm / revolution)
G99 F1.0 (1.00 mm / revolution)
G99 F100 (1.00 mm / revolution)

3.11.4 Rapid positioning (G00)

midj;J mr;Rthf;fpYk; xUNru mjptpiuthf toolI
efh;j;Jtjw;F G00 gad;gLfpwJ. ,e;j commandd; NghJ>
programy; Fwpg;gplg; gl;bUf;Fk; feed rate tpyf;fg;gl;L> xt;nthU
mr;Rf;Fkhd mjpfgl;r feed rate cld; efh;j;jg;gLk;. G00 xU
modal command MFk;.

Example: (Rapid movement from A to B)

X
A(55,25)

B(10,0)

Fig.3.8 Rapid positioning

Absolute mode: N030 G00 X10 Z0

Incremental mode: N030 G00 U–45 W–25
Mixed mode: N030 G00 U–45 Z0 (or) G00 X10 W–25

3.16
3.11.5 Interpolation methods
Contouring gad;ghLfspy; njhlh;r;rpahd Neh;f;Nfhl;L kw;Wk;
tisthd ghijfis cUthf;Ftjw;F NCapy; interpolation
Kiwfs; gad;gLj;jg; gLfpd;wd.
 Linear interpolation: njhlh;r;rpahd xU Neh;f;Nfhl;Lg;
ghijia cUthf;Ftjw;F ,J gad;gLfpwJ.
 Circular interpolation: xU circular arcI cUthf;Ftjw;F
,J gad;gLfpwJ.
 Helical interpolation
 Parabolic interpolation
 Cubic interpolation

a) Linear interpolation (G01)

njhlh;r;rpahd xU Neh;f;Nfhl;Lg; ghijia cUthf;Ftjw;F
G01 gad;gLj;jg; gLfpwJ. Neh;f;Nfhl;bd; Muk;gg; Gs;sp> KbTg;
Gs;sp kw;Wk; gad;gLj;jg;gl Ntz;ba feed rate (F) Mfpatw;iw
programmer Fwpg;gpl Ntz;Lk;. G01f;fhd format fPo;f;fz;lthW:

G01 X_ Z_ F_

Example: (Programming from A–B–C–D)

X
D(60,-23) A

C(30,-25)
B(20,0)

Fig.3.9 Linear interpolation

N030 G00 X20 Z0

N040 G01 X30 Z–25 F150
N050 G00 X60 Z–23

b) Circular interpolation
tisthd arcfis cUthf;Ftjw;F ,e;j Kiw
gad;gLj;jg; gLfpwJ. Radius my;yJ arcd; ikag; Gs;spapd; mr;Rj;
3.17
J}uq;fis nfhLg;gjd; %yk; circular interpolation ngwg;gLfpwJ.
R word addressIf; nfhz;L Neubahf radius msitf;
Fwpg;gplyhk;. ikag; Gs;spapd; mr;Rj; J}uq;fis Fwpg;gpLkNghJ>
incremental Kiw gad;gLj;jg;gl Ntz;Lk;. I kw;Wk; K word
addresfis gad;gLj;jp> arcd; Muk;gg; Gs;spapypUe;J ikag;
Gs;spapd; J}uq;fs; Fwpg;gplg; gl Ntz;Lk;.

(i) Circular interpolation – clockwise (G02)

G02 f;fhd format fPo;f;fz;lthW:

G02 X_ Z_ R_ F_ (or) G02 X_ Z_ I_ K_ F_

Example: (Programming from A–B–C–D–E)

X
E(60,-28) A

R5
D(30,-30)
I=5
C(20,-20) B(20,0)

Fig.3.10 Circular interpolation – clockwise

N030 G00 X20 Z0 N030 G00 X20 Z0

N040 G01 X20 Z–20 F150 N040 G01 X20 Z–20 F150
(OR)
N050 G02 X30 Z–30 R5 F50 N050 G02 X30 Z–30 I5 K0 F50
N060 G00 X60 Z–28 N060 G00 X60 Z–28

(ii) Circular interpolation – Counter-clockwise (G03)

G03f;fhd format fPo;f;fz;lthW:

G03 X_ Z_ R_ F_ (or) G03 X_ Z_ I_ K_ F_

Example: (Programming from A–B–C–D–E)

N030 G00 X20 Z0 N030 G00 X20 Z0
N040 G01 X20 Z–20 F150 N040 G01 X20 Z–20 F150
(OR)
N050 G03 X30 Z–30 R5 F50 N050 G03 X30 Z–30 I0 K–5 F50
N060 G00 X60 Z–28 N060 G00 X60 Z–28

3.18
 X
E(60,-28) A

R5
D(30,-30)
C(20,-20)
K=-5 B(20,0)

Fig.3.11 Circular interpolation – Counter-clockwise

3.11.6 Tool nose radius compensation (G41, G42)

(a) Tool nose radius compensation (b) Tool nose radius compensation
- not active - active
Fig.3.12 Tool nose radius correction

 xU tbtj;ij cUthf;Ftjw;fhd finish cuttingd;NghJ> nose

radius msTf;F toolI offset nra;J toold; rhpahd ghij
ngwg; gLfpwJ.
 Cutter compensation Ig; gad;gLj;jp> rpf;fyhd
fzf;fPLfisj; jtph;f;fyhk;. Machining nra;ag;gl Ntz;ba
contourf;fhd program vOjpdhy; NghJkhdJ.
 Nose radius compensation nfhLf;fhtpl;lhy;> rhpthd
gug;Gfspy; machining eilngWk;NghJ> rpwpa msT metal
ePf;fg; glhky; tplg;gLfpwJ.
 ,e;j correction trjp nray;gLj;jg;gl;bUg;gpd;> controller
jhdhfNt NghJkhd compensation nra;J> Njitapy;yhj
metalI ePf;fptpLk;.

3.19
Example part program 3.01:
 Write a part program for producing the component shown
below in turning centre.

R10
A(50,0)
D(50,-60) I=10
B(30,0)
C(30,-50)
Ø50

Ø30

10 50

Fig.3.13 Component for part program 3.01

% (Program start)
O4030 (Program Number)
N010 G21 (Metric units – mm)
[BILLET X50 Z80 (Work piece dimension)
N020 G50 S4000 (Maximum spindle speed 4000 rpm)
N030 G98 (Feed in mm/min.)
N040 G96 S300 (Spindle speed at 300 m/min.)
N050 G42 (Tool nose radius compensation right)
N060 M06 T0101 (Select tool 01 with offset No.01)
N070 M03 (Spindle ON – forward)
N080 G00 X50 Z0 (Rapid position to A)
N090 G00 X30 Z0 (Rapid position from A to B)
N100 G01 X30 Z–50 F150 (Turning from B to C)
N110 G02 X50 Z–60 R10 F50 (Clockwise circular interpolation
(or) from C to D)
G02 X50 Z–60 I10 K0 F50
N120 G40 (Nose radius compensation cancel)
N130 G28 U0 W0 (Tool return to reference point)
N140 M05 (Spindle Stop)
N150 M30 (Program stop and rewind)

3.20
3.11.7 Canned cycles or Fixed cycles
xU Fwpg;gpl;l thpirapy; toold; efh;Tfis jpUk;g jpUk;g
ngWtjw;fhf> controller system memoryy; Vw;fdNt Nrkpj;J
itf;fg;;gl;Ls;s fl;lisfspd; njhFg;Ng canned cycle my;yJ
fixed cycle vdg;gLk;. jpUk;g jpUk;g kw;Wk; nghJthf
Nkw;nfhs;sg;gLk; machining operationfSf;F canned cyclefs;
gad;gLj;jg; gLfpd;wd.

Advantages of using canned cycles

1) Programming nra;tjw;fhd Neuk; FiwfpwJ.
2) Program vspikahdjhf ,Uf;Fk;.
3) ProgramI Nrkpj;J itf;f Fiwthd memory space NghJkhdJ.

a) Rough turning (or) Box turning canned cycle [G90]

Rapid
Feed Start position
Rapid
Final point Feed
(X,Z)

Fig.3.14 Box turning canned cycle (G90)

G90 f;fhd format : G90 X_ Z_ F_

,q;F, X, Z - coordinat kjpg;Gfs; ; F- Feed rate

,e;j canned cycle fPo;f;fz;l efh;Tfis Vw;gLj;JfpwJ.

 Depth of cutIf; nfhLg;gjw;fhf X mr;rpy; mjptpiuthf efUk;
 Z mr;rpy; Fwpg;gplg;gl;l Gs;sp tiu> nfhLf;fg;gl;l feed ratey;
efUk;
 nfhLf;fg;gl;l feed ratey; Muk;g X epiyf;F jpUk;g tUk;
 Muk;g epiyf;F mjp tpiuthf jpUk;g tUk;

3.21
Example part program 3.02 [Rough turning canned cycle]:
 Write a part program for producing the component shown
below in turning centre with a depth of cut of 2.5mm for each
pass, using canned cycle.
Ø50

Ø40

60

Fig.3.15 Component for part program 3.02

%
O4060
N010 G21
[BILLET X50 Z80
N020 G98
N030 G96 S300
N040 G42
N050 M06 T0202 (Rough turning tool)
N060 M03
N070 G00 X50 Z0
N080 G00 X45 Z0
N090 G90 X45 Z–60 F150 (First cut)
N100 X40 Z–60 (Second cut)
N110 G40
N120 G28 U0 W0
N130 M05
N140 M30

c) Thread cutting canned cycle [G92]

Nkw;nfhs;sg;gLk; efh;Tfis fUj;jpy; nfhz;lhy; thread
cutting cycle MdJ> rough turning cycle G90Ig; Nghd;wNj MFk;.
G90 f;fhd format : G90 X_ Z_ F_

,q;F, X, Z - coordinat kjpg;Gfs; ; F – Feed rate (threadd; pitch)

3.22
Example part program 3.03 [Thread cutting canned cycle]:
 Write a part program for cutting external threads on the component
shown below in turning centre using thread cutting canned cycle.
M25x2

Ø25
5 30

Fig.3.16 Component for part program 3.03

V-threadfis cUthf;f> depth MdJ> mjd; pitch mstpy;
0.64 klq;F ,Uf;f Ntz;Lk;.
nfhLf;fg;gl;l threadd; pitch, p = 2mm
Total depth of cut, d = 0.64 x p = 0.64 x 2 = 1.28mm.
xt;nthU passf;Fkhd depth of cut kw;Wk; mtw;wpw;fhd
X kjpg;Gfs; fPNo nfhLf;fg; gl;Ls;sd.

Depth of cut 0.5 0.5 0.28

X coordinate 24 23 22.44

%
O4080
N010 G21 G99
[BILLET X25 Z50
N020 G97 S1000 M03
N030 M06 T0202
N040 G00 X24 Z2 M08
N050 G92 X24 Z–30 F2
N060 X23 Z–30
N070 X22.4 Z–30
N080 G28 U0 W0
N090 M09
N100 M05
N110 M30

3.23
d) Multiple turning canned cycle (or) Stock removal cycle [G71]
Turning gad;ghLfspy;> xU pockety; cs;s metalI
ePf;Ftjw;F multiple turning canned cyclefs; gad;gLj;jg; gLfpd;wd.
,e;j cycley; Muk;gg; Gs;spapy; tool epWj;jg;LfpwJ. ntl;b ePf;fg;
gl Ntz;ba pocketfspd; ,Wjp tbtj;ijg; nghWj;J> G codefis
gad;gLj;jp programming nra;ag;gLfpwJ. G71 cycleIf; nfhz;L
,e;j pocketfs; machining nra;ag;gLfpwJ. Njitg;gLk; midj;J
roughing cutfSk; controller %yk; jhdhfNt cUthf;fg; gLfpwJ.
R Start point
U(Depth of cut)

Pocket

U(Finishing allowance)
w

Fig.3.17 Multiple turning canned cycle

,e;j canned cycle fPo;f;fz;l ,uz;L blockfisf; nfhz;bUf;Fk;.

G71 U_ R_
G71 P_ Q_ U_ W_ F_

Kjy; block MdJ multiple rough turning cyclef;Fj;

Njitahd parameterfis tiuaWf;fpwJ.
,jpy;> U = xt;nthU passf;Fkhd depth of cut
R = Return passd; NghJ workpiecey; ,Ue;J tool tpyfpr;
nry;y Ntz;ba J}uk;
,uz;lhtJ block MdJ multiple rough turning cyclef;Fj;
Njitahd parameterfis tiuaWf;fpwJ.
,jpy;> P = Machining nra;ag;gl Ntz;ba workpieced; gug;igf;
Fwpg;gpLk; Kjy; blockd; sequence number
Q = Machining nra;ag;gl Ntz;ba workpieced; gug;igf;
Fwpg;gpLk; filrp blockd; sequence number
U = X jpirapy; nfhLf;fg;gLk; finishing allowance
W = Z jpirapy; nfhLf;fg;gLk; finishing allowance
F = Feed rate

3.24
Finish turning canned cycle [G70]
Roughing canned cycle G71 rpwpjsT metalI finishing
allowance Mf tpl;Lr; nry;Yk;. ,jid machining nra;tjw;F
finish turning canned cycle G70 gad;gLj;jg; gLfpwJ.

G70 cycled; format : G70 P_ Q_ F_

Example part program 3.04:

 Write a part program for producing the following component
on CNC lathe.

(Note:xt;nthU passf;Fkhd depth of cut 1 mm MfTk;> finishing

allowance 0.5 mm MfTk; fUjg;gLfpwJ).

Ø35
Ø25 R5
R7.5

10 10 10 30

Fig.3.18 Component for part program 3.04

%
O4150
N010 G21
[BILLET X35 Z60
N020 G50 S4000
N030 G98
N040 G96 S300 M03
N050 M06 T0101
N060 G00 X35 Z0
N070 G71 U1 R1
N080 G71 P090 Q150 U0.5 W0.5 F100

3.25
 N090 G00 X0

N100 G03 X15 Z–7.5 R7.5 F5 
N110 G01 X15 Z–25 F100 
 Blocks specifying the
N120 G02 X25 Z–30 R5 F5  contour position
N130 G01 X25 Z–40 F100 
N140 G01 X35 Z–50 
N150 G01 X35 Z–60


N160 G70 P090 Q150 F5
N170 G28 U0 W0
N180 M05
N190 M30
f) Multiple thread cutting cycle [G76]
External threafis cUthf;Ftjw;F ,e;j cycle cjTfpwJ.
G76 codef;fhd format fPo;f;fz;lthW:
G76 X_ Z_ A_ I_ K_ D_ F_
,q;F> X = Core diameter of the thread (X22.4)
Z = Length of the thread (Z–30)
A = Angle of the thread (A60)
I = Thread taper (usually zero) (I0)
K = Total depth of the thread in microns (K1280)
D = Depth of first cut in microns (D500)
F = Feed rate (pitch) (F2)

Example part program 3.05 [Multiple thread cutting cycle]:

 Write a part program for cutting external threads on the
component shown below in turning centre using multiple
thread cutting cycle.
M25x2
Ø25

5 30

Fig.3.19 Component for part program 3.05

3.26
 %
O4110
N010 G21 G99
[BILLET X25 Z50
N020 G97 S1000 M03
N030 M06 T0202 (Thread cutting tool)
N040 G00 X24 Z2 M08
N050 G76 X22.4 Z–30 A60 I0 K1280 D500 F2
N060 G28 U0 W0
N070 M09
N080 M05
N090 M30

g) Peck drilling cycle [G74]

Fanuc controller systemj;jpy; peck drillingf;F G74 code gad;
gLj;jg;gLfpwJ. DrillI workpiecey; ,Ue;J ghJfhg;ghd J}uj;jpy;
epWj;jpa gpwF drilling cycleI miof;f Ntz;Lk;. gpd;G drill MdJ
xt;nthU incremental depth msTf;Fk; drill nra;J gpd;G chipI
ntspNaw;Wtjw;F gpd;Ndhf;fp jpUk;g tUk;. Programy; nfhLf;fg;
gl;bUf;Fk; Z depth msT tiu ,J jpUk;g jpUk;g eilngWk;.
G74 codef;fhd format : G74 X_ Z_ K_ F_
,q;F> X = Finish diameter; Z = Finish Z – depth
K = Peck depth; F = Feed

Example part program 3.06 [Peck drilling cycle]:

 Write a part program for drilling in the component shown below
in turning centre using peck drilling cycle.
Ø12
Ø30

30 40

Fig.3.20 Component for part program 3.06

3.27
 %
O4120
N010 G21 G98
[BILLET X30 Z70
N020 G97 S1800 M03
N030 M06 T0303 (Twist drill 12 mm)
N040 G00 X0 Z2 M08
N050 G74 X0 Z–40 K5 F100
N060 G28 U0 W0
N070 M09
N080 M05
N090 M30

h) Grooving canned cycle [G75]

Start
K Tool

Fig.3.21 Grooving canned cycle [G75]

Njitahd diameter msT tUk; tiu Kjy; cut
Nkw;nfhs;sg; gLfpwJ> gpd;G Muk;g X epiyf;F jpUk;g gpd;Ndhf;fp
te;J> K word %yk; Fwpg;gplg;gl;l msTf;F Z jpirapy; efUk;.
,t;thW programy; Fwpg;gplg;gl;Ls;s Z msit milAk; tiu
gy passfs; Nkw;nfhs;sg; gLfpwJ. X coordiante kjpg;ig zero
Mff; Fwpg;gpl;L> ,e;j cycleI parting off operationf;Fk;
gad;gLj;jyhk;.
G76 codef;fhd format : G75 X_ Z_ I_ K_ F_
,q;F, X = Finish diameter ; Z = Finish Z – depth
I = Peck depth (radial) ; K = Z shift amount
F = Feed

3.28
Example part program 3.07 [Grooving cycle]:
 Write a part program to cut a groove on the component shown
below in turning centre using grooving cycle. The width of the
grooving tool is 4mm.
Start

Ø20

Ø30
25 12 25

Fig.3.22 Component for part program 3.07

%
O4130
N010 G21 G98
[BILLET X30 Z60
N020 G97 S1000 M03
N030 M06 T0404 (Grooving tool 4mm width)
N040 G00 X30 Z29
N050 G75 X20 Z–37 I5 K4 F100
N060 G28 U0 W0
N070 M05
N080 M30

3.12 Part programming for machining centres

3.12.1 Preset [G92]
ngUk;ghyhd CNC machinefspy; machined; ve;j xU
Gs;spiaAk; floating datum Mf Fwpg;gpLk; trjp ,izf;fg;
gl;bUf;Fk;. ,jid gad;gLj;jp> ghfj;jpd; kPJ mike;j VNjDk;
xU trjpahd Gs;spia programmer Njh;T nra;J mjid program
zero point Mf vLj;Jf; nfhs;syhk;. ,e;jg; Gs;spia G92 code
%yk; programy; Fwpg;gpl Ntz;Lk;.
Example: G92 X200 Y170 Z50

3.29
3.12.2 Cutter radius compensation (or) Cutter offset compensation

Programmed path

Cutter

Offset path of cutter

Fig.3.23 Cutter radius compensation

Contouring gad;ghLfspy;> ghfj;jpy; machining eilngw

Ntz;ba ghijapypUe;J toold; ghij mjd; radius msTf;F
vg;nghOJk; tpyfp ,Uf;f Ntz;Lk;. Tool tpyfp nry;y Ntz;ba
,e;j J}uk; cutter offset vdg;gLk;. jw;Nghija etPd machine tool
controllerfs;> cutter offset njhlh;ghd fzf;fPLfis jhdhfNt
Nkw;nfhs;fpd;wd.
,jw;F fPo;f;fz;l G codefs; gad;gLj;jg; gLfp;d;wd.
 G40 (Cutter radius compensation off)
 G41 (Cutter radius compensation left): Tool efUk;
jpirapy; ghh;f;Fk;NghJ> program nra;ag;gl;l ghijf;F
,lJ gf;fj;jpy; cutterI efh;j;jp itf;f Ntz;Lnkdpy;> G41
gad;gLj;jg;gl Ntz;Lk;. WorkpieceIr; Rw;wp clockwise
jpirapy; cutter efUk;NghJ ,J gad;gLj;jg;gLk;.

 G42 (Cutter radius compensation right): Tool efUk;

jpirapy; ghh;f;Fk;NghJ> program nra;ag;gl;l ghijf;F
tyJ gf;fj;jpy; cutterI efh;j;jp itf;f Ntz;Lnkdpy;> G42
gad;gLj;jg;gl Ntz;Lk;. WorkpieceIr; Rw;wp anti-lockwise
jpirapy; cutter efUk;NghJ ,J gad;gLj;jg;gLk;.
Vw;fdNt Nrkpj;J itf;fg;gl;Ls;s cutter radius
compensation kjpg;Gfis D word address %yk; miof;fyhk;.

3.30
 Example: M06 T04
G01 X50 D03 F150
Nkw;fz;l block MdJ tool number 04I mioj;J> mjDld;
03 vd;w milahsk; nfhz;l registery; cs;s radius compensation
kjpg;Gfis ,izj;Jf; nfhs;Sk;.

3.12.3 Tool length compensation

Z

1 2 3 4
L2

L3

L4

Fig.3.24 Tool length compensation

etPd NC Kiwapy;> midj;J toolfSk; mjdjd; ,lj;jpy;

nghUj;jg;gl;l epiyapy; xU tool presetter %yk; mstplg;
gLfpd;wd. Tool lengthy; cs;s NtWghL fz;lwpag;gl;L mjNdhL
njhlh;Gila tool number cld; (manual Mf cs;sPL nra;ag;gl;L)
Nrkpj;J itf;fg; gLfpwJ.

Programy; ,e;j toolfs; miof;fg; gLk;NghJ> me;j

toolf;Fhpa compensation kjpg;Gfs; activate nra;ag;gl;L> tool
efh;tpd;NghJ fzf;fpy; vLj;Jf; nfhs;sg; gLfpd;wd. Kd;$l;bNa
Nrkpj;J itf;fg;gl;Ls;s ,e;j length compensationd; kjpg;Gfs; H
word %yk; miof;fg;gl;L programy; gad;gLj;jg;gLk;.

Example: M06 T02

G81 X150 Y100 Z60 R40 H07 F100
Nkw;fz;l block MdJ tool number 02I mioj;J> mjDld;
07 vd;w milahsk; nfhz;l registery; cs;s length compensation
kjpg;Gfis ,izj;Jf; nfhs;Sk;.

3.31
 Example part program 3.08:
 Write a part program for producing the following component in
machining centre using Fanuc controller. The size of the
material used is 100x100x10mm.
The diameter of the cutter is assumed as 10mm.
%
O4190
N010 G21 (Metric mode)
[BILLET X100 Y100 Z10
(Applicable only for
[TOOLDEF T1 D10 t DENFORD CNC simulator)
[EDGEMOVE X0 Y0 Z0
N020 G92 X0 Y0 Z0 (Presetting at S1)
N030 M06 T01 (Tool change)
N040 M03 S1500 (Spindle speed at 1500 rpm)
R10 R10 3(100,100) 3(100,100)
4(0,100) 4(0,100)

(20,80) (20,80)
(40,80) (80,80)
(40,80) (80,80)
F E F DE D
100

100
60

60

60

60

(20,20) (60,20)
(20,20) (80,20)
(60,20) (80,20)
S2(0,20,2) S2(0,20,2)
A BA C B C
R10 R10
20

20

S1(0,0,2) S1(0,0,2)
20 5020 50 1(0,0) 1(0,0)
40 2040 2(100,0)
20 2(100,0)

100 100
Tool movementTool movement

Fig.3.25 Component for part program 3.08

After second cut

After first cut
(Finished product)
Fig.3.26
3.32
 (Absolute programming)
N050 G90 (Absolute mode)
(Cutting along 1–2–3–4)
N060 G41 (Cutter radius compensation, left)
N070 G00 X0 Y0 Z2 (Position S1)
N080 G00 Z–5 (Depth of cut)
N090 G01 X100 Y0 F1.5 (Position 2)
N100 G01 X100 Y100 (Position 3)
N110 G01 X0 Y100 (Position 4)
N120 G01 X0 Y0 (Position 1)
N130 G40 (Cutter compensation cancel)
(Cutting along A–B–C–D–E–F)
N140 G42 (Cutter radius compensation, right)
N150 G00 X0 Y20 Z2 (Position S2)
N160 G00 Z–5 (Depth of cut)
N170 G01 X60 Y20 F1.5 (Position B)
N180 G03 X80 Y20 R10 F0.5 (Circular interpolation from B–C)
N190 G01 X80 Y80 F1.5 (Position D)
N200 G01 X40 Y80 F1.5 (Position E)
N210 G03 X20 Y80 R10 F0.5 (Circular interpolation from E–F)
N220 G01 X20 Y20 F1.5 (Position A)
N230 G40 (Cutter compensation cancel)
N240 G28 X0 Y0 Z0 (Return to reference point)
N250 M05 (Spindle STOP)
N260 M30 (Program end and rewind)

The above program can also be written in incremental mode as follows:

(Incremental programming)
N050 G91 (Incremental mode)
(Cutting along 1–2–3–4)
N060 G41 (Cutter radius compensation, left)
N070 G00 X0 Y0 Z2 (Position S1)
N080 G00 Z–7 (Depth of cut)
N090 G01 X100 Y0 F1.5 (Position 2)
N100 G01 X0 Y100 (Position 3)
N110 G01 X–100 Y0 (Position 4)
3.33
 N120 G01 X0 Y–100 (Position 1)
N130 G40 (Cutter compensation cancel)
(Cutting along A–B–C–D–E–F)
N140 G42 (Cutter radius compensation, right)
N150 G00 X0 Y20 Z7 (Position S2)
N160 G00 Z–7 (Depth of cut)
N170 G01 X40 Y0 F1.5 (Position B)
N180 G03 X20 Y0 R10 F0.5 (Circular interpolation from B–C)
N190 G01 X0 Y60 F1.5 (Position D)
N200 G01 X–40 Y0 F1.5 (Position E)
N210 G03 X–20 Y0 R10 F0.5 (Circular interpolation from E–F)
N220 G01 X0 Y–60 F1.5 (Position A)

3.12.4 Canned cycles

a) Drilling cycle [G81]

Ra
pid

Clearance plane
Rapid
depth

Feed
Hole

Breakthrough
distance

Fig.3.27 Drilling canned cycle [G81]

Through holefis cUthf;Ftjw;fhd drilling operationfis

Nkw;nfhs;tjw;F G81 canned cycle gad;gLj;jg; gLfpwJ.
G81f;fhd format : G81 X_ Y_ Z_ R_

,q;F> X,Y = Drilling nra;ag;gl Ntz;ba Gs;spapd; coordinate

kjpg;Gfs;
Z = Drilling nra;ag;gl Ntz;ba holed; nkhj;j depth
R = Work surfacey; ,Ue;J drill epWj;jg;gl Ntz;ba
J}uk;.

3.34
 G81 xU modal command Mf ,Ug;gjhy;> mJ nraypy;
cs;sNghJ nfhLf;fg;gLk; xt;nthU Gs;spapYk; drilling operation
jpUk;g jpUk;g eilngWk;. vdNt> G80 code jw;NghJs;s canned
cycleI cancel nra;tNjhL> G00 fl;lisia nray;glTk; itf;Fk;.

fPo;f;fz;l canned cyclefspd; formatk; drilling cycle [G81] Ig;

Nghd;wNj MFk;.
G82 Counter sinking, counter boring cycle
G84 Tapping cycle
G85 Reaming cycle
G86 Boring cycle
G87 Multiple boring cycle

b) Peck drilling cycle [G83]

Deep hole drilling nray;ghLfspy; ,e;j cycle gad;gLfpwJ.
,e;j cycley;> workpiece surfacey; ,Ue;J feed tpl;L tpl;L
nfhLf;fg;gLk;. G83 codef;fhd format fPo;f;fz;lthW:
G83f;fhd format : G83 X_ Y_ Z_ R_ Q_

,jpy;> Q = xt;nthU passf;Fkhd depth of cut.

Depth of cut (Z) nfhLf;Fk;NghJ> drill shoulder kw;Wk; drilld;

Kid Mfpatw;wpw;F ,ilNaahd J}uj;ij> drill nra;ag;gl
Ntz;ba holed; nkhj;j depth cld; $l;bf; nfhs;s Ntz;Lk;.

Drill shoulder kw;Wk; drilld; Kidf;F ,ilNaahd J}uk;

1
= x Diameter of drill
3
Example:
18mm diameter nfhz;l drill bit cjtpahy; 30mm depth
nfhz;l xU hole I drill nra;tjw;F>
1
Depth of cut, Z= 30 + x 18 = 36 mm
3

Example part program 3.09:

 Write a part program to drill four holes of 8mm diameter in a
100x100x10mm plate. The centre of each hole is at a distance
of 15mm from the nearest edges of the plate. Take the speed
as 2000rpm and feed as 0.1mm/rev.

3.35
 15
4 3

50

Ø8-4HOLES

1 2
15

15 70 15

10
Fig.3.28 Component for part program 3.09

%
O4210
N010 G21
[BILLET X100 Y100 Z10
[TOOLDEF T01 D08
[EDGEMOVE X0 Y0 Z0
N020 G92 X0 Y0 Z0
N030 M06 T01
N040 M03 S2000
N050 G90 G95 (Feed in mm/rev.)
N060 G00 X0 Y0 Z2
N070 G81 X15 Y15 Z–13 R2 F0.1 (Hole 1)
N080 X85 Y15 (Hole 2)
N090 X85 Y85 (Hole 3)
N100 X15 Y85 (Hole 4)
N110 G80
N120 G00 Z2
N130 G28 U0 W0
N140 M05
N150 M30

3.36
Example part program 3.10:
 Write a part program for producing the component shown
below in machining centre using Fanuc controller system.
20 20
Ø8.5-5HOLES

20
Ø15 Counter-boring
15mm depth
30

M10x1.5
20

50 50
10

15
30

Fig.3.29 Component for part program 3.10

Cutting conditions
Tool Speed Feed rate
Tool name
No. (rpm) (mm/rev)
01 Centre drill 2000 0.5
02 Twist drill 750 0.1
Counter bore
03 1500 0.1
(15mm)
04 Tap (M10) 250 1.5

%
O4220
N010 G21
N020 G92 X0 Y0 Z0
(Centre drilling 5 holes)
N030 M06 T01
3.37
N040 M03 S2000
N050 G90 G95
N060 G00 X0 Y0 Z2
N070 G81 X50 Y20 Z–5 R2 F0.5 (Hole 1)
N080 Y50 (Hole 2)
N090 Y80 (Hole 3)
N100 X20 Y50 (Hole 4)
N110 X80 (Hole 5)
N120 G80
N130 G00 Z2
N140 M05
(Drilling 5 holes of 8.5 mm)
N150 M06 T02
N160 M03 S750
N170 G90 G95
N180 G00 X0 Y0 Z2
N190 G83 X50 Y20 Z–33 R2 F0.1
N200 Y50
N210 Y80
N220 G83 X20 Y50 Z–13 R2 F0.1
N230 X80
N240 G80
N250 G00 Z2
N260 M05
(Counter boring)
N270 M06 T03
N280 M03 S1500
N290 G82 X50 Y50 Z–13 R2 F0.1
N300 G80
N310 G00 Z2
N320 M05
(Tapping)
N330 M06 T04
N340 M03 S250
N350 G84 X20 Y50 Z–17 R2 F1.5
N360 X80 Y50
N370 G80

3.38
 N380 G00 Z2
N390 M05
N400 G28 X0 Y0
N410 M30

3.12.5 Sub program

Sub program vd;gJ tof;fkhd part programIg; Nghd;w
midj;J mk;rq;fisAk; nfhz;l jdpahd program MFk;. xU
jdpg;gl;l program number cld; sub programfs; memoryy;
Nrkpj;J itf;fg;gLk;.

Njitahd xU Fwpg;gpl;l mk;rk; main programy; Njitg;

gLk;NghJ> mjNdhL njhlh;Gila sub program miof;fg;gl;L
nray;gLj;jg;gLk;. Sub programd; nray;ghL Kbe;jTld;> program
control jpUk;gTk; main programf;F te;J tpLk;.

Main program Sub program

%… SUB 12
N010 … N100 …
N020 … N110…
………. ……….
………. ……….
………. ……….
………. N150 RETURN
N100 CALL SUB12
N110 …
N120 …
xU sub programf;Fs; kw;nwhU sub program IAk; mioj;J
gad;gLj;j KbAk;. Fanuc controllery; fPo;f;fz;l ,uz;L tifahd
sub programfs; gad;gLj;jg; gLfpd;wd.
(a) Subroutines (b) Macros

(a) Subroutines
Subroutinefs; xU Fwpg;gpl;l main program cld;
njhlh;Gila jw;fhypfkhd subprogamfs; MFk;.

Format of subroutine
Subroutinef;fhd format MdJ main programIg; Nghd;Nw
,Uf;Fk;. Mdhy;> ,J M99 vd;w code %yk; epiwT nra;ag;gLk;.
,e;j M99 code MdJ xU jdpahd blocky; nfhLf;fg;gl Ntz;Lk;.

3.39
 O1432 Subroutine number
N010 …..
N020 …..
………… t Program block
…………
N100 M99 Return to calling program

Subroutine calling [M98]

Main programf;Fs; subroutineI miog;gjw;F M98 vd;w code
gad;gLj;jg; gLfpwJ. ,jd; format fPo;f;fz;lthW:

N050 M98 Prrrnnnn

,jpy;> ‘rrr’ vd;gJ subroutine vj;jid Kiw jpUk;g jpUk;g

nray;gl Ntz;Lk; vd;gijf; Fwpf;fpwJ. 999 Kiw
subroutinefis jpUk;g jpUk;g nray;gl itf;f
,aYk;. kjpg;G VJk; Fwpg;gplg; gltpy;iynadpy;>
subroutine xU Kiw nray;gLj;jg;gLk;.
‘nnnn’ vd;gJ nray;gLj;jg; gl Ntz;ba subroutined;
milahs vz; MFk;.

Example:
N050 M98 P0021432 (Subroutine 1432 ,uz;L Kiw gad;gLj;jg;gLk;)
N110 M98 P8432 (Subroutine 8432 xU Kiw gad;gLj;jg;gLk;;)

Example part program 3.11:

 Write a part program for producing the component shown
below in machining centre, using subroutines.

,e;j ghfj;jpy; fPo;f;fz;l operationfs; nra;ag;gl Ntz;Lk;.

1) VO holefis centre drilling nra;tJ
2) 8.5mm drill bitIf; nfhz;L VO holefis drilling nra;tJ
3) M10 tapIf; nfhz;L VO holefspYk; tapping nra;tJ
xt;nthU operationf;Fk; toolI VO holefspd; epiyfspYk;
epWj;JtJ jpUk;g jpUk;g eilngWfpwJ. vdNt> ,e;j nray;Kiw
jdpahf xU sub program Mf vOjg;gl;L> Njitg;gLk;NghJ
miof;fg; gl;L gad;gLj;jg; gLfpwJ.

3.40
 200

50

200
50
50

M10x1.5 -7 Nos.

50 50 50

30

Fig.3.30 Component for part program 3.11

Tool Speed Feed rate

Tool name
No. (rpm) (mm/rev)
01 Centre drill 2000 0.5
Twist drill
02 750 0.1
(8.5mm)
03 Tap (M10) 250 1.5

%
O4230
N010 G21
N020 G92 X0 Y0 Z0
N030 M06 T01 (Centre drill)
N040 M03 S2000
N050 G90 G95
N060 G00 X0 Y0 Z2
N070 G81 Z–5 R2 F0.5
N080 M98 P4321 (Calling subprogram 4321 once)
N090 M06 T02 (Twist drill 8.5mm)
N100 M03 S750

3.41
 N110 G00 X0 Y0 Z2
N120 G81 Z–33 R2 F0.1
N130 M98 P4321
N140 M06 T03 (Tap)
N150 M03 S250
N160 G00 X0 Y0 Z2
N170 G84 Z–32 R10 F1.5
N180 M98 P4321
N190 G28 X0 Y0 Z0
N200 M30

(Sub program)
O4321 (Sub program name)
X50 Y50
Y100
Y150
X100 Y100
X150 Y50
Y100
Y150
G80
G00 Z2
M05
M99 (Return to main program)

b) Macros
Macro vd;gJ controller memoryy; epue;jukhf Nrkpj;J
itf;ff; $ba sub programfs; MFk;. vdNt> ,tw;iw ve;j
programYk; mioj;J gad;gLj;jyhk;.

Macro calling in Fanuc [G65]

Main programf;Fs; macroI mioj;Jg; gad;gLj;Jtjw;F
G65 preparatory function gad;gLj;jg; gLfpwJ. ,jw;fhd format
fPo;f;fz;lthW:
G65 P4322 A_ B_ C_ . . . . . .

,jpy;> P4322 miof;fg;gl Ntz;ba sub program number MFk;.

A, B, C Mfpait argumentfis epakpg;gjw;F gad;gLj;jg;
gLk; word addressfs; MFk;.

3.42
 xt;nthU word addressk; mjw;F ,izahd variable
numberI fPo;f;fz;lthW subprogramy; ngw;wpUf;Fk;.
Word address A B C D E F H I J K M Q
Variable number #1 #2 #3 #7 #8 #9 #11 #4 #5 #6 #13 #17

Word address R S T U V W X Y Z
Variable number #18 #19 #20 #21 #22 #23 #24 #25 #26

Fanuc controllery;> variablefs; # vd;w FwpaPL %yk; mwpag;

gLfpd;wd. ,tw;wpd; kjpg;G 0000ypUe;J 9999 tiu NtWgLk;.
Example:
G65 P4322 A12.6 B24.4 C15.0 D10 X48.3
Main programy; cs;s Nkw;fz;l block MdJ 4322 vd;w sub
programI miof;Fk;. ,jd; tpisTfs; fPo;f;fz;lthW:

Word address Equivalent variable

Value
in main program in subprogram
A #1 12.6
B #2 25.4
C #3 15.0
D #7 10
X #24 48.3

3.12.6 Mirror imaging

rkr;rPuhd tbtk; nfhz;l ghfq;fSf;fhd part program vOJk;
NghJ> ngUk;ghyhd program blockfs; rpwpa khWjy;fSld; jpUk;g
jpUk;g tUk;. ,jpy; nrytplg;gLk; Neuj;ijf; Fiwf;f> ngUk;ghyhd
CNC controllerfspy; mirror imaging trjp ,izf;fg; gl;bUf;Fk;.

Mirroring nra;a Vw;wjhf mikAk; mbg;gil ghfj;ij

Kjypy; fz;lwpa Ntz;Lk;. ,e;j ghfj;jpw;fhd part program kl;Lk;
Kjypy; vOjg;gl Ntz;Lk;. gpd;G nghUj;jkhd mirror imaging
codefisg; gad;gLj;jp ,e;j part program kw;w ghfq;fSf;Fk;
jpUk;g jpUk;g gad;gLj;jg;gLk;.

Mirroring nra;Ak;NghJ> ve;j mr;irg; nghWj;J mirroring

nra;ag;gLfpwNjh me;j mr;irg; nghWj;j midj;J msTfSk;
sign khw;wk; nra;ag;gLfpwJ. cjhuzkhf> X mr;irg; nghWj;J
mirroring nra;jhy;> mjw;Fg; gpd;G midj;J X kjpg;GfSk; sign
khw;wk; nra;ag;gLk;.
3.43
 Fig.3.31 Mirror imaging
Fanuc controllery; mirroring nra;tjw;F fPo;f;fz;l M codefs;
gad;gLj;jg; gLfpd;wd.
 M70 – X axis mirror ON
 M71 – Y axis mirror ON
 M80 – X axis mirror OFF
 M81 – Y axis mirror OFF

Example part program 3.12 (Mirror imaging):

 Write a part program for contouring operation on the
component as shown below, in machining centre, using
subprogram and mirroring.
Y
20

2 1
(-X,+Y) (+X,+Y)
10 20 20
10

X
100

(0,0)

(-X,-Y) (+X,-Y)
4 3

100

Fig.3.32 Component for part program 3.12

X kw;Wk; Y mr;Rfisg; nghWj;J ,e;j component rkr;rPuhf
cs;sJ. trjpf;fhf> componentd; ikag; Gs;spahdJ program
zero point Mf vLj;Jf; nfhs;sg; gLfpwJ.
3.44
 %
O4200
[BILLET X100 Y100 Z10
[TOOLDEF T01 D5
[EDGEMOVE X–50 Y–50 Z0
N010 G21 G90 G94
N020 M06 T01
N030 M03 S1500
N040 G00 X0 Y0 Z2
N050 M98 P2001 (Calling sub program 2001)
N060 M70 (X axis mirror ON: The sign of all X values
are reversed)
N070 M98 P2001
N080 M80 (X axis mirror OFF)
N090 M71 (Y Axis mirror ON: The sign of all Y values
are reversed)
N100 M98 P2001
N110 M81 (Y axis mirror OFF)
N120 M70 (X axis mirror ON)
N130 M71 (Y axis mirror ON)
N140 M98 P2001
N150 M80
N160 M81
N170 G28 X0 Y0
N180 M05
N190 M30
Sub program
O2001
G00 X10 Y10 Z2
G01 Z–2 F30
G01 X30 Y10
G03 X10 Y30 R20
G01 X10 Y10
G00 Z2
M99

3.45
3.12.7 Pocketing
xU work pieced; rkjsg; gug;gpy; ,Ue;J Fwpg;gpl;l
Moj;jpw;F Njitahd tbtpy; metalI ntl;b ePf;Fk; nray;Kiw
pocketing my;yJ pocket milling vdg;gLk;. Kjypy; roughing
operation %yk; mjpf msT metal ntl;b ePf;fg;gLk;. gpd;G finish
end millIf; nfhz;L finishing nra;ag;gLk;.

Circular pocketing
,e;j canned cycle ,uz;L blockfisf; nfhz;bUf;Fk;.
G170 P_ Q_ R_ X_ Y_ Z_ I_ J_ K_
G171 P_ T_ S_ R_ F_ B_ J_
For G170 block,
P0 = Roughing cycle; P1 = Finishing cycle
Q = Incremental depth of cut; R = Refrence plane
X,Y = Coordinate of centre of pocket; Z = Depth of pocket
I = Finishing allowance in walls of pocket
J = Finishing allowance in base of pocket
K = Radius of pocket

For G171 block,

P = Cut width percentage; T = Tool number
S = Spindle speed during roughing; R = Feedrate in Z
F = Feedrate during roughing; B = Finishing spindle speed
J = Finishing feedrate.

Rectangular pocketing
,e;j canned cycle ,uz;L blockfisf; nfhz;bUf;Fk;.
G172 P_ Q_ R_ X_ Y_ Z_ I_ J_ K_
G173 I_ K_ P_ T_ S_ R_ F_ B_ J_ Z_
For G172 block,
P0 = Roughing cycle; P1 = Finishing cycle
Q = Incremental depth of cut; R = Referance plane
X,Y = Cordinate of lower left corner of pocket
Z = Depth of pocket; I = Length of pocket
J = Width of pocket; K = Corner radius (always 0)

3.46
For G173 block,
I = Finishing allownce in walls of pocket;
K = Finishing allownce in base of pocket
P = Cut width percentage; T = Tool number
S = Spindle speed during roughing; R = Feedrate in Z
F = Feedrate during roughing; B = Finishing spindle speed
J = Finishing feedrate; Z = Safe height

Example part program 3.13 (Pocketing):

 Write a part program for pocketing operation on the
component as shown in the figure.

100
25 5

Ø30
25
100
30
10

10 30 10

Fig.3.33 Component for part program 3.13

%
O2300
[BILLET X100 Y100 Z10
[TOOLDEF T01 D5
[EDGEMOVE X0 Y0 Z0

3.47
 N010 G21 G90 G94
N020 M06 T01
N030 M03 S1500
N040 G00 X0 Y0 Z5
N050 G172 P0 Q1 R0 X10 Y10 Z-5 I30 J30 K0 (Circular – Roughing)
N060 G173 I0.1 K0.1 P50 T1 S1500 R60 F30 B1800 J60 Z5
N070 G172 P1 Q0.1 R0 X10 Y10 Z-5 I30 J30 K0 (Circular – Finishing)
N080 G173 I0 K0 P50 T1 S1500 R60 F30 B1800 J60 Z5
N090 G00 Z5
N100 G00 X75 Y75 Z5
N110 G170 P0 Q1 R0 X75 Y75 Z-5 I0.1 J0.1 K15.0 (Rectangular–Roughing)
N120 G171 P50 T1 S1200 R60 F30 B1800 J60
N130 G170 P1 Q0.1 R0 X75 Y75 Z-5 I0 J0 K15.0 (Rectangular–Finishing)
N140 G171 P50 T1 S1200 R60 F30 B1800 J60
N150 G00 Z5
N160 G28 X0 Y0
N170 M05
N180 M30

3.13 Rapid prototyping

Subtractive my;yJ additive manufacturing njhopy;
El;gj;ijg; gad;gLj;jp jhdhfNt nghUl;fis tpiue;J cw;gj;jp
nra;Ak; Kiwf;F rapid prototyping vd;W ngah;.

Subtractive manufacturing :
,k;Kiwapy;> xU
KOikahd solid blocky; ,Ue;J materialI gbg;gbahf ntl;b
ePf;Ftjd; %yk; Njitahd Kg;ghpkhd tbt nghUl;fs;
cUthf;fg;gLfpd;wd. goikahd cw;gj;jp nray;Kiwfs;
my;yJ GJikahd CNC machining Kiwapy; subtractive
prototypefs; cUthf;fg; gLfpd;wd.

Additive manufacturing : ,k;Kiwapy;> liquid, powder

my;yJ nky;ypa sheet tbt nghUl;fis layerfshf xd;wpd;kPJ
xd;W mLf;fp> mtw;iw xd;whf ,izg;gjd; %yk; Njitahd
Kg;ghpkhd tbt nghUl;fs; tpiuthf cUthf;fg;gLfpd;wd.

3.48
 Subtractive rapid prototype Additive rapid prototype
1) Material ntl;b ePf;fg;gLfpwJ. Material Nrh;f;fg;gLfpwJ.
2) jplkhd gpizg;G Layerfshy; Md gpizg;G
3) mjpf typik Fiwe;j typik
4) vspa tbtk; kl;LNk rpf;fyhd tbtq;fisAk;
cUthf;f KbAk;. cUthf;fyhk;.
5) nkJthd nray;Kiw Ntfkhd nray;Kiw
6) mjpf nryT Fiwe;j nryT

Materials
gy;NtW prototyping njhopy; El;gq;fSk; mtw;wpy;
gad;gLj;jg;gLk; base materialfSk; fPNo ml;ltizg;gLj;jg;
gl;Ls;sJ.
Prototyping technologies Base materials
Selective laser sintering (SLS) Thermoplastics, metal powders
Fused deposition modeling (FDM) Thermoplastics, eutectic metals.
Stereolithography (SLA) Photopolymer
Laminated object manufacturing (LOM) Paper
Electron beam melting (EBM) Titanium alloys
3D printing (3DP) Various materials
Laser Engineered Net Shaping (LENS) Metal powders

Applications of rapid prototyping

 Rapid manufacturing  Visualization
 Metal casting  Architecture
 Education  Geospatial
 Healthcare  Entertainment
 Retail  Biotechnology
 Jewellery  Footwear
 Industrial design  Automotive
 Aerospace  Archaeology
 Dental and medical industries

3.49
Advantages of rapid prototyping
1) Designy; cs;s jtWfis vspjhf fz;lwpayhk;.
2) Designy; khw;wj;ij vspjhf Vw;gLj;jyhk;.
3) nghUspd; cz;ikahd ,Wjp tbtj;ij mwpayhk;.
4) cw;gj;jjp Neuk; kw;Wk; nryT FiwT.
5) nghUspd; juk; Nkk;gLj;jg;gLk;.
6) User kw;Wk; designerf;F ,ilNa rpwe;j njhlh;G cUthFk;.

3.13.1 Stereolithography (SLA)

Laser
Scanner
system
Movable
table
Knife edge

Sealed
Chamber
Object being fabricated
Photopolymer Vat

Fig.3.34 Stereolithography

Stereolithography vd;gJ %yg; nghUl;fis

gbg;gbahf
Nrh;j;J> nghUl;fspd; khjphpfs;> prototype, pattern kw;Wk; rpy
cgNahfkhd nghUl;fis kpf tpiuthf cw;gj;jp nra;ag;
gad;gLk; xU nray;Kiw MFk;.

Process
,e;j Kiwapy;> vat vdg;gLk; xU miwapy; mjd;
Nkw;gug;Gf;F rw;W fPohf efUk; tifapy; xU table nghUj;jg;
gl;bUf;Fk;. Vaty; liquid polymer resin epug;gg; gl;bUf;Fk;. Fwpg;gpl;l
epwKs;s xspahdJ resin kPJ gha;r;rg; gLk;NghJ> mJ liquidy;
,Ue;J solid Mf khwp tpLk;. Resiny; ,Ue;J Gif ntspNaWtij
jtph;g;gjw;fhf> ,e;j mikg;G KOtJkhf seal nra;ag; gl;bUf;Fk;.

3.50
 cUthf;fg;gl Ntz;ba nghUspd; Njhw;wj;ij liquid
polymerd; Nkw;gug;gpy; trace nra;AkhW laser beam efh;j;jg;gLk;.
Laser beam gLk; ,lq;fspy; cs;s resin MdJ solid Mf khwp
tpLk;. xU scanner mikg;gpd; cjtpahy; laser beam MdJ X-Y
jpirapy; efh;j;jg;gLk;.

xU layer KOtJkhf trace nra;ag;gl;L fbdkhf;fg;

gl;lTld;> xU layer thickness msTf;F table MdJ fPo;Nehf;fp
efh;j;jg;gLk;. nghUs; KOtJkhf tbtikf;fg;gl;L vaty; cs;s
tabley; cl;fhUk; tiu tracing kw;Wk; recoating nray;Kiw jpUk;g
jpUk;g nra;ag; gLfpwJ.
nghUs; KOtJkhf cUthf;fg;gl;lTld;> vaty; ,Ue;J
ntspNa vLf;fg;gl;L cyh;j;jg;gLk;. mjpfg;gbahd resin
Nkw;gug;gpy; ,Ue;J topj;njLf;fg;gLk;. Post Curing Apparatus (PCA)
%yk; ,Wjpahf curing nra;ag;gLk;.
Advantages of Stereolithography
 kpf mjpfkhd accuracy
 kpfr; rpwe;j surface finish
 cgfuzq;fspd; tpiy kw;w nray;Kiwfisf; fhl;bYk; FiwT.
 vspa nray;Kiw.
 nghUl;fs; machining nra;tjw;F Vw;w fbdj;jd;ikAld; ,Uf;Fk;.
 Master patternfshf nghUl;fisg; gad;gLj;jyhk;.

Disdvantages of Stereolithography
 Post curing Njitg;gLk;.
 Support structurefs; Njitg;gLk;.
 Ventilation Njitg;gLk;.
 kPjKs;s nghUl;fs; tp~j;jd;ik nfhz;lJ.

3.13.3 Fused Deposition Modeling (FDM)

fUj;JU khjphpfs;> nghwpapay; khjphpfs; kw;Wk; ,aq;Fk;
khjphpfs; Mfpatw;iw cUthf;f Fused Deposition Modeling (FDM)
rpwe;jJ MFk;.
Process
Coily; Rw;wp itf;fg; gl;Ls;s plastic filament MdJ xU
extrusion nozzle topahf nrYj;jg;gLk;. Nozzle #lhf;fg;gl;L plastic
cUf;fg;gLfpwJ. cUf;fg;gl;l plastic nrYj;jg;gLk; tPjj;ijf;
3.51
fl;Lg;gLj;j mechanism cs;sJ. NkYk; fPOk; FWf;F thf;fpYk;
efUk; tifapy; cs;s xU mechanical stagey; nozzle nghUj;jg;
gl;bUf;Fk;.

X-Y-Z
stage system Plastic filament
supply coil

Extrusion
nozzle
Object being
fabricated

Thermal
housing Table

Fig.3.35 Fused Deposition Modeling

Nozzley; ,Ue;J> cUf;fg;gl;l plastic MdJ njspf;fg;gl;L

xU layerI cUthf;FfpwJ. ,e;j plastic cldbahf fbdj;jd;ik
mile;J> mjw;F fPNoAs;s layer cld; cWjpahf gpizf;fg;
gLfpwJ.

Plastic cUFk; ntg;gepiyf;Fr; rw;Wf; Fiwthd

ntg;gepiyapy; itf;fg;gl;Ls;s xU mLg;giwf;Fs; ,e;j mikg;G
KOtJk; itf;fg;gl;bUf;Fk;. Overhang kw;Wk; undercut cs;s
nghUl;fis cUthf;Fk;NghJ support structure tbtikf;fg;gl
Ntz;Lk;. ,Wjpahf ,it ntl;b ePf;fg;gLk;.

Advantages of FDM
 vspa kw;Wk; rj;jkpy;yhj nray;Kiw
 Ntfkhd nray;Kiw
 cw;gj;jp nra;ag;gl;l nghUl;fs; mjpf typik nfhz;ljhf
,Uf;Fk;.
 gy;NtW tifahd plasticIAk; %yg;nghUl;fshfg;
gad;gLj;jyhk;.
 cw;gj;jp nryT kw;w nray;Kiwfisf; fhl;bYk; FiwT.

Disadvantages of FDM
 Support structurefis gad;gLj;JtJ mtrpak; MFk;.

3.52
3.13.2 Selective Laser Sintering (SLS)
Selective laser sintering (SLS) vd;gJ %yg;nghUl;fis
gbg;gbahf Nrh;j;J prototype khjphpfs; kw;Wk; rpwpa nghUl;fis
Fiwe;j mstpy; cw;gj;jp nra;ag; gad;gLk; nray;Kiw MFk;.
Laser
Scanner system
Sealed chamber

Roller
Fabrication powder bed

Powder Object being fabricated

delivery system

Build cylinder
Powder
delivery piston
Fabrication piston

Fig.3.36 Selective Laser Sintering

Process
,k;Kiwapy;> J}shf;fg;gl;L kpfTk; ,Wf;fkhf jpzpf;fg;gl;l
thermoplastic %yg; nghUspd; kPJ laser beam nfhz;L trace nra;ag;
gLfpwJ. Laser beam gLk; ,lq;fspy; ntspg;gLk; ntg;gj;jhy;
powder cUFfpwJ. xU scanner system ,jid topelj;JfpwJ. ,e;j
mikg;G KOtJk; seal nra;ag;gl;L> plastic powderd;
cUFepiyf;Fr; rw;Wf; Fiwthd ntg;gepiyapy; itf;fg; gLfpwJ.

xU layer Kbe;jTld;> build cylindery; cs;s piston MdJ

xU layer jbkd; msTf;F fPo;Nehf;fp efUk;. Powder supply piston
Nky;Nehf;fp efhe;J Njitahd powderI mDg;Gk;. ,jpYs;s xU
roller MdJ powderI build cylinderd; kPJ gug;gp mOj;JfpwJ.

KOikahd nghUs; cUthFk; tiu ,e;j process njhlh;e;J

eilngWk;. Kbtpy;> nghUshdJ cah;j;jg;gl;L> mjpfg;gbahd
powder Jilj;J ePf;fg;gLfpwJ. ,Wjpahf finishing nra;ag; gLfpwJ.

Advantages of SLS
 vspa nray;Kiw
 Supportfs; Njitg;gLtjpy;iy
 Final curing Njitapy;iy
 gy;NtW tifahd powderfisAk; gad;gLj;jyhk;.
 rpf;fyhd tbtKs;s nghUl;fisAk; cw;gj;jp nra;a KbAk;.
3.53
 Disadvantages of SLS
 Surface finish Neh;j;jpahf ,Uf;fhJ.
 cw;gj;jp nra;ag;gl;l nghUl;fs; porous jd;ikAld; ,Uf;Fk;.
 nghUl;fspd; typik Fiwthf ,Uf;Fk;.

3.13.4 Three Dimensional (3D) Printing

Multichannel inkject head Liquid adhessive supply

Roller
Fabrication powder bed

Powder Object being fabricated

delivery system

Build cylinder
Powder
delivery piston
Fabrication piston

Fig.3.37 3D Printing

Process
3D printing MdJ xU inkjet printing systemj;ijf;
nfhz;bUf;Fk;. ,jpy; gad;gLj;jg;gLk; material MdJ powder
Mf;fg;gl;L xU bedd; kPJ gug;gg; gl;bUf;Fk;. xU multi-channel
jet %yk; jput epiyapYs;s xl;Lk; nghUshdJ ,e;j powder
mateial kPJ gba itf;fg;gLk;. xl;Lk; nghUs; gbe;j ,lj;jpy;
cs;s powder MdJ xd;NwhL xd;W xl;bf;nfhs;Sk;.

xU layer Kbe;jTld;> build cylindery; cs;s piston MdJ

xU layer jbkd; msTf;F fPo;Nehf;fp efUk;. Powder supply piston
Nky;Nehf;fp efhe;J Njitahd powderI mDg;Gk;. ,jpYs;s xU
roller MdJ powderI build cylinderd; kPJ gug;gp mOj;JfpwJ.

KOikahd nghUs; cUthFk; tiu ,e;j process njhlh;e;J

eilngWk;. Kbtpy;> nghUshdJ cah;j;jg;gl;L> mjpfg;gbahd
powder Jilj;J ePf;fg;gLfpwJ. ,t;;thW xU green object
fpilf;fpwJ. nghUs; cilgLtij jtph;g;gjw;fhf> mij
gad;gLj;Jtjw;F Kd;G infiltration nra;ag; gLfpwJ.

3.54
Advantages of 3D printing
 ntt;NW materialfis cs;slf;fpa ve;j xU nghUisAk;
xNu processy; nra;ayhk;.
 rpf;fyhd Kg;ghpkhz tbtk; nfhz;l nghUl;fisAk;
vspjhf cUthf;fyhk;.
 nghUl;fis gy tz;zk; nfhz;ljhfTk; cUthf;fyhk;.
 kpf tpiuthd nray;Kiw MFk;.
 Equipment tpiy FiwT.
 gad;gLj;JtJ vspJ.

3.13.5 Rapid tooling

Rapid prototype njhopy;El;gk; kw;Wk; tof;fkhd tooling
Kiwfisf; nfhz;L> mouldfis mjptpiuthf cw;gj;jp
nra;Ak; nray;Kiw Rapid Tooling (RT) vdg;gLk;.

1) Direct method of rapid tooling

 Rapid prototype nray;Kiwiaf; nfhz;L tooling mouldfs;
Neubahf cw;gj;jp nra;ag;gLk;. ,jpy; CAD model MdJ
cs;sPlhf nfhLf;fg;gLk;. nghJthf stereolithography
my;yJ selective laser sintering Kiw ,jpy;
gad;gLj;jg;gLk;.
 nray;Kiwapy; cs;s gbepiyfs; Fiwf;fg;gl;L> Jy;ypak;
mjpfhpf;fg;gLfpwJ. Njitahd surface finishI ngWtjw;F
post-curing nra;ag;gl Ntz;Lk;.

2) Indirect method of rapi tooling

 Rapid prototype %yk; jahhpf;fg;gl;l ghfq;fis master
patternfshf gad;gLj;jp mould cUthf;fg;gLfpwJ.
PatternI jahhpf;f gad;gLj;jg;gl;l nray;Kiwiag;
nghWj;J> ,k;Kiwapy; cUthf;fg;gl;l mouldd; Jy;ypak;
mikAk;. Stereolithography Nghd;w kpfj; Jy;ypakhd
Kiwfs; ,jw;F gad;gLj;jg;gLk;.
 xU ngl;bf;Fs; patern njhq;f tplg;gLk;. ,e;j patternI
KOtJkhf #Ok; tifapy; cUfpa silicone rubber
Cw;wg;gLk;. jpl epiyia mile;jTld;> parting line
ntl;lg;gl;L pattern ntspNa vLf;fg;gLk;. jw;NghJ
Njitahd mould cavity cUthfp ,Uf;Fk;.

3.55
Advantages of rapid tooling
 Tooling Neuk; FiwT
 Fiwe;j nryT
 Design epiyapNyNa toold; nray;jpwid Nrhjidaplyhk;.
 Designy; cs;s jtWfis vspjpy; rhp nra;ayhk;.
 rpf;fyhd tbtq;fisAk; cUthf;fyhk;.
Disadvantages of rapid tooling
 Toold; tho;ehs; FiwT
 Accuracy FiwT
 typik FiwT

Review Questions
5 Marks Questions :
1) What are the data required for manual part programming?
2) What is meant by ‘machine zero point’ and ‘machine reference
point’?
3) Explain the NC dimensioning methods with example.
4) Write short notes on CNC program procedure.
5) Describe the following terminology: i) Character ii) Word iii) Block
6) What is meant by word address format?
7) Explain the format of a part program.
8) Briefly explain preparatory and miscellaneous functions.
9) Explain the following: i) Tool function ii) Feed function.
10) Write short notes on interpolation schemes.
11) Briefly explain about tool offset and tool nose radius
compensation.
12) Describe any five G functions.
13) What is a canned cycle? Give two examples.
14) Explain peck drilling cycle.
15) Write short notes on tool length compensation.
16) Explain the terms macros, subroutines, and canned cycles used
in CNC programming.
17) What is rapid prototyping? Differentiate subtractive and additive
prototypes.

3.56
18) List out the rapid prototyping techniques.
19) List out the materials used for RP.
20) What are the applications and advantages of RP?
21) Briefly explain rapid tooling.

10 Marks Questions :
1) With neat sketch, explain NC coordinate system.
2) Explain about the datum points and reference points in CNC.
3) Explain the terms linear interpolation and circular interpolation
with an example.
4) Explain stock removal canned cycle with an example.
5) Write a part program for thread cutting operation in a CNC lathe.
6) Explain grooving canned cycle with an example.
7) What is cutter compensation? When it is used and how it is
programmed?
8) What are canned cycles? Explain with sketches canned cycles for
drilling and tapping.
9) Write a part program to drill three holes in a rectangular work
part. The part is 10mm thick. Assume the dimensions and
positions of the hole.
10) Explain the use of subprogram with a simple CNC program.
11) Write a part program to explain mirroring operation in CNC
machining centre.
12) Explain pocketing in CNC machining centre with an example.
13) Explain stereolithography process with a simple sketch.
14) Explain FDM process of RPT.
15) Explain the selective laser sintering process. Mention its
advantages and disadvantages.
16) Explain 3D printing. Give its advantages.



3.57
 Unit – IV
COMPUTER INTEGRATED MANUFACTURING,
FLEXIBILE MANUFACTURING SYSTEMS,
AUTOMATIC GUIDED VEHICLE AND ROBOT
4.1 Computer Integrated Manufacturing (CIM)
CAD/CAM nray;ghLfs; kw;Wk; cw;gj;jpj; njhlh;ghd
midj;J tzpfr; nray;ghLfs; Mfpait mlq;fpaNj
Computer Integrated Manufacturing vdg;gLk;. Database kw;Wk;
jfty; njhlh;G njhopy; El;gq;fisg; gad;gLj;jp CIM ,e;j
midj;J nray;ghLfisAk; xUq;fpizj;J fl;Lg;gLj;JfpwJ.

4.1.1 Concept of CIM

Scope of CIM

Scope of CAD/CAM

Design

Business Factory Mfg.

functions operations planning

Mfg.
control

Fig.4.1 Concept of C I M
xU epWtdj;jpd; cw;gj;jp njhlh;ghd midj;J nray;ghL
fisAk; computer system cjtpAld; xUq;fpizj;J> mtw;iw
Nkk;gLj;jp> midj;J nray;ghLfSk; jhdhfNt Nkw;nfhs;sg;
gLk; tifapy; nra;tNj CIMd; mbg;gil Nehf;fk; MFk;. ,e;j
xUq;fpizf;fg;gl;l computer systemj;jpy;> xU nray;ghl;bd;
output MdJ kw;nwhU nray;ghl;bd; input Mf mikfpwJ. Sales
orderIg; ngWtjpypUe;J nghUis cw;gj;jp nra;J nfhLf;Fk;
tiu ,e;j rq;fpypj; njhlh; mikfpwJ.
4.1
4.1.2 Evolution of CIM
 Computer Integrated Manufacturing (CIM) vd;gJ CAD kw;Wk;
CAMd; xUq;fpize;j tsh;r;rpiaf; Fwpg;gjhFk;. CAD kw;Wk;
CAMd; tsh;r;rpahdJ Massachusetts Institute of Technology
(MIT) vd;w epWtdj;ijNa nghpJk; rhh;e;jJ.
 1950fspy; MIT MdJAPT vdg;gLk; xU NC part
programming languageI cUthf;fpaJ. 1962y;> Kjy; NC
machineI MIT cUthf;fpaJ.
 CNC njhopy; El;gkhdJ coordinate measuring machinefspd;
cUthf;fj;jpw;F toptFj;jJ. ,tw;wpd; tpisthf automated
inspection kw;Wk; robot Mfpait tsh;r;rp mile;jd. ,e;j
Nkk;ghLfs; midj;Jk; ,ize;J 1980fspy; flexible
manufacturing system (FMS) vd;w njhopy; El;gj;jpw;F tpj;jpl;lJ.
 1980fspy;, cw;gj;jp Kiwapd; ngUk;ghyhd nray;ghLfs;
computer %yk; fl;Lg;gLj;jg;gl;ld. vdpDk;> ,it
midj;ijAk; xUq;fpizj;J jfty;fisg; ghpkhwpf;
nfhz;lhy; kl;LNk computer kakhf;Ftjdhy; cz;lhFk;
KO gyidAk; mila KbAk;. ,e;j rpe;jidNa computer
integrated manufacturing cUthtjw;F toptFj;jJ.

4.1.3 CIM Wheel

 CIM wheel vd;gJ xU CIM systemj;jpy; cs;s
nray;ghLfis Fwpg;gJ MFk;. epWtdj;jpd; sales
department %ykhf orderfs; ngwg;gLfpd;wd. CAD system
cjtpAld; Gjpa nghUSf;fhd model cUthf;fg; gLfpwJ.
NkYk; assembly drawing kw;Wk; bill of material Mfpait
jahhpf;fg; gLfpd;wd.
 Design departmentd; output MdJ manufacturing
engineering departmentd; input Mf mikfpwJ. ,q;F
process planning, tool design kw;Wk; cw;gj;jp njhlh;ghd ,ju
nray;ghLfs; Nkw;nfhs;sg;gLk;.
 Manufacturing engineering departmentd; output MdJ PPC
departmentd; input Mf mikfpwJ. ,q;F computerd;
cjtpAld; MRP kw;Wk; scheduling Nkw;nfhs;sg;gLk;. ,t;thW
sales ordery; ,Ue;J nghUis cw;gj;jp nra;J delivery
nra;Ak; tiu computerIg; gad;gLj;JtNj CIM MFk;.
4.2
 CAD
Geometric modeling
Engineering analysis
Design review and evaluation
Automated drafting

Design
Computerized
CAM
Business System
Cost estimation
Order entry Business Factory Mfg. CAPP
Accounting functions operations planning NC part programming
Payroll
MRP, Capacity planning
Customer billing
Mfg.
control

CAM
Process control
Process monitoring
Shop floor control
Computer aided inspection

Fig.4.2 CIM Wheel

4.1.4 Benefits of CIM

1) Machined; gad;ghL mjpfhpf;fpwJ.
2) Direct kw;Wk; indirect labourfspd; vz;zpf;if FiwfpwJ.
3) nghUspd; cw;gj;jp Neuk; FiwfpwJ.
4) In-process inventoryd; msT FiwfpwJ.
5) SchedulingI Njitf;Nfw;g khw;wp mikj;Jf; nfhs;s KbAk;.
6) Scrap kw;Wk; rework FiwfpwJ.
7) njhopw;rhiyapd; jpwd; mjpfhpf;fpwJ.
8) ghJfhg;ghd #oy; Vw;gLj;jg; gLfpwJ.

4.1.5 Integrated CAD/CAM

 CAD/CAM njhopy;El;gk; %yk; design kw;Wk; manufacturing
nray;ghLfs; xUq;fpizf;fg;g Lfpd;wd. ,JNt integrated
CAD/CAM vdg;gLk;. CAD/CAMd; Nehf;fk; design kw;Wk;
manufacturingy; cs;s rpy nray;ghLfis jhdhfNt
nra;tJ kl;Lky;yhky; > designy; ,Ue;J manufacturingf;F
jfty;fis jhdhfNt nry;YkhW nra;tJk; MFk;.

4.3
 CA CA CNC Material
process CMM Production
Tool Program handling programs
planning Design Centre control
Computer
Aided
Design Common database

Design Common database

analysis
Finite Production
Element Scheduling Project
Simulation MRP Manage- control
Modeling ment

Fig.4.3 Common database linkage

 xUq;fpizf;fg;gl;l CAD/CAMy;> cw;gj;jp nra;ag;gl
Ntz;ba nghUspd; model kw;Wk; design databaseI CAD
system cUthf;FfpwJ. ,e;j databasy; geometric data, bill
of material kw;Wk; nghUisg; gw;wpa ,ju Fwpg;Gfs;
Mfpait mlq;fp ,Uf;Fk;.
 ,e;j nghJthd databaseIg; gad;gLj;jp> CAM system me;j
nghUis cw;gj;jp nra;tjw;Fj; Njitahd process planI
cUthf;FfpwJ. ,jw;F AutoCAM softwarefs; gad;gLj;jg;
gLfpd;wd.
 ghfq;fis cw;gj;jp nra;aj; Njitahd NC part
programfis CAM system jhdhfNt cUthf;fpf;
nfhs;Sk;. ,e;j part programfs; CAM system %yk; network
topahf machinef;F Neubahf download nra;ag;gLfpwJ.
 ,t;thW CAD/CAM xUq;fpizg;ghy;> product design, NC part
program cUthf;Fjy;> ghfq;fis cw;gj;jp nra;jy; Mfpa
midj;Jk; computer cjtpAld; epiwNtw;wg;gLfpwJ.

4.2 Flexible Manufacturing System (FMS)

Flexible Manufacturing System (FMS) vd;gJ KOtJk;
jhdpaq;fp Kiwapy; ,aq;Fk; xU GT machine cell MFk;. ,jpy; gy
machine toolfs;> automated material handling kw;Wk; storage system
Mfpait xd;Wld; xd;W ,izf;fg;gl;L xU central computer
%yk; fl;Lg;gLj;jg;gLk;.

Objectives of FMS
1) njhopw;rhiyapy; cs;s tsq;fspd; gad;ghl;il mjpfhpj;jy;.
2) Process cycle timeIf; Fiwj;jy;.

4.4
 3) ntt;;NtW machine toolfspy; ntt;NtW part stylefis xU
Nru cw;gj;jp nra;jy;.
4) Njitfspy; Vw;gLk; khw;wq;fSf;F Vw;g prorduct mixy;
flexibilityI Vw;gLj;Jjy;.
5) Machine break-down, tool failure Nghd;w re;jh;g;gq;fspy;>
NtnwhU work stationy; cw;gj;jpia njhlUjy;.
6) cw;gj;jp vz;zpf;ifia mjpfhpj;Jf; nfhs;Sk; tifapy;
nghpjhf;fg;glf; $ba xU systemj;ij cUthf;Fjy;

4.2.1 FMS components

FMSy; fPo;f;fz;l ghfq;fs; mlq;fpAs;sd.
1) Processing stations or work stations
2) Material handling and storage system
3) Computer control system
4) Human labour

1) Workstations: FMSy; gad;gLj;jg;gLk; equipmentfs;

my;yJ work stationfshdJ> me;j system %yk; Nkw;nfhs;sg;gLk;
Ntiyiag; nghWj;J mikAk;. Machining operationfSf;fhf
tbtikf;fg; gl;;l systemj;jpy; CNC machine toolfs; gad;gLj;jg;
gLk;. ,Ug;gpDk;> press working, forging, assembly, inspection Nghd;w
,ju nray;ghLfspYk; FMS gad;gLj;jg; gLfpwJ.
2) Material handling and storage system: FMSy; cs;s
stationfSf;F ,ilNa materialI ghpkhwpf; nfhs;tjw;F ,e;j
system cjTfpwJ. ,jpy; tof;fkhf gad;gLj;jg;gLk; gy;NtW
material transport equipment, inline transfer machinefs;> kw;Wk;
industrial robotfs; Mfpait mlq;Fk;. ,e;j system MdJ
automated storage / retrieval system (AS/RS)cld; xUq;fpizf;fg;
gl;bUf;Fk;.

3) Computer control system: FMS computer system MdJ>

micro computerfs; kw;Wk; xU central computer Mfpatw;iwf;
nfhz;bUf;Fk;. ,it xt;nthU machineIAk; kw;Wk; ,ju
ghfq;fisAk; fl;Lg;gLj;Jk;. Systemj;jpd; xl;Lnkhj;j
nray;ghLfSk; jilapd;wp Rygkhf eilngWtjw;fhf midj;J
ghfq;fspd; nray;ghLfisAk; central computer xUq;fpizf;fpwJ.

4.5
 4) Human labour: FMSy; human labour fPo;f;fz;l
nray;fis Nkw;nfhs;thh;.
 Raw workpartfis systemj;jpy; loading nra;jy;
 nra;J Kbf;fg;gl;l ghfq;fis systemj;jpy; ,Ue;J
unloading nra;jy;
 Toolfis khw;Wjy; kw;Wk; nghUj;Jjy;
 Machinefis guhkhpj;jy; kw;Wk; gOJ ghh;j;jy;
 Machining systemj;Jf;fhd NC part programI cUthf;Fjy;
4.2.2 FMS layouts
FMSy; fPo;f;fz;l layout configuationfs; fhzg;gLfpd;wd.
1) Inline layout 2) Loop layout 3) Ladder layout
4) Open field layout 5) Robot centered layout

1) In-line layout
Part transport system Partially completed
workparts
Loading Work flow Unloading
(Manual) (Manual)

Starting Processing Processing Processing Processing Completed

workparts station station station station workparts

Fig.4.4 In-line layout

 ,e;j layouty;> machinefs; kw;Wk; handling system Mfpait
xU Neh;f;Nfhl;by; mikf;fg; gl;bUf;Fk;.
 xU tiuaWf;fg;gl;l thpirapy; work part, xU workstationy;
,Ue;J kw;nwhU stationf;F efh;e;J nry;Yk;.
 ,jpy; work part xU jpirapy; kl;LNk efh;e;J nry;Yk;.
Backflow mDkjpf;fg;gltjpy;iy.

2) Loop layout
 ,e;j layouty;> tl;l tbt (loop) ghijapy; work stationfs;
mikf;fg;gl;bUf;Fk;. mNj tbtpy; mikf;fg;gl;l part
transport system %yk; work part ifahsg;gLfpwJ.
 Partfs; nghJthf loopI Rw;wp xU jpirapy; kl;LNk nry;Yk;.
 xt;nthU work stationYk; xU secondary handling system
gad;gLj;jg;gLk;.
 Loopd; xU Kidapy; loading / unloading stationfs;
epWtg;gl;bUf;Fk;.

4.6
 Processing Processing
station station
Part transport loop
Starting
workparts
Load/
Unload Direction of
(Manual) workflow
Completed
workparts

Processing Processing Secondary

station station handling system

Fig.4.5 Loop layout

3) Ladder layout

Processing
station

Processing
station Direction of
workflow

Processing
station

Starting Completed
workparts Load/ workparts
Unload
(Manual)

Fig.4.6 Ladder layout

 Ladder layouty;> Neuhd ghijfSf;F ,ilapy; Vzpg;gbfs;
Nghd;w FWf;Fg; ghijfs; mikf;fg; gl;bUf;Fk;. ,jpy; work
stationfs; epWtg;gl;bUf;Fk;.
 ,e;j Vzpg;gbfs; mikg;gpd; %yk;> xU machiney; ,Ue;J
kw;nwhU machinef;F work partI efh;j;Jtjw;fhd topfs;
mjpfhpf;fg; gLfpd;wd.
 ,jpy; secondary handling system Njitg;glhJ.
 ,J ruhrhp flf;Fk; J}uj;ijf; Fiwf;fpwJ. Jamming
Vw;gLtijAk; jtph;f;fpwJ.
 ,t;thW work stationfSf;fpilNaahd transport time
fzprkhd msT Fiwf;fg; gLfpwJ.

4.7
4) Open field layout
Starting
workparts
Load/
Inspection

AGV
Unload
(Manual) station
Completed
workparts

Processing Cleaning
station station

Processing Processing
station station

Processing Processing
station station

AGV

Fig.4.7 Open field layout

 ,e;j layouty; gy loop kw;Wk; ladderfisf; nfhz;bUf;Fk;.
 mjpf vz;zpf;ifapy; ghfq;fisf; nfhz;l part familyfis
cw;gj;jp nra;tjpy; ,j;jifa layoutfs; gad;gLj;jg;
gLfpd;wd.
 ,jpy; cs;s gy;NtW workstationfspy;> Kjypy; fpilf;fg;
ngWk; workstationf;F nry;YkhW partfs; jpUg;gp
tplg;gLfpd;wd.

5) Robot centered cell layout

Turning
centre

Parts
Robot conveyor

Turning
centre

Fig.4.8 Robot centered cell layout

4.8
  ,e;j layouty;> xd;W my;yJ mjw;F Nkw;gl;l robotfs;
material handling system Mf gad;gLj;jg; gLfpd;wd.
 RoYk; tif ghfq;fisf; ifahs;tjw;F Vw;g industrial
robotfs; gripperfisf; nfhz;bUf;Fk;.
 cUis tbt kw;Wk; disc tbt ghfq;fspd; cw;gj;jpapy; ,e;j
tif layout nghpJk; gad;gLj;jg; gLfpwJ.

4.2.3 Types of FMS

FMS fPo;f;fz;l tifg;gLk; :
1) Flexible turning cell (FTC)
2) Flexible Manufacturing Cell (FMC)
3) Flexible Transfer Line (FTL)
4) Flexible Machining System (FMS)

1) Flexible Turning Cell (FTC)

 ,J xU CNC turning centre kw;Wk; xU parts storage system
Mfpatw;iwf; nfhz;lJ MFk;.

 ,jpy; cs;s C-axis kw;Wk; turrety; cs;s gy;NtW tifahd

toolfspd; cjtpahy;> turning, milling, off-centre drilling,
tapping, helical groove cutting Nghd;w gy;NtW tifahd
operationfis vspjhf nra;a ,aYk;.

 mjhtJ xU nghUis cw;gj;jp nra;tjw;F Njitahd

midj;J operationfisAk; xNu machineIf; nfhz;Nl
nra;J Kbf;f ,aYk;.

 Automatic part changer, automatic tool changer, tool breakage

sensors, automatic tool length compensation, in-process
gauging, automatic chuck changing Nghd;w gy;NtW trjpfis
flexible turning cell ngw;wpUf;Fk;.

 ,e;j trjpfis gad;gLj;Jtjd; %yk;> machine ,aq;fhky;

,Uf;Fk; Neuk; nghpjstpy; Fiwf;fg; gLfpwJ. ,jdhy; CNC
turning centrefspd; flexibility kw;Wk; cw;gj;jp jpwd;
mjpfhpf;fg; gLfpwJ.

4.9
2) Flexible Manufacturing Cell (FMC)
 ,e;j mikg;ghdJ> automatic material handling kw;Wk;
automatic tool changer trjpfSld; $ba ,uz;L my;yJ
%d;W CNC machinefisf; nfhz;bUf;Fk;.
 ,J gy;NtW tbtk; kw;Wk; msTfisf; nfhz;l ntt;NtW
work piecefis jhdpaq;fp Kiwapy; vspjhf machining
nra;aty;yJ.
 rpwpa mstpyhd batch productionf;F ,J Vw;wJ.
 Flexible manufacturing cellf;fhd cjhuzq;fs; :
 Loading kw;Wk; unloading NtiyfSf;fhd xU robot,
workpiecefis Nrkpj;J itg;gjw;fhd xU pallet
Mfpatw;Wld; $ba xU turning centre.
 Modular fixturing, multiple pallets, advanced tool
management system, automatic tool changer, automatic
head changer, robots Mfpatw;Wld; $ba xd;W my;yJ
,uz;L horizontal machining centrefs;.
 Pick and place robot, automatic storage and retrieval system,
rail guided vehicle Mfpatw;Wld; $ba xU turning centre
kw;Wk; machining centre Nrh;e;j mikg;G.

3) Flexible Transfer Lines (FTL)

 Transfer line vd;gJ xU automatic material handling
systemj;Jld; ,izf;fg;gl;L> xU Fwpg;gpl;l thpirapy;
mikf;fg;gl;l gy machinefisf; nfhz;l cw;gj;jp mikg;G
MFk;.
 Mdhy;> flexible transfer line MdJ> khwf; $ba production
orderfSf;F Vw;wthW cldbahf cw;gj;jp mikg;gpid
khw;wp mikf;Fk; tifapy; tbtikf;fg; gl;ljhFk;.
 Vw;fdNt nghUj;jg;gl;l machinefspd; ,l mikg;ig
khw;whky;> material flow kw;Wk; workpiece transfer
Mfpatw;iw khw;wp mikf;Fk; tifapy; ,J tbtikf;fg;
gl;bUf;Fk;.
 Transfer linef;fhd flexibility MdJ> material handling control,
material flow kw;Wk; processing stationfs; Mfpa ,jd;
midj;J ghfq;fSf;Fk; nfhLf;fg;gLk;.
4.10
  Flexible transfer linefspy; gy;NtW tifahd workpiecefis
mjpf vz;zpf;ifapy; cUthf;fyhk;.

4) Flexible Machining System (FMS)

 ,J gy flexible automated machinefs; ,ize;j mikg;G
MFk;. ,e;j machinefs; midj;Jk; xU automatic material
handling systemj;Jld; ,izf;fg;gLk;.
 ,e;j mikg;gpd; %yk; gy;NtW tifahd nghUl;fis
vspjpy; cUthf;f ,aYk;.
 xU nghUis cw;gj;jp nra;Ak;NghJ> xt;nthU machinef;Fk;
machining time NtWgLk;. xU buffer storage mikg;gpd; %yk;
,e;j machining time NtWghL <Lfl;lg; gLfpwJ.
 CNC kw;Wk; flexible transfer line Mfpatw;wpd; %yk;
machinefSf;F flexibility nfhLf;fg; gLfpwJ.

4.2.4 Applications of FMS

1) Milling, turning, drilling Nghd;w machining operationfs;
2) Part assembly
3) Sheet metal press working
4) Forging
5) Welding
6) Inspection and testing

4.2.5 Benefits of FMS

1) cw;gj;jp tPjk; mjpfhpf;fpwJ.
2) Njitahd machinefspd; vz;zpf;if FiwfpwJ.
3) kdpjh;fspd; jiyaPL FiwfpwJ.
4) Inventory FiwfpwJ.
5) cw;gj;jp Neuk; FiwfpwJ.
6) cw;gj;jp fl;Lg;ghL Nkk;gLj;jg; gLfpwJ.
7) nghUspd; juk; Nkk;gLj;jg; gLfpwJ.
8) Njitahd ,lk; FiwfpwJ.
9) Njitahd Ml;fspd; vz;zpf;if FiwfpwJ.

4.11
4.2.6 Intelligent manufacturing system
ComputerI mbg;gilahff; nfhz;l Artificial Intelligence (AI)
El;gq;fis gad;gLj;jp nghUl;fis cw;gj;jp nra;tNj
Intelligence Manufacturing System vdg;gLk;. nghJthf kdpj
mwpNthL njhlh;Gila nray;fis nra;aty;y xU rhjdj;jpd; jpwd;
Artificial Intelligence vdg;gLk;. Reasoning, planning kw;Wk; problem
solving Mfpait ,j;jifa nray;ghLfspy; mlq;Fk;.

Applications of AI in manufacturing
1) Expert system in process planning
Expert system vd;gJ> Fwpg;gpl;l gpur;rpidia jPh;f;Fk;
Jiwapy;> xU expertIg; Nghd;w nray;ghl;Lj; jpwd; nfhz;l
computer program MFk;. nghUl;fis jukhdjhfTk; Fiwe;j
tpiyapYk; cw;gj;jp nra;atjw;Nfw;w process planI
cUthf;Ftjpy; expert system cjtpahf cs;sJ.
2) Computer vision
,e;j mikg;gpy;> xU fhl;rpiag; gw;wpa gl cUt Fwpg;G
computerf;F nfhLf;fg; gLfpwJ. ,e;j fhl;rp gFg;gha;T
nra;ag;gl;L relational matching Kiwapy;> me;jf; fhl;rpapy; cs;s
nghUs; fz;lwpag;gLfpwJ. Automated inspection, material handling
systemj;Jf;fhd automated guidance Mfpatw;wpy; computer vision
nghpJk; gad;gLfpwJ.
3) AI based scheduling
ntt;NtW cw;gj;jp nray;Kiwf;fhd Fwpg;gpl;l Neuq;fis
xJf;FtJ scheduling MFk;. SchedulingI Nkw;nfhs;tjw;F
knowledge based expert system gad;gLj;jg; gLfpwJ.

4) Decision support system

CIM #oypy;> job acceptance, planning kw;Wk; scheduling
Nghd;wtw;wpy; njhlh;r;rpahf gy KbntLf;Fk; nray;ghLfs;
mikfpd;wd. AI based decision support systemj;jpy;> ,e;j
nray;fis Nkw;nfhs;tjw;F ntt;NtW program modulefs;
gad;gLj;jg; gLfpd;wd

5) Other applications
 rhpahd cw;gj;jp rhjdq;fis Njh;e;njLj;jy;
 Database management nray;ghLfs;
4.12
  Material handling nray;ghLfs;
 Tool Nja;khdj;ij mstpLjy;
 CNC machinefspy; gpiofisf; fz;lwpjy;

4.3 Automated Guided Vehicle (AGV)

Automated guided vehicle vd;gJ xU material handling
cgfudk; MFk;. ,J jdpahf ,af;fg;gl;L> factory floord; kPJ
tiuaWf;fg;gl;l xU ghijapy; nry;YkhW top elj;jg;gLfpwJ.
,jpy; cs;s on-board battery %yk; ,jw;F power fpilf;fpwJ.

4.3.1 Working principle of AGV

Automated guided vehicle Kiwahf ,aq;Ftjw;F fPo;f;fz;l
Kf;fpa ghfq;fs; cs;sd.
1) Vehicle guidance system 2) Vehicle routing system
3) Traffic control system

1) Vehicle guidance system

Guidance system vd;gJ AGV nry;;y Ntz;ba ghijia
jPh;khdpg;gJ kw;Wk; mg;ghij topNa nry;YkhW vehiclefis
fl;Lg; gLj;JtJ MFk;.

AGV wire
sensing unit

Factory floor
Coil

Magnetic field
Guide wire
Slot cut in floor

Fig.4.9 Wire guidance used in AGV

 Guide wire method : njhopw;rhiyapd; jiuapDs; ntl;;lg;gl;l
gs;sj;jpy; electrical wirefs; Gijf;fg;gLk;. ,jd; %yk;>
pathwayIr; #o;e;J magnetic field cUthf;fg;gLk;. Vehicley;
cs;s on-board sensorfs; ,jidg; gpd;gw;wpr; nry;Yk;.
 Paint strips method : Paint stripfspd; cjtpAld; ghijfs;
tiuaWf;fg; gLfpd;wd. ghijiag; gpd;gw;Wtjw;F> vehicley;
optical sensor system gad;gLj;jg; gLfpwJ.

4.13
2) Routing system
AGV layoutfspy; gy loopfs;> branchfs;> side trackfs;> pick-
up kw;Wk drop off stationfs; Mfpait mlq;fp ,Uf;Fk;. gy;NtW
ghij tofspy;> kpfTk; nghUj;jkhd top Njh;T nra;ag;gl
Ntz;Lk;.
 Frequencies select method: ntt;NtW ghijfspy; nry;Yk;
guide wirefs; ntt;NtW frequencyfisf; nfhz;bUf;Fk;.
Vehicle nry;y Ntz;ba ,lj;ijg; nghWj;J> kpfr; rhpahd
ghijia mjd; frequencyI mbg;gilahff; nfhz;L Njh;T
nra;Jf; nfhs;Sk;.
 Path switch select method: Njitahd ghijiaj; jtpu
kw;w midj;J ghijfspYk; powerI epWj;Jtjd; %yk;>
nghUj;jkhd ghij Njhe;njLf;fg; gLfpwJ.

3) Traffic control system

VehiclefSf;F ,ilNaahd FWf;fPLfisf; Fiwg;gJk;>
Nkhjy;fis jtph;g;gJNk AGVy; cs;s traffic control systemj;jpd;
Fwpf;Nfhs; MFk;.
 Forward sensing control: kw;w vehiclefs; kw;Wk; vjpNu
cs;s jilfs; Mfpatw;iwf; fz;Lzu on-board sensorfs;
gad;gLj;jg; gLfpd;wd.
 Zone control: xU zoney; xU vehicle ,Uf;Fk; NghJ>
kw;nwhU vehicle me;j zonef;Fs; nry;y mDkjpf;fg; gl
khl;lhJ.
 Safety devices : top elj;Jk; ghijapypUe;J> Fwpg;gpl;l
J}uj;jpw;F Nky; tpyfpr; nry;Yk;NghJ> vehicleI jhdhfNt
epWj;jptpLk; mikg;G> jilfis czUk; sensor, emergency
bumper Nghd;w ghJfhg;G rhjdq;fs; nghUj;jg;
gl;bUf;Fk;.

4.3.2 Types of AGV

1) Towing vehicles 2) Unit load carriers
3) Pallet trucks 4) Fork trucks
5) Light load vehicles 6) Assembly line vehicles

4.14
 Towing Unit load Pallet truck

Fork truck Light load Assembly line

Fig.4.10 Types of AGV

1) Towing vehicle : ,jpy; xd;W my;yJ mjw;F Nkw;gl;l

trailerfs; ,izf;fg;gl;L xU train mikf;fg; gLfpwJ. mjpf
gSthd nghUl;fis mjpf J}uj;jpw;F vLj;Jr; nry;y
nghJthf ,J gad;gLfpwJ.
2) Unit load carriers : Unit loadfis xU stationy; ,Ue;J
kw;nwhU stationf;F efh;j;Jtjw;F ,it gad;gLj;jg;
gLfpd;wd. ,tw;wpy; powered rollerfs;> efh;e;J nfhz;bUf;Fk;
beltfs; my;yJ lift platformfs; nghUj;jg;gl;bUf;Fk;. mjpf
vz;zpf;ifapy; nghUl;fis kpjkhd J}uj;jpw;F vLj;Jr;
nry;y> unit load carrierfs; gad;gLfpd;wd.
3) Pallet trucks : Palletized loadfisjiukl;lj;jpy; ,Ue;J
vLj;Jr; nry;tjw;F pallet truckfs; gad;gLfpd;wd. rpy
Mapuk; fpNyhfpuhk; tiu vil nfhz;l nghUl;fis vLj;Jr;
nry;Yk; jpwid ,e;j pallet truckfs; ngw;Wss;sd. rpy
truckfspy; xU palletf;F gjpyhf ,uz;L palletfis
ifahSk; trjp ,Uf;Fk;.
4) Fork trucks : jiukl;lj;jpYk; standfspd;
kPJk; cs;s
loadfis ifahSk; jpwid fork truckfs; ngw;Ws;sd.
Njitg;gLk;NghJ loadfis Njf;fp itf;fTk; ,jpy; trjp
cs;sJ. Loadfis ntt;NtW cauq;fspy; ghpkhw;Wtjw;F
nghJthf ,it gad; gLfpd;wd.

4.15
 5) Light load vehicles : ,J 250 fpNyhfpuhk; my;yJ mjw;F
Fiwthd vil nfhz;l nghUl;fis vLj;Jr; nry;tjw;fhf
tb tikf;fg;gl;l rpwpa vehicle MFk;.
6) Assembly line vehicles :,it njhlh;r;rpahd assembly
nray;ghLfspy; gad;gLk; light load vehiclefs; MFk;.
gFjpahf Kbf;fg; gl;;l sub assemblyfis thpirahf
mikf;fg;gl;l assembly work stationfSf;F nfhz;L
nry;tjw;F Vw;g ,it tbtikf;fg; gl;bUf;Fk;.

4.3.3 Applications of AGV

1) Driverless train operations 2) Storage and distribution
3) Assembly line application 4) Flexible manufacturing system
5) Office mail delivery 6) Hospital material transport

4.3.4 Benefits of AGV

1) Dispatching, tracking kw;Wk; monitoring rpwg;ghf fl;Lg;gLj;jg;gLk;.
2) tsq;fis gadspfj;jf;f Kiwapy; gad;gLj;j ,aYk;.
3) nghUl;fspd; efh;it rpwg;ghf fl;Lg;gLj;j ,aYk;.
4) nghUl;fspy; ghjpg;G Vw;gLtJ jtph;f;fg; gLfpwJ.
5) nghUl;fis efh;j;Jtjhy; cUthFk; rj;jk; FiwfpwJ.
6) nghUl;fspd; efUk; ghijia vspjhf khw;wyhk;.
7) Njitahd floor space Fiwf;fg; gLfpwJ.
8) Inventory Fiwf;fg; gLfpwJ.
9) Ml;fspd; Njit Fiwf;fg; gLfpwJ.

4.4 Robots
Robot vd;gJ gy;NtW tifg;gl;l nray;fis Nkw;nfhs;
tjw;fhf> nghUl;fs;> ghfq;fs;> toolfs; my;yJ ,ju rpwg;G tif
rhjdq;fis efh;j;Jtjw;nfd tbtikf;fg;gl;l> program %yk;
fl;LgLj;jf; $ba> xU multi-functional manipulator MFk;.
4.4.1 Basic elements of robot
xU industrial robot fPo;f;fz;l ghfq;fisf; nfhz;bUf;Fk;.
1) Base 2) Manipulator
3) End effectors 4) Actuators
5) Transmission elements 6) Control system
7) Sensors 8) Interfaces

4.16
 Base
Wrist
assembly

Fig.4.11 Elements of robot

 Base: ,J robotd; mbg;gFjp MFk;. ,J epiyahfg;

nghUj;jg; gl;Nlh my;yJ efuf;$bajhfNth ,Uf;fyhk;.
Base cld; manipulator ,izf;fg; gl;bUf;Fk;.
 Manipulator: ,jpy; body, arm kw;Wk; wrist assembly mlq;Fk;.
Body kw;Wk; arm assembly MdJ positioning nra;tjw;F
cjTfpwJ. Wrist assembly MdJ orientationf;F cjTfpwJ.
njhlh;r;rpahd linkfs; kw;Wk; jointfs; cld; manipulator
mikf;fg; gl;bUf;Fk;.
 End effectors: ,J robot wrist cld; ,izf;fg; gl;bUf;Fk;.
End effector xU gripper MfNth tool MfNth ,Uf;fyhk;.
xU toolI Neubahf robot wrist cld; jpUfp nghUj;jyhk;.
Work piecefs; my;yJ toolfis gpbj;Jf; nfhs;tjw;F
gripperfs; gad;gLfpd;wd.
 Actuators: Robot linkfs; kw;Wk; mjNdhL njhlh;Gila
cgfuzq;fis ,af;Ftjw;fhd motorfs; ,jpy; mlq;Fk;.
 Transmission elements: Beltfs;> pulleyfs;> ball screwf;fs;>
gearfs; kw;Wk; ,ju ,ae;jpu ghfq;fs; ,jpy; mlq;Fk;.

4.17
  Control system: Njitahd signalfis cUthf;Ftjw;Fk;>
robotd; ntt;NtW efh;Tfis xUq;fpizj;Jf; fl;Lg;
gLj;Jtjw;Fk; control system gad;gLj;jg; gLfpwJ.
 Sensors: ,it robotf;fspy; gad;gLk; feed back cg
fuzq;fs; MFk;. ,jpy; cameraf;fs;> amplifierfs; kw;Wk;
mit njhlh;ghd hardwarefs; Mfpait mlq;Fk;.
 Interfaces: xU robotit kw;w robotf;fs;> computer system,
machinefs;> material handling system kw;Wk; mJ njhlh;ghd
rhjdq;fSld; ,izg;gjw;F interface gad;gLfpwJ.

4.4.2 Robot configurations

Kf;fpa robot configurationfs; fPo;f;fz;lthW :
 Polar coordinate configuration
 Cylindrical coordinate configuration
 Cartesian coordinate configuration
 Jointed arm configuration
 SCARA (Selective Compliance Assembly Robot Arm) configuration

(a) Polar coordinate (b) Cylindrical coordinate

(c) Cartesian coordinate (d) Jointed arm

Fig.4.12 Various robot configuration

4.18
  Polar coordinate : ,jpy; xU Kd;gpd; efUk; sliding arm
cs;sJ. ,J nrq;Fj;J mr;R kw;Wk; fpilkl;l mr;irg;
nghWj;J RoYk;.
 Cylindricatl coordinate : ,jpy; xU nrq;Fj;J column
cs;sJ. xU arm assembly MdJ ,e;j columnj;ij
nghWj;J NkYk; fPOk; efUk;. Arm MdJ columj;jpd;
mr;rpy; ,Ue;J cs;Nehf;fpAk; ntspNehf;fpAk; efuf;
$baJ. NkYk; columnj;ijg; nghWj;J ,J RoYk;.
 Cartesian coordinate : ,J rectilinear robot my;yJ x-y-z
robot vdTk; miof;fg;Lk;. ,jpy; %d;W jpirfspYk; efuf;
$ba %d;W sliding jointfs; ,Uf;Fk;. ,it xd;Wf;nfhd;W
nrq;Fj;jhf ,Uf;F k;.
 Jointed arm : ,J kdpjdpd; ifiag; Nghd;w mikg;G
nfhz;lJ. ,jpy; baseIg; nghWj;J RoYk; tifapy; xU
nrq;Fj;J column ,Uf;Fk;. Columnj;jpd; Nkw;Gwk; shoulder
joint cs;sJ. ,jd; output link MdJ elbow joint cld;
,izf;fg; gl;bUf;Fk;.
 SCARA : ,J jointed arm robotIg; Nghd;wNj MFk;. Mdhy;
,jd; shoulder kw;Wk; elbow MdJ nrq;Fj;J mr;irg;
nghWj;J RoYk;. ,jd; %yk; nrq;Fj;J jpirapy;
nghUj;Jk; Ntiyfis ,e;j robot vspjhf nra;Ak;.

4.4.3 Basic robot motions

xU cgNahfkhd Ntiyiar; nra;tNj robotd; Nehf;fk;
MFk;. Robot armd; Kbtpy; ,izf;fg;gl;Ls;s end effector
my;yJ hand vdg;gLk; ghfj;jpd; %yk; ,j;jifa Ntiy
rhj;jpakhfpwJ. End effectorf;F Njitahd gbg;gbahd
efh;itf; nfhLg;gjw;F MW tifahd mbg;gil efh;Tfs;
my;yJ degrees of freedom cs;sd.

Arm and body motions :

1) Vertical traverse : ArmMdJ NkYk; fPOk; efh;tJ. xU
fpilkl;l mr;rpidg; nghWj;J armI pivot nra;tjhNyh
my;yJ xU vertical slided; kPJ armI efh;j;jpNah ,e;j efh;T
ngwg;gLfpwJ.
2) Radial traverse : Armd;ePsj;ij mjpfhpg;gJk;
Fiwg;gJkhd efh;T. (Armd; Kd; gpd; efh;T)
4.19
 3) Rotational traverse : xU nrq;Fj;J mr;irg; nghWj;J
armd; Row;rp (Robot armd; ,lJ my;yJ tyg;gf;f Row;rp)
Rotational
traverse

Vertical
traverse Arm and body
assembly
rse
Wrist bend ave
tr
ial
R ad

Base
Wrist
assembly

Wrist swivel

Wrist yaw
Fig.4.13 Basic robot motions

Wrist motions :
4) Wrist swivel : Wristd; Row;rp
5) Wrist bend : Wrist NkYk; fPOk; efh;tJ. ,jpy; wristd;
Row;rpAk; mlq;Fk;.
6) Wrist yaw : Wristd; tyJ my;yJ ,lJ gf;f miyT.

4.4.4 Robot programming method

Robotf;fhd gy;NtW programming Kiwfs; fPo;f;fz;lthW :
1) Manual method
2) Walkthrough method
3) Leadthrough method
4) Off-line programming

1) Manual method : ,J xU machineI Ntiy nra;tjw;F

jahh; gLj;JtJ Nghd;w Kiw MFk;. Robot fl;Lg;ghl;L
njhFjpapy; cs;s mechanical stop, cam, switch kw;Wk; relay
Nghd;wtw;iw Njitahd mstpy; rhpnra;J mikg;gJ MFk;.
4.20
Fiwthd cycle time nfhz;l vspa tif robotfSf;F ,k;Kiw
Vw;wJ. cjhuzk; : Pick-and -place nray;ghLfs;.

2) Walkthrough method : ,k;Kiwapy; xU work cycley;

cs;s mLj;jLj;j thpirahd efh;Tf;F Vw;whw;Nghy robot arm
kw;Wk; hand MdJ programmer %yk; manualMf efh;j;jg;gLk;.
xt;nthU efh;Tk; memoryy; gjpT nra;ag;gl;L> Ntiy
eilngWk;NghJ mJ jpUk;g ,af;fg;gLk;. Spray painting kw;Wk;
arc welding robotfspy; ,k;Kiw nghpJk; gad;gLj;jg; gLfpwJ.

3) Leadthrough method : ,k;Kiwapy; robotd; mLj;jLj;j

efh;thdJ teach pendant vdg;gLk; fUtp %yk; fl;Lg;gLj;jg;
gLfpwJ. Teach pendant vd;gJ robotd; efh;tpid fl;Lg;gLj;Jk;
tifapy; nghUj;jg;gl;l switch kw;Wk; dialfisf; nfhz;l fUtp
MFk;. Robotd; xt;nthU efh;Tk; memoryy; gjpT nra;ag;gl;L>
gpd;G work cycled; NghJ ,af;fg; gLfpwJ. ,J kpfTk; vspa
kw;Wk; trjpahd Kiw MFk;.

4) Off-line programming : ,k;Kiwapy; xU computer

cjtpAld; robotf;fhd off-line programfs; cUthf;fg; gLfpd;wd.
Program jahh; nra;ag;gl;lTld;> robotd; memoryy; cs;sPL
nra;ag;gl;L work cycled; NghJ ,af;fg;gLfpwJ.

Advantages of off-line programming :

 Robotf;F fw;Wf; nfhLg;gjhy; Vw;gLk; Neu ,og;G jtph;f;fg;
gLfpwJ.
 Robot NtnwhU Ntiyia nra;J nfhz;bUf;Fk;NghNj off-
line programming nra;a ,aYk;.
 Robot kw;Wk; mjd; cgfuzq;fspd; gad;ghL mjpfhpf;fpwJ.
 CAD / CAM database kw;Wk; jfty; ikaj;Jld; robotI
xUq;fpizf;f KbAk;.

4.4.5 Robot sensors

Robot mjd; Ntiyfis jpwk;gl nra;tjw;F kdpjh;fisg;
Nghd;Nw czUk; jpwd; mtrpak; MFk;. ,j;jifa czUk;
mikg;Gfs; fPo;f;fz;lthW :
1) Vision sensors 2) Tactile sensors
3) proximity sensors 4) Voice sensors

4.21
1) Vision sensors
xU videocamera, xsp kw;Wk; image datait
gFj;jwptjw;fhd computer program Mfpait robot visiony;
mlq;Fk;. ,jd; %yk; xU nghUs; ,Uf;Fk; ,lk; kw;Wk; epiyia
fz;lwpa KbfpwJ.

Vision sensorfspd; gad;fs;:

 Conveyory; ,Ue;J ghfq;fis fz;lwpe;J vLf;fpwJ.
 xU Fwpg;gpl;l ghfj;ij milahsk; fz;lwpfpwJ.
 nghUl;fis NrhjidapLfpwJ.
 Assemly nray;ghLfspy; rhpahd alignmentf;F cjTfpwJ.

2) Tactile sensors
jq;fSf;Fs;shfNth my;yJ gpw nghUl;fis
njhLk;NghNjh cUthFk; tpirapd; mbg;gilapy; robottpid
,af;f ,t;tif sensorfs; gad;gLfpd;wd. Touch sensors kw;Wk;
stress sensors Mfpait tactile sensorfspd; ,uz;L tiffshFk;.
 xU nghUisj; njhLfpwjh vd;gij czh;j;Jtjw;F Touch
sensorfs; cjTfpd;wd. xU vspa microswitch MdJ touch
sensor Mf nray;gLk;.
 njhLk;NghJ cUthFk; tpirapd; kjpg;ig mstpl stress
sensorfs; gad;gLfpd;wd. Strain-gauge tifapyhd
fUtpfs; stress sensorfshfg; gad;gLfpd;wd.
Tactile sensorfspy; gad;fs; :
 Assemblyd; NghJ> alignment kw;Wk; joining nray;ghLfs;
 Inspectiond; NghJ> mstpLk; nray;ghLfs;

3) Proximity sensors
xU nghUshdJ kw;nwhU nghUSf;F mUfpy; cs;sjhf
vd;gij czh;tjw;F proximity sensorfs; cjTfpd;wd. End
effectord; kPNjh my;yJ mjw;F mUfpNyh ,t;tif sensorfs;
nghUj;jg; gl;bUf;Fk;. Eddy-current proximity detectorfs; kw;Wk;
magnetic field sensorfs; Mfpait ,jw;F cjhuzq;fs; MFk;.

Proximity sensorfspd; gad;fs; :

 xU nghUs; cs;sjh ,y;iyah vd;gij czh;e;J mwpa
cjTfpd;wd.

4.22
  Robot cld; gzpGhpAk; gpw gzpahsh;fis fhak;
miltjpypUe;J ghJfhf;fTk; ,it cjtpfpd;wd.

4) Voice sensors
Robotfspy; tha;nkhopf; fl;lisfis cs;thq;fp gFj;jwpAk;
mikg;G nghUj;jg; gl;bUf;Fk;. ,e;j mikg;ghdJ tha;nkhopf;
fl;lisfis Vw;fdNt databasey; gjpT nra;ag;gl;ls;s
fl;lisfSld; xg;gpl;L ghh;f;Fk;. me;j fl;lisapy; mlq;fpAs;s
thh;j;ij fpilj;jTld> mjw;nfd program nra;ag;gl;Ls;s
nray;fis thpirahfr; nra;Ak;.
Voice sensorfspd; gad;fs; :
 Robot programI tpiuthf nra;tjw;F gad;gLfpd;wd.
 mghafukhd #oy;fspy; gOJghh;f;Fk; Ntiyfis
nra;tjw;F cjTfpd;wd.

4.4.6 End effectors

Robot armd; ,Wjpapy; ,izf;fg;gl;Ls;s fUtpfs; end
effectorfs; vdg;gLk;. ,it end of arm tooling (EOAT) my;yJ
manipulatorfs; vdTk; miof;fg;gLk;. Robot wristfshf
nray;gLkhW ,it tbtikf;fg;gl;L gad;gLj;jg;gLk;. Grippers
kw;Wk; processing tools Mfpait ,U tifahd end effectorfs;
MFk;.

Grippers
Gripper vd;gJ nghUl;fis gw;wpg; gpbg;gjw;fhf
tbtikf;fg;gl;l xUtif end effector MFk;. ghfq;fspd; tbtk;>
msT kw;Wk; vil Mfpatw;iwg; nghWj;J gripperfs;
tbtikf;fg; gLfpd;wd. Robot gad;ghLfspy; fPo;f;fz;l
gripperfs; gad;gLj;jg; gLfpd;wd.
1) Mechanical grippers 2) Vacuum grippers
3) Magnetic grippers 4) Other grippers

1) Mechanical grippers
 Mechanical gripperfs; ,uz;L my;yJ mjw;F Nkw;gl;l efUk;
mirAk; tpuy;fs; my;yJ jawfisf; nfhz;bUf;Fk;. ,e;j
tpuy;fs; RoYk; tifapNyh my;yJ NeuhfNth efUk;.

4.23
  Robot controller %yk; ,af;fg;gl;L ,e;j tpuy;fs; %lNth
my;yJ jpwf;fNth nra;ag;gLfpd;wd. ,jd; %yk;
nghUl;fs; gw;wpg; gpbf;fg; gLfpd;wd.
 nghUl;fspy; NkhJtij jtph;g;gjw;fhf ,tw;wpy; collision
sensorfs; nghUj;jg;gl;bUf;Fk;.
 Mechanical grippefspd; ntt;NtW tbtq;fs; :
 Dual grippers : ,jpy; xU end effectory; ,uz;L gripperfs;
,Uf;Fk;. Machine loading kw;Wk; unloading Ntiyfspy;
,it gad;gLfpd;wd.
 Interchangeable fingers : xU end effectory; gy tbtpyhd
tpuy;fs; nghUj;jg;gl;bUf;Fk;. ntt;NtW ghfq;fis
ifahs;tjw;F Vw;g jFe;j tpuy;fs; khw;wp gad;gLj;jg;gLk;.
 Multiple fingered grippers : kdpjdpd; ifiag; Nghd;W
tpuy;fs; ,jpy; nghUj;jg;gl;bUf;Fk;.
2) Vacuum grippers
 nghpa kw;Wk; vspjpy; cile;J tpLk; nghUl;fis
ifahs;tjw;F vacuum gripper gad;gLfpwJ.
 jl;ilahd nghUl;fis gw;wpg; gpbf;f suction cupfis
gad;gLj;JfpwJ. ,it round my;yJ oval tbtpy; ,Uf;Fk;.
Rubber my;yJ plastic My; nra;ag;gl;bUf;Fk;. Suction
cupfspd; msitg; nghWj;J grip strength mikAk;.
 Cupf;Fs; ntw;wplk; Vw;gLj;j rpwpJ Neuk; vLj;Jf;
nfhs;tjhy;> nghUl;fis cldbahf gw;wpg; gpbf;fhJ.
 FWfpa ,ilntspfspy;> rpwpa kw;Wk; vspjpy; cile;J
tpLk; nghUl;fis J}f;Ftjw;Fk; itg;gjw;Fk; ,it
cjTfpd;wd. Vacuum gripperfs; nghUs; KOtJkhf gutp
gpbf;f Ntz;ba mtrpak; ,y;iy.

3) Magnetic grippers
 Magnetic gripperfs; fhe;j tpiria gad;gLj;jp
nghUl;fis efh;j;Jfpd;wd.
 ,it cNyhfq;fis kl;LNk cldbahf gpbf;Fk;. ,it
nghUl;fis tpiuthf jpwk;gl efh;j;Jfpd;wd.

4.24
  Gripperd; ve;j xU gFjpapYk; nghUl;fs; xl;bf;nfhs;Sk;.
vdNt> ntt;NtW msT nfhz;l nghUl;fisAk; ,J
vspjhf gpbj;Jf; nfhs;Sk;.
 nghUl;fis ,wf;fp tpl;l gpwFk; mtw;wpy; rpwpjsT fhe;jj;
jd;ik epiyj;jpUf;Fk;.
 kpd; fhe;jq;fs; my;yJ epiy fhe;jq;fs; ,tw;wpy;
gad;gLj;jg; gLfpd;wd.

4) Other grippers
 Expanding gripper : ,it tphptilaf; $ba tube My;
nra;ag;gl;l tpuy;fis nfhz;bUf;Fk;. ,it nghUl;fis
ntspg;Gwk; #o;e;Njh my;yJ cs;spUe;J tphptile;Njh
gw;WfpwJ.
 Adhesive gripper : Robot wrist topahf njhlh;e;J
nrYj;jg;gLk; xl;Lk; nghUspd; %yk; ghfq;fs; gpbf;fg;
gLfpd;wd. Fabric Nghd;w vil Fiwthd> nefpOk; jd;ik
nfhz;l nghUl;fis gpbg;gjw;F ,it cjTfpd;wd.
 Hook gripper :Overhead conveyorfspy; ,Ue;J containerfis
load kw;Wk; unload nra;tjw;F ,it gad;gLfpdwd.
 Ladle gripper : jput my;yJ J}s; epiyapy; cs;s rpy
nghUl;fis ifahs;tjw;F ,J gad;gLfpwJ.

Processing tools
 Workpiecey; rpy cw;gj;jp nray;fis nra;tjw;F toolfis
robot gad;gLj;JfpwJ.Robot MdJ epiyahd my;yJ
nkJthf efUk; nghUl;fspd; kPJ toolfis ,af;FfpwJ.
 Toold; epiy kw;Wk; nray;ghL Mfpa ,uz;ilAk; robot
fl;Lg;gLj;JfpwJ.
 ToolI ,af;Fjy;> epWj;Jjy; kw;Wk; fl;Lg;gLj;Jjy; Nghd;w
nray;fSf;fhd fl;lisfis gpwg;gpf;Fk; trjpia robot
ngw;wpUf;f Ntz;Lk;.
 cjhuzq;fs; : Spot welding gun, arc welding tool, spray
painting gun, rotating spindle for drilling, grinding, and similar
operations, assembly tool, heating torch, ladle, water jet cutting
tool, Nghd;wit.

4.25
4.4.7 Characteristics of robot applications
fPo;f;fz;l gzpr; #oy;fspy; industrial robotfs; jpwk;gl
gad;gLj;jg; gLfpd;wd.
 mghafukhd Ntiyfs; : mghafukhd> ghJfhg;gw;w
my;yJ trjpf;Fiwthd gzpr; #oy;fspy; industrial
robotfs; gad;gLj;jg;gLk;. Forging, spray painting, arc
welding kw;Wk; spot welding Nghd;wit ,jpy; mlq;Fk;.
 xNu Ntiyia jpUk;g jpUk;g nra;jy; : jpUk;g jpUk;g
nra;ag;gLk; xNu tifahd vspa NtiyfSf;F robot
gad;gLj;jg;gLk;. ,jd; %yk; mjpf epiyg;Gj; jd;ik
kw;Wk; repeatability fpilf;Fk;.
 ifahsf; fbdkhd Ntiyfs; : kpf mjpf gSthd
ghfq;fs; kw;Wk; fUtpfis ifahs;tjw;F robotfis
gad;gLj;jyhk;.
 Multishift Ntiyfs; : Multishift NtiyfSf;F robotfis
gad;gLj;Jk;NghJ $Ljy; ,yhgk; fpilf;Fk;. ,J ,uz;L
my;yJ %d;W NgUf;fhd Ntiyia Vw;Wr; nra;Ak;.
 mbf;fb khwhj Ntiyr; #oy; : mbf;fb khw;wk; Vw;glhj
ePz;l fhy cw;gj;jp #oy;fspy; robotfs; gad;gLj;jg;gLk;.

4.4.8 Applications of industrial robots

nghUl;fspd; cw;gj;jpapy; gy;NtW epiyfspy; industrial
robotfs; gad;gLj;jg; gLfpd;wd. mj;jifa gad;ghLfspy;
fPo;f;fz;lit mlq;Fk;.
1) Material transfer 2) Machine loading 3) Welding
4) Spray coating 6) Assembly 6) Inspection

1) Material transfer
Work piecefis Xhplj;jpy; ,Ue;J kw;nwhU ,lj;jpw;F
vLj;Jr; nry;tjw;F robotfs; gad;gLj;jg; gLfpd;wd. ,j;jifa
gad;ghLfspy; fPo;f;fz;lit mlq;Fk;.
 vLj;Jg; nghUj;Jk; vspa tif nray;ghLfs;
 xU conveyory; ,Ue;J kw;nwhU conveyorf;fF work
piecefis khw;Wjy;.

4.26
  xU conveyory; ,Ue;J ghfq;fis Njitahd pattern kw;Wk;
thpirapy; xU palletf;F Vw;Wjy; ( palletizing)
 Conveyory; ,Ue;J ghfq;fis carton my;yJ boxfSf;F
Vw;Wjy;
 xU pallety; ,Ue;J ghfq;fis conveyorf;F Vw;Wjy;
(depalletizing)
2) Machine loading
Work piecefis machinefSf;F supply nra;jy;
kw;Wk;
Kbf;fg;gl;l ghfq;fis machiney; ,Ue;J unload nra;jy; Mfpa
nray;fSf;F robotfs; gad;gLj;jg; gLfpd;wd.
fPo;f;fz;l cw;gj;jp nray;Kiwfspy; loading kw;Wk;
unloading NtiyfSf;F robotfs; gad;gLj;jg; gLfpd;wd.
 Die casting  Injection moulding
 Transfer moulding  Hot forging
 Upset forging  Stamping press operations
 Turning kw;Wk; milling Nghd;w machining operationfs;

3) Welding
 Spot welding kw;Wk; arc welding Nghd;w welding nray;fSf;F
industrial robotfs; nghpJk;
gad;gLj;jg; gLfpd;wd. End
effectorf;F gjpyhf welding gun nghUj;jg;gLk;.
 Spot weldingy;, Njitahd ,lk; kw;Wk; jpirapid rhpahf
miltjw;F MW mr;Rfs; Njitg;gLk;. Point-to-point
fl;Lg;ghL nfhz;l playback robotfs; nghpJk; gad;gLj;jg;
gLfpd;wd. Automobilefspy; spot welding nra;tjw;F jointed
arm robotfs; cjTfpd;wd.
 Arc weldingI jhdpaq;fp nray;Kiwahf khw;Wtjw;F
robotfs; gad;gLfpd;wd. ,jw;F continuous path fl;Lg;ghL
nfhz;l robotfs; Njitg;gLk;. MW ,izg;Gisf;
nfhz;l jointed arm robotfs; ngUkstpy; gad;gLj;jg;
gLfpd;wd.
 Weldingf;F robotfis gad;gLj;Jtjhy; Vw;gLk; ed;ikfs;:
 mjpf productivity
 Nkk;gLj;jg;gl;l ghJfhg;G
 mjpf cWjpahd weldfs;
4.27
4) Spray coating
 Paint, stain, plastic powder, sand absorber my;yJ
,ju
nghUl;fspd; Jfs;fis kw;nwhU nghUspd; kPJ gbar;
nra;tjw;fhd spray coating nray;ghLfspy; robotfs;
gad;gLj;jg; gLfpd;wd.
 tPl;L cgNahf rhjdq;fs;> car body, engine Nghd;wtw;wpd;
kPJ spray coating nra;jy;> kuj;jhy; nra;ag;gl;l
nghUl;fspd; kPJ spray staining nra;jy;> Fspayiw
rhjdq;fspd; kPJ porcelain coating nra;jy; Mfpait ,jpy;
mlq;Fk;.

 Robotf;F continuous path fl;Lg;ghL Njitg;gLk;. Jointed

arm robotfs; nghpJk; gad;gLj;jg; gLfpd;wd.

 Spray coating nray;ghLfSf;F robotfis gad;gLj;Jtjhy;

VwlgLk; ed;ikfs;:
 ghJfhg;G  xUgbj;jhd coating
 Fiwthd material gad;ghL  Fiwthd Mw;wy; Njit
 mjpf productivity

5) Assembly
 jw;NghJ servo control Kiwapy; fl;Lg;gLj;jg;gLk; robotfs;
assembly operatinfspy; jpwk;gl gad;gLj;jg; gLfpd;wd.
Jointed arm, Cartesian coordinate kw;Wk; SCARA Mfpa
configurationfs; ngUk;ghYk; gad;gLj;jg; gLfpd;wd.

 nghUj;Jk; Ntiyfspy; accuracy kpf Kf;fpakhdjhFk;.

Njitg;gLk; robotfspd; vz;zpf;ifia Fiwg;gjw;fhf>
robotfspd; end effector MdJ gy Ntiyfis nra;a
Ntz;Lk;.

 Automobile njhopw;rhiyfspy; fly wheelfs;> spring strutfs;>

front coverfs;> front kw;Wk; rear axlefs;> steering gear, door
linerfs;> wind shield, wheelfs;> chasis Nghd;wtw;wpd;
assemblyy; robotfs; nghpjstpy; gad;gLj;jg; gLfpd;wd.

4.28
6) Inspection
 mstPLfis rhpghh;j;jy; kw;Wk; ,ju NrhjidapLk;
nray;ghLfspy; robotfs; gad;gLfpd;wd. mtw;wpy; rpy
nray;ghLfs; :
 nfhLf;fg;gl;l
nray;Kiw Kbe;J tpl;ljh vd;gij
cWjp nra;a cjTfpwJ.
 Assemblyd;NghJ ghfq;fs; Kiwahf mLf;fg;gl;Ls;sjh
vd;gij cWjp nra;a gad;gLfpwJ.
 %yg;nghUl;fs; kw;Wk; nra;J Kbf;fg;gl;l ghfq;fspy;
cs;s FiwghLfis fz;lwpa cjTfpwJ.
 Mechanical probefs;> xsp czUk; jpwd; kw;Wk; ,ju
mstpLk; fUtpfSld; $ba robotfs; ,jpy;
gad;gLj;jg;gLk;.
 Inspection operationfspy; gad;gLj;jg;gLk; robotf;fs;
Kiwahf program nra;ag;gl Ntz;Lk;.

Review Questions
5 Marks Questions :
1) Define CIM. Explain the concept of CIM.
2) Write short notes on evolution of CIM.
3) Briefly explain CIM wheel.
4) List out the benefits of CIM.
5) Explain the integrated CAD/CAM.
6) What is FMS? State the objectives.
7) Write short notes on (a) Flexible manufacturing cells (b) Flexible
transfer lines.
8) What are the benefits and applications of FMS?
9) Explain the intelligent manufacturing system.
10) What is AGV? List out the different types of AGV
11) What are the applications and benefits of AGV?
12) Define robot. List out the basic elements in an industrial robot.
13) Explain the configurations of robot.
14) Explain the basic robot motions.
4.29
15) Explain the various robot programming methods.
16) What are robot sensors? Explain their uses in robots.
17) What are end effectors? List out the types.
18) Explain the various types of grippers used in robot.
19) List out the processing tools used as end effectors in robot.
20) Briefly explain the application of robot in material handling.
21) Explain the applications of robot in welding industry.

10 Marks Questions :
22) Explain about the FMS components.
23) Briefly explain the types of layout configurations used in FMS.
24) Explain the types of FMS.
25) Explain the working principle of AGV.
26) Briefly explain the various types of AGV with line sketches.
27) Explain the various industrial applications of robot.



4.30
 Unit – V
CONCURRENT ENGINEERING,
QUALITY FUNCTION DEPLOYMENT,
PRODUCT DEVELOPMENT CYCLE,
AND AUGMENTED REALITY
5.1 Sequential engineering

Design Planning Manufacture Quality Marketing

Fig.5.1 Sequential engineering

 Sequential engineering Kiwapy;> nghUl;fis tbtikj;jy;>

cw;gj;jp nray;Kiwfis cUthf;Fjy;> quality kw;Wk;
testing nray;Kiwfis eph;zapj;jy; Mfpait xd;wd; gpd;
xd;whf eilngWk;.

 R & D FOthdJ design njhlh;ghd Ntiyfis Kbj;jTld;>

jfty;fis planning FOtpw;F mDg;Gk;. mq;fpUe;J jfty;
manufacturing Jiwf;F mDg;gp itf;fg;gLk;. ,e;j
FOf;fSf;F ,ilNa ve;j xU interactionk; ,Uf;fhJ.

 nghUspy; nra;ag;gl Ntz;ba khw;wq;fshdJ planning

my;yJ manufacturing my;yJ assembly nray;ghl;bd;NghJ
fz;lwpag;glyhk;. vdpDk; ,e;j khw;wq;fs; designy;
cl;GFj;jg;gl Ntz;Lk;.

 ,j;jifa #o;epiyapy;> design epiyapypUe;J midj;J

nray;ghLfSk; jpUk;g nra;ag;gl Ntz;Lk;. ,jdhy; $Ljy;
nryTk; nghUis cw;gj;jp nra;tjpy; mjpf NeuKk; MfpwJ.

5.2 Concurrent engineering

 xd;wpize;J nrayhw;Wk; xU FOtpidf; nfhz;L> nghUis
cw;gj;jp nra;Ak; nray;Kiwfis Nkk;gLj;Jk; xU etPd
KiwNa concurrent engineering MFk;. ,J simultaneous
5.1
 engineering my;yJ parallel engineering vdTk; miof;fg;gLk;.
,e;j Kiwapy;> nghUis tbtikf;Fk; jpwd; Nkk;gLtJld;
cycle timek; FiwfpwJ.

 R & D, engineering, manufacturing, materials management,

quality assurance, marketing Nghd;w Jiwfspy; ,Ue;J
gpujpepjpfs; xd;whf ,ize;J nghUis cUthf;Ffpwhh;fs;.
Muk;gk; KjNy xt;nthUtUk; kw;wtUld; fye;J MNyhrpj;J>
mth;fsJ Ntiyfis ,ize;J nra;fpwhh;fs;.

Market Product
analysis design

Sales and System

distribution design

Manufacturing

Fig.5.2 Concurrent engineering

 Concurrent engineering Kiwia jpwk;gl epiwNtw;Wtjw;F

product development, production planning kw;Wk;
manufacturing JiwfSf;F ,ilNa gykhd team work
mtrpak; MFk;.

 gy;Jiw ty;Yeh;fspd; xj;Jiog;G kw;Wk; DFMA (Design for

Manufacturing and Assembly) kw;Wk; FMEA (Failure Mode and
Effect Analysis) Nghd;w etPd Kiwfisg; gad;gLj;JtJk;
Kf;fpak; MFk;.

 ,jd; %yk; nghUspd; tbtikg;G rpwg;ghf Nkk;gLj;jg;gl;L>

nghUspy; Vw;glf;$ba FiwghLfs; vspjhf fz;lwpag;gLk;.
,jdhy; lead time Fiwf;fg;gl;L> nghUspd; cw;gj;jp nryT
FiwfpwJ. NkYk; nghUspd; quality mjpfhpf;fpwJ.

5.2
5.2.1 Sequential Vs Concurrent engineering

Sequential engineering Concurrent engineering

1) nghUis cUthf;Fk; nghUis cUthf;Fk; gy;NtW
eilKiwfs; xd;wd;gpd; eilKiwfs; ,izahf
xd;whf eilngWk;. eilngWk;.
2) JiwfSf;F ,ilNa JiwfSf;F ,ilNa
xUq;fpizg;G ,Uf;fhJ. xUq;fpizg;G ,Uf;Fk;.
3) tbtikg;gpy; cs;s tbtikg;gpy; cs;s gpiofis
gpiofis vspjhf fz;lwpa vspjhf fz;lwpayhk;.
KbahJ.
4) tbtikg;gpy; khw;wj;ij tbtikg;gpy; khw;wj;ij
VwgLj;JtJ fbdk;. VwgLj;JtJ vspJ.
5) tbtikg;ig khw;Wtjhy; tbtikg;ig khw;Wtjhy;
Vw;gLk; nryT mjpfk;. Vw;gLk; nryT FiwT.
6) kpfr;rpwe;j tbtikg;ig kpfr;rpwe;j tbtikg;ig
ngw KbahJ. ngw KbAk;.
7) nghUis cUthf;Ftjw;fhd nghUis cUthf;Ftjw;fhd
Neuk; mjpfk;. Neuk; FiwT.

5.2.2 Need of concurrent engineering

 ngUfp tUk; cyfshtpa Nghl;b.
 mbf;fb khWfpd;w Efh;Nthhpd; Njitfs;.
 nghUspd; FWfpa MAl;fhyk;.
 g y ngh Ul; f i s xNu Neuj; j p y; tb t ik g; gjw; fhf x U q; f p i ze; J
nr ay; gLk; gy J iw f i s f; nfh z; l nghpa ep Wt d q; fs; .
 Ntfkhf tsh;e;J tUk; Gjpa kw;Wk; etPd njhopy;El;gq;fs;.

5.2.3 Benefits / Advantages of concurrent engineering

1) kpfr;rpwe;j design ngwg;gLfpwJ.
2) Designy; cs;s gpiofis vspjpy; fz;lwpe;J rhp nra;ayhk;.
3) nghUis cUthf;Ftjw;fhd Neuk; FiwT.
4) Fiwthd cw;gj;jp nryT.
5) mjpf cw;gj;jp tPjk;.
6) nghUspd; juk; Nkk;gLj;jg;gLk;.
7) nghUspd; ek;gfj;jd;ik Nkk;gLk;
8) thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.

5.3
5.3 Quality Function Deployment (QFD)
Quality Function Deployment (QFD) vd;gJ> xU nghUis
cUthf;Ftjw;fhd midj;J epiyfspYk;> thbf;ifahsh;fspd;
Njitfis mg;nghUspd; gz;Gfshf khw;wp mikf;Fk; xU
nray;Kiw MFk;. thbf;ifahsh;fspd; Njitfs; ‘voice of the
customer’ vd;w nrhw;nwhlh; %yk; Fwpf;fg;gLfpwJ. Neub
tpthjq;fs;> fzf;nfLg;Gfs;> Gs;sp tpguq;fs;> waranty jfty;fs;>
fs mwpf;iffs; Nghd;wit %yk; Njitfs; ngwg;gLfpd;wd.
5.3.1 Phases in QFD
QFD nray;Kiwapy; fPo;f;fz;l gbepiyfs; cs;sd :
1) Product planning 2) Product design
3) Process design 4) Process control

1) Product planning
 Product planning matrix my;yJ house of quality cUthf;FtJ
,jpy; mlq;Fk;. thbf;ifahshpd; Njitfs; kw;Wk; nghUspd;
nray;ghLfSf;F ,ilNaahd cwT fz;lwpag;gLfpwJ.
 Muk;g ,yf;F, importance ratings, difficulty rating kw;Wk;
nghUspd; gy;NtW NjitfSf;F ,ilNaahd njhlh;G
fz;lwpag; gLfpwJ. ,e;j matrix MdJ gFg;gha;T
nra;ag;gl;L> product plan ,Wjp nra;ag;gLfpwJ.

2) Product design
 nghUspd; Njitfs; kw;Wk; nghUisg; gw;wpa tpguq;fs;
Mfpait product conceptI cUthf;Ftjw;F mbg;gil
NjitahFk;. nghUis jug;gLj;Jjy;> %isia frf;Fjy;>
Muha;r;rp kw;Wk; Nkk;ghL Mfpatw;wpd; %yk; Gjpa product
concept cUthf;fg;gLfpwJ.
 nghUspd; xt;nthU NjitiaAk; G+h;j;jp nra;fpwjh vd
gy;NtW product conceptfSk; kjpg;gPL nra;ag; gLfpwJ.
,jpy; kpfr; rpwe;j product concept Njh;T nra;ag;gLk;. ,J
block diagram my;yJ design layout %yk; Fwpf;fg;gLk;.

3) Process design
 Product planf;F Vw;wthW gy;NtW cw;gj;jp nray;Kiwfs;
kjpg;gL
P nra;ag;gLfpd;wd. thbf;ifahshpd; Njitfis

5.4
 epiwT nra;AkhW nghUis cw;gj;jp nra;Ak; rpwe;j
nray;Kiw fz;lwpag; gLfpwJ.
 nray;Kiwia fl;Lg;gLj;Jjy;> juf;fl;Lg;ghL>
nghUj;Jjjy;> cgfuzq;fspd; guhkhpg;G kw;Wk;
NrhjidapLjy; Nghd;wtw;wpw;fhd tphpthd jpl;lkpLjy;
jahhpf;fg;gLk;. ,yf;if miltjw;fhf design kw;Wk;
manufacturing JiwfSf;F ,ilNa xUq;fpizg;G ,Uf;f
Ntz;Lk;.
4) Process control
 nray;Kiw> juf;fl;Lg;ghL> Nrhjidaply;> cgfuzq;fis
guhkhpj;jy; kw;Wk; gapw;rp mspj;jy; Nghd;wtw;wpw;fhd
nrayhf;f FwpaPL eph;zapf;fg;gLk;.
 nraypog;ig jtph;g;gjw;fhf> Kf;fpa nray;Kiwfspy;
fl;Lg;ghl;L ebtbf;iffs; Nkw;nfhs;sg;gLk;.
 QFD nray;Kiw jilapd;wp eilnghw quality kw;Wk;
manufacturing JiwfSf;F ,ilNa xUq;fpizg;ig
Vw;gLj;j Ntz;Lk;.
5.3.2 House of Quality (HOQ)

Interactions

Product
Requirements
Priority

Customer Competitive
Relationships
Requirements Evaluation

Technical Evaluation
Target Value
Technical Difficulty
Importance Rating

Fig.5.3 House of Quality

5.5
 House of Quality (HOQ) vd;gJ thbf;ifahshpd; Njitfs;
kw;Wk; nghUspd; nray;jpwd;fs; Mfptw;wpw;F ,ilNaAs;s
njhlh;gpid tpsf;Fk; xU glk; MFk;. ,J xU tPL Nghd;w
Njhw;wk; cilaJ. ,J product planning matrix vdTk;
miof;fg;gLk;. HOQ cUthf;Ftjpy; cs;s gbepiyfs; :
1) Matrixd; ,lJ gf;fk; thbf;ifahshpd; Njitfs;
Fwpf;fg;gLk;. xt;nthU Njitf;Fk; mjd; Kf;fpaj;Jtj;jpd;
mbg;gilapy; 1 Kjy; 5 tiuapyhd ju kjg;gPL toq;fg;gLk;.
2) jw;NghJ Nghl;bapy; cs;s nghUl;fSld; xg;gpl;L> Kd;gpUe;j
nghUl;fs; kjpg;gplg;gLfpd;wd. nghUl;fspd; Fiw epiwfis
fUj;jpy; nfhz;L> Gjpa nghUisg; gw;wpa fUj;jhf;fk;
cUthf;fg;gLk;.
3) thbf;ifahshpd; NjitfSf;F Vw;g> nghUspd;
nray;jpwd;fs; eph;zapf;f;fg;gLk;.
4) thbf;ifahshpd; Njitfs; kw;Wk; nghUspd;
nray;jpwd;fSf;F ,ilNaahd njhlh;Gfs; Vw;gLj;jg;gLk;.
,it strong, medium kw;Wk; weak vd FwpaPLfs; %yk;
Fwpf;fg;gLk;.
5) jw;NghJ Nghl;bapy; cs;s nghUl;fSld; xg;gpl;L> Kd;gpUe;j
nghUl;fs; njhopy;El;g hPjpapy; kjpg;gplg;gLfpd;wd. nghUspd;
tiuaWf;fg;gl;l nray;jpwd;fis mbg;gilahff; nfhz;L
,e;j kjpg;gPL nra;ag;gLfpwJ.
6) nghUspd; nray;jpwd;fSf;fhf Kjw;fl;l ,yf;F kjpg;Gfs;
eph;zapf;fg;gLfpd;wd.
7) nghUspd; nray;jpwd;fSf;F ,ilNa rhj;jpakhd Neh;kiw
kw;Wk; vjph;kiw njhlh;Gfs; fz;lwpag; gLfpd;wd. ,it
FwpaPLfs; %yk; Fwpf;fg;gLfpd;wd.
8) Kf;fpaj;Jtj;ij mbg;gilahff; nfhz;l important ratings
cUthf;fg;gLk;. xt;nthU njhlh;G FwpaPl;bw;Fk; xU weighting
factor nfhLf;fg;gLk;. Impprtant rating kw;Wk; weighting factorI
ngUf;fp tUk; njhifia> column thhpahf $l;l Ntz;Lk;.
9) xt;nthU nghUSf;Fk; xU difficulty rating nfhLf;f
Ntz;Lk;. 5 kpfTk; fbdk; vd vLj;Jf;nfhz;L> 1 Kjy; 5
tiuapyhd vz;fs; toq;fg;gLk;.

5.6
 10) ,e;j matrix gFg;gha;T nra;ag;gl;L> product plan ,Wjp
nra;ag;gLk;. ,yf;F kjpg;Gfs; ,Wjp nra;ag;gLk;.
thbf;ifahshpd; Njitfs; khWgLk; tiu ,e;j product
planning matrix njhlh;e;J nraypy; ,Uf;Fk;.

5.3.3 Advantages of QFD

 thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.
 ,ilg;gl;l tbtikg;G khw;wq;fs; FiwAk;.
 nghUis cUthf;Ftjw;fhd nryT FiwAk;.
 Gjpa nghUis tbtikg;gjw;fhd Neuk; FiwAk;.
 Team workI Nkk;gLj;Jk;.
 nghUspd; juk; Nkk;gLk;.
 Rejection kw;Wk; rework FiwAk;.
 tpw;gid mjpfhpf;Fk;.

5.3.4 Disadvantages of QFD

 mjpf jfty;fs; Nrfhpf;f Ntz;Lk;.
 thbf;ifahshpd; NjitfSf;F Vw;g nghUspd; nray;
jpwd;fis tbtikg;gJ fbdk;.
 gy;jpwd; nfhz;l RWRWg;ghd FO mtrpak;.
 nghUspd; tpiy> tho;ehs; Nghd;w ,ju fhuzpfs; fUjg;
gLtjpy;iy.
 thbf;ifahshpd; Njitfs; mbf;fb khWk; jd;ik cilaJ.

5.4 Failure Modes and Effects Analysis (FMEA)

Failure Modes and Effects Analysis (FMEA)
vd;gJ
nraypog;Gf;F rhj;jpakhd fhuzpfs;> nghUspd; nray;ghl;by;
mtw;wpd; tpisTs;; kw;Wk; nraypog;ig Kd;$l;bNa jtph;g;gjw;fhd
eilKiwfs; Mfpatw;iw fz;lwpa cjTk; nray;Kiw MFk;.

5.4.1 When to use FMEA?

fPo;f;fz;l #oy;fspdy; FMEA gad;gLj;jg;gLk;.
 Gjpa nghUl;fis cUthf;Fk;NghJ
 xU nghUspy; khw;wq;fis Vw;gLj;Jtjw;F Kd;G
 xU nghUspy; Fiwia fz;lwpe;j gpd;G
 Gjpa nfhs;iffis mwpKfg;gLj;Jk;NghJ

5.7
  thbf;ifahsh;fsplk; ,Ue;j mjpf Gfhh;fs; tUk;NghJ
 tpw;gidf;F gpd;ghd nryT tof;fj;ij tpl mjpfkhf
,Uf;Fk;NghJ

5.4.2 Steps in FMEA

FMEA Kiwapy; cs;s mbg;gil gbepiyfs; :
1) nghUspd; block diagram cUthf;fg;gLk;. ,jpy; Kf;fpa ghfq;fs;
fl;lq;fshf Fwpf;fg;gl;L NfhLfshy; ,izf;fg;gLk;.
2) xt;nthU ghfj;jpd; nray;ghl;bw;Fkhd nraypof;Fk; topfs;
(failure modes) gl;bayplg;gLk;. xt;nthU nraypog;G toapYk;
nghUspd; nray;ghl;by; Vw;gLk; midj;J tpisTfSk;
fz;lwpag;gLk;.
3) tpisTfs; mtw;wpd jPtPuj;jd;ik (severity) mbg;gilapy;
thpirg;gLj;jg;gLk;. 1 vd;gJ tpisT ,y;iy vd;gijAk;> 10
vd;gJ kpfj;jt
P uP khd tpisT vd;gijAk; Fwpf;Fk;.
4) xt;nthU nraypog;Gf;Fk; rhj;jpakhd fhuzpfs;
fz;lwpag;gLk;. xt;nthU fhuzpf;Fk; mjd; rhj;jpaf; $W
mbg;gilapy; probility factor nfhLf;fg;gLk;. 1 vd;gJ
rhj;jpak; ,y;iy vd;gijAk; 10 vd;gJ epr;rak; rhj;jpak;
vd;gijAk; Fwpf;Fk;.
5) nraypog;G Vw;gLtjw;F Kd;Ng mjw;fhd fhuzpfis jLg;gJ
my;yJ thbf;ifahsiu miltjw;F Kd;Ng nraypog;ig
fz;lwptJ Mfpatw;wpw;fhd fl;Lg;ghl;L eilKiwfs;
(current controls) fz;lwpag;gLk;.
6) Current controls
%yk; nraypog;Gf;fhd fhuzpfis
fz;lwptjw;fhd rhj;jpak; (Detection) Muhag;gLk;. 1 vd;gJ
epr;rakhf fhuzpfis fz;lwpa KbAk; vd;gijAk; 10 vd;gJ
epr;rakhf fhuzpfis fz;lwpa KbahJ vd;gijAk; Fwpf;Fk;.
7) Risk Priority Number (RPN) fz;lwpag;gLfpwJ.
RPN = (Severity) x (Probability) x (Detection). RPN I mbg;gil
ahff; nfhz;L nraypog;G topfs; thpirg; gLj;jg;gLk;.
8) mjpf RPN nfhz;l nraypog;G topfis Fiwg;gjw;fhd
eltbf;iffs; ghpe;Jiuf;fg;gLk;. nghUspd; tbtikg;ik
Nkk;gLj;Jjy;> nraypog;ig fz;lwpAk; fl;Lg;ghl;L topfis
mjpfhpj;jy; Nghd;wit ,jpy; mlq;Fk;.
5.8
9) vLf;fg;gl;l eltbf;iffs; gjpT nra;ag;gLk;. Nkw;fz;l
nray;Kiwfs; jpUk;gTk; Nkw;nfhs;sg;gl;L> Gjpa RPN
fz;lwpag;gLk;.

5.4.3 Benefits of FMEA

 nghUspd; ek;gfj;jd;ik kw;Wk; juk; Nkk;gLk;.
 thbf;ifahshpd; jpUg;jp Nkk;;gLk;.
 Team workI Nkk;gLj;Jk;.
 nghUspd; cw;gj;jp Neuk; kw;Wk; nryT FiwAk;.
 nghUspd; tbtikg;G khw;wk; kw;Wk; mJ njhlh;ghd nryT
FiwAk;.
 Failure kw;Wk; warranty nryTfs; FiwAk;.
 epWtdj;jpd ,yhgk; mjpfhpf;Fk;.

5.5 Value Engineering

Value engineering (VE) vd;gJ xU nghUis tbtikf;Fk;
NghJ mjd; kjpg;ig (value) Nkk;gLj;Jtjw;fhf Nkw;nfhs;sg;gLk;
Kiwahd mZFKiw MFk;. xU nghUspd; kjpg;ghdJ mjd;
nray;ghL kw;Wk; tpiy Mfpatw;wpw;F ,ilNaahd tpfpjk; MFk;.
vdNt> xU nghUspd; nray;ghl;il Nkk;gLj;JtJ my;yJ
tpiyia Fiwg;gjd; %yk; mjd; kjpg;ig mjpfhpf;fyhk;.

Value engineeringd; Nehf;fk; :

 xU nghUspy; cs;s ghfq;fspd; vz;zpf;ifia Fiwj;jy;
 nray;ghl;il ghjpf;fhj tifapy;> NtnwhU %yg;
nghUis gad;gLj;jp tpiyiaf; Fiwj;jy;
 guhkhpg;G nryit Fiwj;jy;
 nghUspd; juk; kw;Wk; Njhw;wj;ij Nkk;gLj;Jjy;
 nghUspd; jpwid Nkk;gLj;Jjy;

5.5.1 Types of values

 Cost value : ,J xU nghUis cw;gj;jp nra;tjw;fhd material,
labour kw;Wk; ,ju nryTfspd; gz kjpg;gPL MFk;.
 Use value : ,J xU nghUis gad;gLj;Jk;NghJ mjd;
gz;Gfs; kw;Wk; nray;ghLfs; %yk; fpilf;Fk; gyd;fspd; gz
kjpg;gPL MFk;.

5.9
 Esteem value : ,J xU nghUspd; Njitia mjpfhpf;ff; $ba
mjd; gz;Gfs; kw;Wk; nray;ghLfspd; gz kjpg;gPL MFk;.
xU nghUis thq;fj; J}z;Lk; mjd; rpwg;G mk;rj;ij ,J
Fwpf;Fk;.
 Exchange value : ,J xU nghUspd; khw;W tpfpjj;ij
(exchangeability) eph;zapg;gjpy; mjd; gz;Gfs; kw;Wk;
nray;ghLfspd; gz kjpg;gPL MFk;.
nghJthf, Use value + Esteem value  Exchange value
 Time value : ,J xU nghUs; fpilf;fg;ngWk; Neuj;jpidg;
nghWj;j mjd; kjpg;gPL MFk;.
 Place value : ,J xU nghUs; fpilf;fg;ngWk; ,lj;jpidg;
nghWj;j mjd; kjpg;gPL MFk;.

5.5.2 Identification of poor value areas

Poor value areas vd;git Njitaw;w
nryTfis
cUthf;Fgit MFk;. ,it nghUspd; tbtikg;G>
%yg;nghUl;fis thq;Fjy;> nghUl;fis ifahSjy;> cw;gj;jp
nray;Kiwfs;> nghUl;fis tpepNahfpj;jy; Nghd;w ve;j xU
epiyapYk; ,Uf;fyhk;. nghUspd; cw;gj;jp nryit Fiwg;gjw;F>
,it Kiwahf fz;lwpag;gl;L ePf;fg;gl Ntz;Lk;. ,jw;F
fPo;f;fz;l Kiwfs; gad;gLfpd;wd.
1) Value tests 2) Function – cost matrix approach

1) Value tests
Value test mbg;gilapy;> xU nghUspd; nray;ghL kw;Wk;
mjw;fhd nryT Mfpatw;iw jPh;khdpg;gjw;fhd xU Nfs;tp-gjpy;
Kiw MFk;. ,k;Kiwapy; cs;s rpy Nfs;tpfs; :
 nghUspd; nray;ghl;bw;F ,e;j ghfk; mtrpakhdjh?
 nghUspd; nray;ghl;il G+h;j;jp nra;tjw;F midj;J
mk;rq;fSk; Njitah?
 Fiwthd tpiyapy; VNjDk; ghfj;ij jahhpf;f KbAkh?
 ,uz;L my;yJ mjw;F Nkw;gl;l ghfq;fis xd;whf
,izf;f Kbakh?
 Fiwthd tpiyapy; Gjpa %yg;nghUs; VNjDk; fpilf;fpwjh?
Nkw;fz;l Nfs;tpfs; %yk; poor value areas fz;lwpag;gLk;.
NkYk; Njitaw;w mk;rq;fs; ePf;fg;gLk;.
5.10
2) Function – cost matrix approach
 Function – cost matrixd; xU gf;fj;jpy; nghUspd; ghfq;fSk;
kw;nwhU gf;fj;jpy; mtw;wpd; nray;ghLfSk; gl;bay;
,lg;gLk;. xt;nthU nray;ghl;bw;fhd nryTk; Nrfhpf;fg;gl;L
,jpy; Fwpf;fg;gLk;.
 xU ghfj;jpd; nkhj;j nrythdJ mjd; gy;NtW
nray;ghLfSf;F gfph;e;J Fwpf;fg;gLk;. ,jpypUe;J> xU
ghfj;jpd; nrytpy; vt;tsT rjtPjk; xt;nthU
nray;ghl;bw;Fk; Njitg;gLfpwJ vd;gij mwpayhk;.
xt;nthU nray;ghl;bd; kjpg;ghdJ value analysis %yk;
fz;lwpag;gLfpwJ.
 xU Kf;fpaj;Jtk; ,y;yhj nray;ghL> mjpf nryit
Vw;gLj;JfpwJ vdpy;> mJ Fwpg;gplj;jf;f poor value area
MFk;. ,j;jifa nray;ghLfis Fiwe;j nrytpy;
nra;tjw;F Vw;w khw;W topfis fz;lwptjd; %yk; nghUspd;
kjpg;G Nkk;gLj;jg; gLfpwJ.

5.5.3 Benefits / Advantages of Value Engineering

1) xU nghUSf;fhd nryT FiwAk;.
2) nghUspd; nray;ghl;L tPjk; Nkk;gLk;.
3) nghUspd; juk; Nkk;gLk;.
4) cw;gj;jp nryT FiwAk;.
5) nghUs; tPzhtJ jtph;f;fg;gLk;.
6) FO czh;T kw;Wk; xOf;fk; Nkk;gLk;.
7) thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.
8) xU nghUspy; cs;s ghfq;fspd; vz;zpf;if FiwAk;.

5.6 Design for Manufacture and Assembly (DFMA)

xU nghUspd; tbtikg;G kw;Wk; cw;gj;jp nray;Kiwia
vspikahf;fp nryitf; Fiwf;Fk; topKiwfis fz;lwpAk;
KiwNa DFMA vdg;gLk;. ,e;j Kiwapy; cw;gj;jp nray;Kiwapd;
Nkk;ghL kw;Wk; nghUspd; juk; caUfpwJ. NkYk; Design,
Manufacturing, Purchasing kw;Wk; Management Mfpa JiwfSf;F
,ilNaahd jfty; njhlh;igAk; Nkk;gLj;JfpwJ.

5.11
Guidelines for DFMA
1) ghfq;fspd; vz;zpf;ifia Fiwf;f Ntz;Lk; : xU
ghfj;ij ePf;Fk;NghJ> me;jg; ghfj;ij cUthf;Fjy;>
nghUj;Jjy;> efh;j;Jjy;> ghJfhj;J itj;jy;> J}a;ikahf
itj;jpUj;jy;> NrhjidapLjy;> gOJghh;j;jy; Mfpatw;wpw;fhd
nryT FiwfpwJ.
2) Modular designI cUthf;f Ntz;Lk; : xU nghUspy; cs;s
ghfj;Jld; vspjhf nghUj;jf; $ba kw;nwhU ghfNk module
vdg;gLk;. Modular design MdJ nghUl;fspy; gOJghh;j;jiy
vspikahf;FfpwJ. NkYk; Fiwthd ghfq;fNs ,Ug;gjhy;
assemblyiaAk; vspjhf;FfpwJ.
3) ghfq;fspd; khWgLk; jd;ikia Fiwf;f Ntz;Lk;:
ghfq;fspd; khWgLk; jd;ikiaf; Fiwg;gjd; %yk;
nghUl;fspd; juk; njhlh;ghd rpf;fy;fis ntFthff;
Fiwf;fyhk;. jug;gLj;jg; gl;l cjphp ghfq;fisg;
gad;gLj;JtJ ,jw;F rpwe;j topahFk;.
4) gy nray;ghLfSilajhf ghfq;fis tbtikf;f Ntz;Lk;:
ghfq;fis gy nray;ghLfs; nfhz;ljhf tbtkikg;gNj
ghfq;fspd; vz;zpf;ifiaf; Fiwf;f cjTk; rpwe;j topahFk;.
5) gy nghUl;fspy; gad;gLj;Jtjw;Nfw;g ghfq;fis
tbtikf;f Ntz;Lk;: xd;wpw;Fk; Nkw;gl;l nghUl;fspy;
gad;gLj;j Vw;wjhf ghfq;fis tbtikf;f Ntz;Lk;. ,jd;
%yk; xU ghfj;jpw;fhd tpiy FiwfpwJ.
6) vspjpy; jahhpf;ff; $bajhf ghfq;fis tbtikf;f Ntz;Lk;:
XusTf;F Njhuhakhd tbtj;ij cw;gj;jp nra;tjw;Nfw;w
nray;Kiwia Njh;e;njLf;f Ntz;Lk;. Finishing kw;Wk; painting
Nghd;wtw;iw jtph;f;fyhk;.
7) jdpahd fastenerfis jtph;f;f Ntz;Lk; : Assemblyd; NghJ
screwf;fisgad;gLj;JtJ mjpf nryTs;s KiwahFk;.
$Lkhdtiuapy; snap fitfis gad;gLj;j Ntz;Lk;.
8) Assembly nra;Ak; jpirfis Fiwf;f Ntz;Lk; : xU
nghUspy; cs;s midj;J ghfq;fisAk; xNu jpirapy; ,Ue;J
nghUj;JkhW mit tbtikf;fg; gl Ntz;Lk;. xU ghfj;ij
Row;wp nghUj;Jk;NghJ mjpf efh;T kw;Wk; Neuk;
Njitg;gLfpwJ.
5.12
9) Assemblyf;F ,zf;fkhd ghfq;fis mjpfhpf;f Ntz;Lk; :
vspjhf assembly nra;tjw;F Vw;w mk;rq;fshd taper, chamber
kw;Wk; radius Mfpait ,Uf;FkhW ghfq;fis tbtikf;f
Ntz;Lk;.
10) Assemblyy; ifahSk; Neuj;ijf; Fiwf;f Ntz;Lk; :
nghUj;jg;gl Ntz;ba ,lj;jpw;F vspjhf vLj;Jr;
nry;tjw;Nfw;w tifapy; ghfq;fs; tbtikf;fg;gl Ntz;Lk;.
ghfq;fis nghUj;Jk;NghJ jhdhfNt efh;e;J Fwpj;j ,lj;jpy;
rhpahf mkUk; tifapy; mit tbtikf;fg;gl Ntz;Lk;.

5.6.1 Benefits / Advantages of DFMA

1) xU nghUspy; cs;s ghfq;fspd; vz;zpf;if FiwAk;.
2) nghUspd; juk; Nkk;gLk;.
3) cw;gj;jp nryT kw;Wk; Neuk; FiwAk;.
4) nghUs; tPzhtJ jtph;f;fg;gLk;.
5) FO czh;T kw;Wk; xOf;fk; Nkk;gLk;.

5.7 Product development cycle

Concept

Service Design

Marketing Planning

Manufacture

Fig.5.4 Product development cycle

Product development cycle fPo;f;fz;ltw;iw cs;slf;fpaJ MFk;.
 Developing the product concept : xUq;fpize;j fUj;Jfs;>
tbtikg;G gFg;gha;T kw;Wk; Ez;zwpTj; jpwd; Mfpatw;iwf;
nfhz;L product concept cUthf;fg;gLfpwJ.
5.13
 Designing the product : Preliminary designd;NghJ> design
conceptf;fhd tbtikg;G cUthf;fg; gLfpwJ. Detailed design
MdJ ghfq;fspd; msTfs;> tolerance kw;Wk; Nkw;gug;Gg;
gz;Gfs; Mfpatw;iw Fwpf;fpwJ.
 Planning : Process sheet jahhpj;jy;> cw;gj;jp nray;Kiwfis
cWjp nra;jy;> work shedulefis jpl;lkpLjy; Nghd;wit ,jpy;
mlq;Fk;.
 Manufacturing the part: xd;W my;yJ mjw;F Nkw;gl;l nray;
Kiwfspd; %yk; ghfkhdJ cw;gj;jp nra;ag;gLfpwJ.
 Marketing : xU nghUspd; nghUshjhuk; rhh;e;j ntw;wp vd;gJ
me;jg; nghUis marketing nra;tjpy; Nkw;nfhs;sg;gLk;
Kaw;rpiag; nghUj;Nj mikAk;.
 Servicing : nghUs; ,aq;Fk; Kiwia tpsf;Fjy;> Fwpg;gpl;l
fhy ,ilntspapy; service nra;jy;> gOjilAk;NghJ
nghUl;fis rhpnra;J nfhLj;jy; Mfpait ,jpy; mlq;Fk;.

5.7.1 Product life cycle

Annual Sales Volume

Time
Introduction Growth Maturity Decline

Fig.5.5 Product life cycle

xU nghUspd; tho;ehs; Row;rpapd; gbepiyfs; :

1) Introduction stage : nghUs; cw;gj;jp nra;ag;gl;L re;ijapy;
mwpKfg;gLj;jg;gLk;. ,e;j epiyapy; nghUSf;fhd Nghl;bahsh;
vtUk; ,Uf;f khl;lhh;fs;. Gjpa nghUis Vw;Wf;nfhs;s rpwpJ
fhyk; gpbf;Fk; vd;gjhy;> tpw;gid FiwthfNt ,Uf;Fk;.
tpsk;gur; nryT mjpfkhf ,Uf;Fk;. ,e;j epiyapy;
epWtdj;jpw;F ,g;nghUshy; e~;lNk Vw;gLk;.

5.14
2) Growth stage : re;ijapy; nghUs; Vw;Wf;nfhs;sg;gLk;.
tpw;gid kw;Wk; tUkhdk; cau Muk;gpf;Fk;. nghUspd; juj;ij
Fiwf;fhky; itj;jhy; kl;LNk ,e;j mjpNtf tsh;r;rpia jf;f
itf;f KbAk;. re;ijapy; Nghl;bapLtjw;F> nghUspd; juj;ij
Nkk;gLj;j Ntz;Lk;. ,jdhy; nghUspd; tpiyAk; FiwAk;.
3) Maturity stage : ,e;jepiyapy; nghUspd; tpw;gid cr;r
fl;lj;ij milAk;. mjpf vz;zpf;ifapy; nghUl;fis cw;gj;jp
nra;tjhy;> nghUspd; tpiy FiwAk;. khw;W jahhpg;GfSld;
Nghl;bahsh;fs; re;ijf;Fs; Eiothh;fs;. tpw;gidia
ngUf;Fjtw;F mjpf gzk; nrytopf;f Ntz;bapUf;Fk;.
4) Decline stage : ,e;j epiyapy; nghUs; nrwpTj;jd;ikia
miltjhy;> tpw;gid kw;Wk; ,yhgk; Fiwaj; njhlq;Fk;.
Fiwthd tpw;gid> mjpf Nghl;bahsh;fs;> thbf;ifahshpd;
Njitfspy; Vw;gLk; khw;wk; Nghd;wtw;why; nghUshdJ
re;ijapy; ,Ue;J tpyf;fg;gLk;.

5.7.2 New product development processes

Idea generation

Idea screening

Concept testing

Business analysis

Product development

Test marketing

Commercialization

Fig.5.6 New product development process

Gjpa nghUis cUthf;Ftjpy; cs;s gbepiyfs; :

1) Idea generation : xU Kiwahd mZFKiwapd; %yk; Gjpa
nghUSf;fhd Nahridfs; cUthf;fg; gLfpd;wd. Copah;fs;>
thbf;ifahsh;fs;> Nghl;bahsh;fs;> tpepNahf];jh;fs; kw;Wk;

5.15
 tpw;gidahsh;fs; MfpNahhplk; ,Ue;J ,e;j Nahridfs;
ngwg;gLfpd;wd.
2) Idea screening : midj;J NahridfSk; ftdkhf kjpg;gplg;
gl;L> mtw;wpd; jFjpf;Nfw;g thpirg;gLj;jg;gLk;. thbf;ifahsh;
jpUg;jp> epWtj;jpd; ,yhgk; kw;Wk; re;ij kjpg;ig cah;j;Jk;
tifapy; ,e;j Nahridfs; ,Uf;f Ntz;Lk;. rhj;jpakpy;yhj
kw;Wk; rhjfkw;w Nahridfs; epuhfhpf;fg;gLk;.
3) Concept testing : ,e;j Nahridfs; product conceptfshf
khw;wg;gLk;. thbf;ifahsh;fs;> Copah;fs; kw;Wk; gq;Fjhuh;fs;
MfpNahhplkpUe;J xU Nfs;tpj; njhFg;gpd; thapyhf product
conceptfs; Fwpj;j feed back ngwg;gLk;. ,jpypUe;J> kpfr; rpwe;j
product concept Njhe;njLf;fg;gLk;.
4) Business analysis : nryT> tpw;gid kw;Wk; ,yhgk; Fwpj;J
kjpg;gplg;gLk;. NkYk; tUq;fhy Njitfs;> nghUshjhu
nfhs;iffs; kw;Wk; tUkhdk; Mfpait Fwpj;Jk;
kjpg;gplg;gLk;. Break even analysis, risk analysis Nghd;wtw;iw
gad;gLj;jp nghUshjhu ty;Yeh;fs; ,it Fwpj;J
KbntLg;ghh;fs;.
5) Product development : Product concept MdJ xU nghUshf
cw;gj;jp nra;ag;gLk;. nghUspd; nray;ghLfis cWjp
nra;tjw;F> Ma;tf kw;Wk; ,af;fr; #oy;fspy; Nrhjidfs;
Nkw;nfhs;sg;gLk;. ,jd; %yk; nghUs; ghJfhg;ghfTk;
jpwk;glTk; nray;gLfpwjh vdf; fz;lwpag;gLk;.
6) Test marketing : Njh;e;njLf;fg;gl;l rpy gFjpfspy;> Gjpa
nghUshdJ Fiwe;j vz;zpf;ifapy; mwpKfg; gLj;jg;gLk;.
thbf;fifahsh;fspd; vjph;tpidfs; ftdpf;fg;gLk;. nghUspy;
Fiw ,Ue;jhy;> mJ fz;lwpag;gl;L epth;j;jp nra;ag;gLk;. mjpf
vz;zpf;ifapy; nghUl;fis re;ijg;gLj;Jtjpy; cs;s Mgj;J
test marketing %yk; jtph;f;fg;gLfpwJ.
7) Commercialization : Gjpa nghUshdJ mjpf vz;zpf;ifapy;
jahhpf;fg;gl;L re;ijapy; tpw;gidf;F tplg;gLk;. tpw;gidia
mjpfhpg;gjw;fhd tpsk;guq;fs; Nghd;w midj;J Kaw;rpfSk;
Nkw;nfhs;sg;gLk;.

5.16
5.8 Augmented reality
Augmented reality (AR) vd;gJ gadhshpd; cz;ikahd
#oypd; kPJ computer %yk; cUthf;fg;gl;l cs;sPLfis
nghUj;Jk; njhopy;El;gk; MFk;. Mdhy;> virtual reality vd;gJ
cz;ikahd #oiy cUtfg;gLj;jg;gl;l kw;nwhU #oiyf;
nfhz;L KOtJkhf khw;wp mikf;Fk; Kiw MFk;. Augmented
reality Kiwapy;> graphics, sound kw;Wk; touch feedback Mfpait
,aw;if #oYld; nghUj;jg;gLfpwJ.

Types of augmented reality

 Marker-based AR : ,J Image Recognition vdTk;
miof;fg;gLk;. ,jpy; camera kw;Wk; QR code Nghd;w marker
Njitg;gLk;. Marker ,Ug;gJ xU reader thapyhf
czug;gl;lTld;> mjw;fhd fl;lisfs; ,af;fg;gl;L
nray;gLj;jg;gLk;.
 Markerless AR : xU rhjdj;jpy; nghUj;jg;gl;l GPS, digital
compass my;yJ accelerometer Nghd;w
mkrq;fs; %yk;
ngwg;gLk; ,lj;ijg;gw;wpa jfty;fis nfhz;L ,J
,aq;FfpwJ. xU ,lj;ij fz;lwptjw;Fk;> mq;F
nry;tjw;fhd topfis fz;lwptjw;Fk; mobile rhjdq;fspy;
,k;Kiw nghpJk; gad;gLfpwJ.
 Projection based AR : nraw;ifahd xspia cz;ikahd
#oypy; nrYj;jp> kdpjdpd; vjph;tpidia czh;tjd; %yk;
,J nray;gLfpwJ. fhw;W ntspapy; Kg;ghpkhz
hologramfis cUthf;Ftjw;Fk; ,k;Kiw cjTfpwJ.
 Superimposition based AR : ,k;Kiwapy;> cz;ikahd
viewy; cs;s xU nghUis> mNjNghd;w NtnwhU nghUshy;
Neuiyapy; khw;wp nghUj;j KbAk;. ,jw;F object recognition
njhopy;El;gk; mtrpak; MFk;.

AR hardware
Processor, display, sensors kw;Wk; input devices Mfpait AR
hardwarey; mlq;Fk;. Camera kw;Wk; accelerometer, GPS, solid state
compass Nghd;w mk;rq;fis nfhz;l smartphonefs; kw;Wk; tablet
computerfs; ,jw;F nghUe;Jk;.

5.17
  Display devices : Head-mounted display, eyeglasses, Google
Glass, HoloLens, Contact lenses, Virtual retinal display.
 Input devices : Speech recognition system, gesture recognition
system kw;Wk; touch input.

AR software
glj;jpy; Njhd;Wk; nghUspd; ,lk; kw;Wk; Njhw;wj;ij
tpthpg;gjw;F Augmented Reality Markup Language (ARML) vd;w
data standard gad;gLj;jg; gLfpwJ. CloudRidAR, ARToolKit,
Mobinett AR, Wikitude, kw;Wk; Meta Nghd;w software development
kitfSk; gad;ghl;by; cs;sd.

5.8.1 Applications of AR
 Architecture : cz;ikahd #oypd; kPJ computer %yk;
cUthf;fg;gl;l fl;blq;fs; mlq;fpa glq;fis nghUj;JtJ.
 Visual art : tiuglq;fis gy;NtW Nfhzq;fspy; ghh;j;jy;.
 Education: Text, graphics, video kw;Wk; audio Nghd;wtw;iw
khzth;fspd; cz;ikhad #oypy; nghUj;Jjy;> kdpj
clypd; gy;NtW ghfq;fis Kg;ghpkhz Kiwapy; ghh;j;jy;>
thdtpaiyg; gw;wp gbg;gjw;fhd SkyView Nghd;w
njhopy;El;gk;> Kjypait.
 Video games : Get On Target, AR air hockey, Titans of Space,
Pokemon Go, Nghd;wit.
 Industrial design : cz;ikahf cUthf;Ftjw;F Kd;Ng
nghUspd; tbtikg;G kw;Wk; nray;ghLfis ghh;j;J
czh;jy;> computery; cUthf;fg;gl;l Kd;Ndhl;l
NrhjidfisAk; cz;ikahd Kd;Ndhl;l NrhjidfisAk
nghUj;jp ghh;j;J tpj;jpahrq;fis fz;lwpjy;> Nghd;wit.
 Medical : X-ray kw;Wk; ultrasound glq;fis
Neuiyahf
ghh;j;jy;> clYf;Fs; fl;bapd; epiyia fz;lwpjy;> jhapd;
fUtiwapy; cs;s fUit Neuiyahf ghh;j;jy;> Kjypait.
 Military : kdpjh;fs; kw;Wk; Njitahd ,lj;ij Fwpg;gpLjy;>
Nghh;f;fs epytuq;fis ,uhZt tPuhpd; fz;zhb topahf
mDg;Gjy;> Kjypait.

5.18
  Broadcast : jl;g ntg;g epiyfis fhz;gpj;jy;> tpisahl;L
xspgug;G> njhiyf;fhl;rp epfo;r;rpfspy; CLUtp gq;nfLj;jy;>
fiyepfo;r;rpfis Neuiyahf njhFj;J mspj;jy;>
Kjypait.

Review Questions
5 Marks Questions :
1) Differentiate sequential engineering and concurrent engineering.
2) Define concurrent engineering? State the need of CE.
3) List out the benefits of CE.
4) List out the advantages and disadvantages of QFD.
5) What is FMEA? When it is used?
6) List out the benefits of FMEA.
7) What is Value engineering? State its aim.
8) Briefly explain the types of values.
9) List out the benefits of value engineering.
10) Explain the stages in product life cycle.
11) Briefly explain Augmented Reality.

10 Marks Questions :
1) Explain concurrent engineering.
2) Define Qualify Function Deployment. Explain the phases in QFD.
3) What is HOQ? Explain the steps in preparing HOQ.
4) Explain the basic steps in Failure Modes and Effects Analysis.
5) Explain the techniques used for identification of poor value areas.
6) Explain the important guidelines for DFMA.
7) Explain product development cycle.
8) Explain the new product development process with a sketch.
9) Explain the applications of Augmented Reality.



5.19
Q & A.1
 Unit – I
COMPUTER AIDED DESIGN
1. Define CAD.
xU nghUspd; designI cUthf;Fjy;> Nkk;gLj;Jjy;>
gFg;gha;jy;> kw;Wk; optimization Mfpatw;wpw;F computerI
gad; gLj;JtNj Computer Aided Design (CAD) MFk;.
2. List out the steps involved in Shiley’s design process.
1) Recognition of need 2) Definition of problem
3) Synthesis 4) Analysis and optimization
5) Evaluation 6) Presentation
3. List out the various activities of CAD.
1) Geometric modelling 2) Engineering analysis
3) Design review and evaluation 4) Automated drafting
4. What are the benefits of CAD?
1) Design cUthf;Fk; tpfpjk; mjpfhpf;fpwJ.
2) Lead time (nkhj;j Neuk;) FiwfpwJ.
3) Design cUthf;Ftjpy; flexibility mjpfhpf;fpwJ.
4) Design error FiwfpwJ.
5) Design gFg;gha;T Nkk;gLfpwJ.
6) Design, documentation kw;Wk; drafting jug;gLj;jg; gLfpwJ.
7) Design cUthf;Fjy; kw;Wk; Nkk;gLj;Jjy; vspjhfpwJ.
8) glq;fis ntt;NtW Nfhzq;fspy; vspjhf fhzyhk;.
5. Mention the important CAD software packages.
AutoCAD, Pro/E, IDEAS, UniGrpahics, CADian, SolidWorks,
CADKey, CATIA, ArchiCAD, Autodesk Inventor, etc.
6. What is transformation?
Computer graphics gad;ghLfspy;> glq;fspd; KbTg;
Gs;spfspy; rpy fzpj nray;ghLfisr; nra;tjd; %yk;
glk; khw;wp mikf;fg; gLfpwJ. ,j;jifa nray;ghLfs;
transformation vdg;gLk;. Translation, scaling kw;Wk; rotation
Mfpait xU rpy mbg;gil transformationfs; MFk;.

Q & A.2
7. Define translation.
Translation vdgJ gl ghfq;fis Xhplj;jpy; ,Ue;J
kw;nwhU ,lj;jpw;F efh;j;Jtijf; Fwpf;Fk;. Matrix tbtpy;
,J fPo;f;fz;lthW Fwpf;fg; gLfpwJ.
(x', y') = (x, y) + T
,q;F> x', y' = efh;j;jg;gl;l Gs;spapd; mr;Rj; J}uq;fs;
x,y = Muk;g epiyapy;> Gs;spapd; mr;Rj; J}uq;fs;
m, n = X kw;Wk; Y jpirapy; efh;j;jg;gl Ntz;ba J}uk;
T = Translation matrix = (m, n)
8. What is scaling?
tiugl ghfj;jpd; msit rpwpjhfNth my;yJ
nghpjhfNth khw;Wtjw;F scaling vd;W ngah;. glj;jpy;
cs;s Gs;spfs; scaling matrix %yk; fPo;f;fz;lthW khw;wp
mikf;fg; gLfpwJ.
(x', y') = (x, y) S
m 0
,q;F, S = Scaling matrix = q r
0 n
,jd; %yk; glj;jpd; msT m klq;F X jpirapYk;>
n klq;F Y jpirapYk; khw;wp mikf;fg;gLk;.
9. What is rotation?
Rotation vd;gJ tiuglj;ij mjd; njhlf;fg; Gs;spiag;
nghWj;J  Nfhzj;jpw;F VNjDk; xU jpirapy; jpUg;Gjy;
MFk;. Matrix tbtpy;> ,e;j epfo;Tf;fhd nray;Kiw
fPo;f;fz;lthW:
(x', y') = (x, y) R
cos sin
,q;F, R = Rotation matrix = q r
–sin cos
10. Write down the rotation matrix for rotating an object
about X-axis.
X mr;irg; nghWj;J  Nfhzj;jpw;F nra;ag;gLk; 3D
rotation fPo;f;fz;lthW matrix tbtpy; Fwpf;fg; gLfpwJ.
(x', y', z') = (x, y, z) Rx

Q & A.3
 ,q;F, cos 0 sin
Rx = X mr;irg; nghWj;J rotation matrix =q 0 1 0 r
–sin 0 cos

11. Define concatenation.

Concatenation vd;gJ mLj;jLj;J epfOk; gy transfor-
mationfis ,izj;J xNu transformation Mf nra;Ak;
nray; MFk;. ,t;thW Vw;gLj;jg;gl;l transformationfs;
concatenated transformationfs; vdg;gLk;. tiuglq;fis
jpUj;jp mikf;Fk;NghJ ,j;jifa transformationfs;
nra;ag;gLfpd;wd.

12. What are the techniques of geometric modelling?

1) Wireframe modelling
2) Surface modelling
3) Solid modelling
13. List out the advantages of wireframe modelling?
1) ,jid tbtikg;gJ vspJ.
2) ModelI Nrkpj;J itf;f Fiwe;j memory NghJkhdJ.
3) Manipulation Neuk; FiwT.
4) Orthographic, isometric kw;Wk; perspective Njhw;wq;fis
,jpypUe;J cUthf;FtJ vspJ.
14. List out various types of surfaces.
1) Ruled surface 2) Surface of revolution
3) Tabulated cylinder 4) Bezier surface
5) B–spline surface 6) NURBS
7) Coons surfaces 8) Swept surface
9) Fillet surface 10) Offset surface
15. List out the applications of surface modelling.
1) ,ize;Js;s ,uz;L ghfq;fSf;fpilNa cs;s
interferenceI NrhjidapLjy;
2) FWf;F ntl;Lj; Njhw;wj;ij cUthf;Fjy;
3) Finite element meshfis cUthf;Fjy;
4) NC tool path cUthf;Fjy;

Q & A.4
16. List out the schemes available for solid modelling.
1) Constructive solid geometry (CSG)
2) Boundary representation (B–rep)
3) Pure primitive instancing
4) Generalized sweep
5) Cellular decomposition
6) Hybrid scheme
17. List out the various solid modelling entities.
1) Block 2) Cylinder 3) Cone
4) Sphere 5) Wedge 6) Torus
18. What is the basic difference between CSG and B-rep?
 CSG Kiwapy;> primitives vdg;gLk; mbg;gil solid
mikg;Gfs; cjtpAld; Njitahd model cUthf;fg;
gLfpwJ.
 B-rep Kiwapy;> xU solid model MdJ mjd;
vy;iyfis eph;zapf;Fk; mbg;gil gl cUtq;fs;
mlq;fpa xU data structure %yk; Fwpg;gplg; gLfpwJ.
19. What is hybrid scheme?
Hybrid scheme
MdJ C-rep kw;Wk; B-rep ,uz;Lk;
,ize;j Kiw MFk;. ,e;j ,uz;L KiwfspYk; cs;s
FiwghLfis ePf;fp> rpwg;G mk;rq;fis ,izj;J Hybrid
scheme gad;gLj;jg; gLfpwJ.
20. List out the applications of solid modelling.
1) Hidden line drawing, section kw;Wk; shaded tiuglq;fis
cUthf;Fjy;
2) Surface area, centre of gravity, moment of inertia, radius
of gyration Nghd;w mass propertyfis fzf;fPL nra;jy;
3) Solid assemblyfSf;fhd kinematics analysis
4) Dynamics interference analysis
5) Process plan cUthf;Fjy;
6) CNC tool path cUthf;Fjy;
21. What is graphic standard?
Dataf;fis ntt;NtW CAD systemfSf;F ,ilNa
ghpkhwpf; nfhs;s cjTgit graphics standards MFk;.

Q & A.5
22. What are the needs for graphics standard?
1) Application program portability
2) Picture data portability
3) Text portability
4) Object database portability
23. List out the common graphics standards.

1) GKS (Graphical Kernel System)

2) OpenGL (Open Graphics Library)
3) IGES (Initial Graphics Exchange Specification)
4) DXF (Drawing Exchange Format)
5) VDI (Virtual Device Interface)
6) VDM (Virtual Device Metafile)
7) WMF (Windows Meta File)
24. What is GKS? State its objectives.
 Fwpg;gpl;l nghJthd nray;ghLfis
Nkw;nfhs;tjw;Fg; gad;gLk; nray;Kiwfspd;
njhFg;Ng Graphical Kernel System MFk;.
 Objectives of GKS :
1) glk; tiutjw;fhd midj;J trjpfisAk; mspj;jy;.
2) Plotterfs;> display devicefs; Nghd;w midj;J graphic
devicefisAk; fl;Lg;gLj;Jjy;.
3) gy;NtW programfis cUthf;Ftjw;F Fiwe;j
memoryINa milj;Jf; nfhs;Sjy;.
25. What is OpenGL?
Open Graphics Library (OpenGL) vd;gJ 2D kw;Wk; 3D
tiuglq;fis rendering nra;tjw;F nghpJk;
gad;gLj;jg;gLk; xU application programming
interface (API) MFk;. ,J graphics processing unit (GPU)
cld; ,ize;J nray;gl;L> hardwareI J}z;Ltjd;
%yk mjpNtf rendering ngwg;gLfpwJ.
26. State the features in OpenGL.
1) Language independent 2) Platform independent
3) Open architecture 4) Vertex and fragment shaders
Q & A.6
 5) Multi texturing 6) Instanced rendering
7) Viewport array 8) Flush Control
27. What are the applications of OpenGL?
1) Computer Aided Design 2) Virtual reality
3) Scientific visualization 4) Information visualization
5) Flight simulation 6) Video games.
28. List out the subsection in IGES format.
1) Start section 2) Global section 3) Directory entry section
4) Parameter data section 5) Terminate section
29. What are the advantages of DXF?
1) DXF MdJ kpfg;nghUj;jkhd vector file tif MFk;.
2) gy;NtW CAD programfSf;F ,ilNa jfty;fis
ghpkhwpf; nfhs;s DXF cjTfpwJ.
3) ve;j xU CAD/CAM softwareYk; ,jid edit nra;a ,aYk;.
4) DXF filefis rpWrpW gFjpfshf vspjpy; gphpf;fyhk;.
5) DXF MdJ nghJg;gad;ghl;bw;F ,ytrkhf fpilf;fpwJ.
30. Define FEA.
Finite element analysis (FEA) vd;gJ
gy;NtW ,aq;F
epiyfspy; ghfq;fspd; gz;Gfis fz;lwpa Nkw;nfhs;sf;
$ba engineering analysisf;F gad;gLk; xU computer
simulation Kiw MFk;.
31. Mention the basic steps in FEA.
1) Pre-processing
2) Analysis (Computation of solution)
3) Post processing (Visualization)
32. List out the applications of FEA.
 Stress kw;Wk; displacementfis fz;lwpjy;
 Heat transfer
 Solid state diffusion
 Reactions with moving boundaries
 Fluid dynamics
 Electromagnetism

Q & A.7
33. What are the advantages of FEA?
 mjpf accuracy
 Nkk;gLj;jg;gl;l design
 kpfg; nghUj;jkhd design parameterfs;
 Virtual prototyping
 Fiwthd hardware prototypefs;
 Ntfkhd kw;Wk; Fiwe;j nryTs;s design cycle
 mjpf productivity
 mjpf tUkhdk;

Unit – II
COMPUTER AIDED MANUFACTURING
1. Define CAM.
Manufacturing, planning kw;Wk; control Mfpa nray;ghLfspy;
computer njhopy;El;gj;ij jpwk;gl gad;gLj;JtNj
Computer Aided Manufacturing (CAM) MFk;.
2. List out the functions of CAM in manufacturing planning.
 Computer Aided Process Planning (CAPP)
 Computer assisted NC part programming
 Computerized machinability data system
 Development of work standard
 Cost estimating
 Production and inventory planning
 Computer aided line balancing
3. List out the functions of CAM in manufacturing control.
 Process monitoring and control
 Quality control
 Shop floor control
 Inventory control
4. List out the benefits of CAM.
1) tbtikg;gpy; mjpf flexibility
2) mjpf cw;gj;jpj; jpwd;

Q & A.8
 3) cw;gj;jp nray;Kiwfspy; mjpf flexibility
4) Fiwthd cw;gj;jp Neuk;
5) mjpf ek;gfj;jd;ik
6) Fiwthd guhkhpg;G
7) Fiwthd scrap kw;Wk; rework
8) rpwe;j eph;thf fl;Lg;ghL
5. What is Group Technology (GT)?
Group Technology (GT) vd;gJ design kw;Wk; manufacturing
nray;Kiwfspy; ghfq;fSf;F ,ilNaAs;s xw;Wikapd;
mbg;gilapy; mtw;iw tifg;gLj;jp> xl;L nkhj;j cw;gj;jp
nryitf; Fiwf;Fk; xU cw;gj;jp topKiw MFk;.
6. What is part family?
Part family vd;gJ gy;NtW ghfq;fs; mlq;fpa njhFg;ghFk;.
,jpy; cs;s ghfq;fs; mtw;wpd; tbtk; kw;Wk; mstpy;
xd;Wgl;Nlh> my;yJ mtw;iw jahhpg;gjw;F
Nkw;nfhs;sg;gLk; nray;Kiwfspy; xd;Wgl;Nlh ,Uf;Fk;.
7. List out the design attributes used in GT.
1) Basic external shape 2) Basic internal shape
3) Material type 4) Part functions
5) Major dimensions 6) Minor dimensions
7) Tolerances 8) Surface finish
8. List out the manufacturing attributes used in GT.
1) Major processes 2) Minor operations
3) Operation sequence 4) Major dimension
5) Surface finish 6) Machine tool
7) Fixture required 8) Cutting tools
9. What are the applications of parts classification and
coding?
1) Design retrieval 2) Machine cell design
3) Automated process planning
10. What are the coding structures used in GT?
1) Hierarchical structure or Monocode structure
2) Chain type structure or Polycode structure
3) Hybrid structure or Mixed mode structure

Q & A.9
11. List out the parts classifications and coding systems.
1) Opitz system 2)MICLASS system
3)The CODE system 4) DCLASS system
5)COFORM system 6) The KK–3 system
12. List out the benefits of Group Technology.
1) Vw;fdNt cs;s designI databasey; ,Ue;J vspjhf
jpUk;g ngw KbAk;.
2) Design standardizationf;Fg; gad;gLfpwJ.
3) Production rate mjpfhpf;fpwJ.
4) Work-in-process kw;Wk; inventory Fiwf;fg; gLfpwJ.
5) Material handling kw;Wk; efh;Tfs; Fiwf;fg; gLfpwJ.
6) Scrap Fiwf;fg; gLfpwJ.
7) Machined; gad;ghl;L tPjk; mjpfhpf;fpwJ.
8) Manufacturing lead-time Fiwf;fg; gLfpwJ.
9) njhopw;rhiyapd; xl;Lnkhj;j efficiency mjpfhpf;fpwJ.
13. What is process planning?
xU nghUis Fwpg;gpl;l msTfSld; cw;gj;jp nra;tjw;F
gpd;gw;wg;gl Ntz;ba kpfg; nghUj;jkhd cw;gj;jp
nray;Kiwfs;> assembly nray;Kiwfs; kw;Wk;
nray;Kiwfspd; thpir Mfpatw;iwf; fz;lwptNj process
planning MFk;.
14. What are the requirements for process planning?
1) cw;gj;jp nra;ag;gl Ntz;ba nghUspd; xU tUlj;
Njit my;yJ batch size.
2) nghUspd; gy;NtW ghfq;fspd; gl;bay;.
3) jw;NghJs;s %yg;nghUl;fspd; msTfs;.
4) jw;NghJ epWtdj;jpy; cs;s ,ae;jpuq;fisg; gw;wpa
tpguq;fs;.
5) Njitahd tool, die, mould, fixture kw;Wk; gauge gw;wpa
tpguq;fs;.
6) Njitg;gLk; accuracy kw;Wk; surface finish.
15. What is CAPP?
Computer programfspd;cjtpAld; process planI
jhdhfNt cUthf;Fk; Kiw Computer Aided Process
Planning (CAPP) vdg;gLk;.

Q & A.10
16. What is the difference between variant approach and
generative approach of CAPP?
 Variant approach topKiwapy;> xt;nthU part
familyf;Fkhd Group Technology (GT) codeI gad;gLj;jp>
Vw;fdNt cs;s master process plany; ,Ue;J jFe;j
process plan Njh;T nra;ag;gl;L edit nra;ag;gLfpwJ.
 Generative approach topKiwapy;> xt;nthU
ghfj;jpw;Fkhd process plan Gjpjhf njhlf;fj;jpypUe;J
jahhpf;fg; gLfpwJ.
17. List out the benefits of CAPP.
1) kpfr;rpwe;j kw;Wk; Fiwe;j nrytpyhd process plan
fpilf;Fk;.
2) mjpf juk; tha;e;j nghUl;fis cw;gj;jp nra;a ,aYk;.
3) Process plannerd; productivity mjpfhpf;fpwJ.
4) Process planning cUthf;Ftjw;F MFk; nkhj;j Neuk;
FiwfpwJ.
5) Computer %yk; cUthf;fg;gLk; route sheetfs; njspthf
,Ug;gjhy; Fog;gkpd;wp vspjpy; Ghpe;J nfhs;s KbAk;.
18. What are the objectives of PPC?
1) tsq;fis jpwk;gl gad;gLj;Jjy;
2) nghUl;fis rhpahd Neuj;jpy; delivery nra;jy;
3) Fiwe;jgl;r inventoryI cWjp nra;jy;
4) cw;gj;jp Neuj;ij Fiwj;jy;
5) nghUl;fspd; juj;ij Nkk;gLj;Jjy;
6) %yg;nghUl;fs; tPzhtij fl;Lg;gLj;Jjy;
7) cw;gj;jp nryit Fiwj;jy;
19. What is master production schedule (MPS)?
 Master production schedule (MPS) MdJ> aggretate
plany; cs;s xt;nthU nghUisAk; jahhpg;gJ gw;wpa
ml;ltiz MFk;.
 ,jpy; jahhpf;fg;gl Ntz;ba nghUspd; tpguk;> vj;jid
nghUl;fs; jahhpf;fg;gl Ntz;Lk;> vg;nghOJ
Kbf;fg;gl Ntz;Lk; vd;gd Nghd;w tpguq;fs; mlq;fp
,Uf;Fk;.

Q & A.11
20. What are the objectives of MPS?
1) epWtdj;jpy; cs;s ,ae;jpuq;fs;> %yg;nghUl;fs; kw;Wk;
Ml;fis jpwk;gl gad;gLj;Jjy;.
2) Fiwe;j gl;r inventoryI guhkhpj;jy;.
3) nghUl;fis Fwpg;gpl;l Neuj;jpy; jahhpj;J mDg;Gjy;.
21. What is capacity planning?
Master production scheduley; cs;sJ Nghd;W nghUl;fis
cw;gj;jp nra;tjw;Fj; Njitg;gLk; Ml;fs; kw;Wk;
,ae;jpuq;fspd; Njitia fz;lwpjNy capacity planning
MFk;. Long-term cw;gj;jpf;F NghJkhd Njitfis
fz;lwpjYk; ,jpy; mlq;Fk;.
22. What is MRP?
Master production scheduleI mbg;gilahff; nfhz;L>
nghUl;fis jahhpf;fj; Njitahd %yg;nghUl;fs; kw;Wk;
Njitg;gLk; ,ju ghfq;fs; mlq;fpa njspthd
ml;ltizia cUthf;Fjy; material requirement planning
(MRP) vdg;gLk;.
23. List out the benefits of MRP.
1) Inventory Fiwf;fg;gLfpwJ.
2) DemandfSf;F Vw;g vspjpy; khw;wp mikj;Jf; nfhs;syhk;.
3) Nkk;gLj;jg;gl;l thbf;ifahsh; Nrit.
4) Setup Neuk; kw;Wk; cw;gj;jp nryT FiwfpwJ.
5) ,ae;jpuq;fspd; gad;ghL Nkk;gLj;jg;gLfpwJ.
6) MPSy; Vw;gLk; khw;wq;fis vspjpy; Vw;Wf;nfhz;L
rkhspf;f ,aYk;.
24. What is MRP-II?
Manufacturing resource planning vd;gJ computerI
mbg;gilahff; nfhz;L ,aq;Fk; xU system MFk;. ,J
MPSy; Fwpg;gplg;gl;Ls;sJ Nghd;W nghUl;fis cw;gj;jp
nra;tjw;Nfw;g planning, scheduling kw;Wk; %yg; nghUl;fs;>
njhopw;rhiyapd; tsq;fs;> ,ju nray;ghLfisf;
fl;Lg;gLj;Jjy; Nghd;wtw;iw Nkw;nfhs;Sk;.

Q & A.12
25. What is shop floor control?
cw;gj;jp eilngWk; ,lj;jpw;F production orderfis
toq;Fjy;> cw;gj;jp eilngWtij gy;NtW work centrerfs;
%yk; fz;fhzpj;J fl;Lg;gLj;Jjy;> orderfspd; jw;Nghija
epytuk; gw;wpa jfty;fis Nrfhp;j;jy; Mfpait shop floor
controly; mlq;Fk;.
26. Define JIT.
Just In Time (JIT) vd;gJ nghUl;fs; tPzhtij jpl;lkpl;L
jtph;j;jy; kw;Wk; cw;gj;jp tpfpjj;ij njhlh;e;J mjpfhpj;jy;
Mfpatw;iw mbg; gilahff; nfhz;L nray;gLk; xU
cw;gj;jp nray;Kiw MFk;.
27. What is ERP?
Enterprise resource planning vd;gJ nghUl;fis kpfr;rpwe;j
Kiwapy; cw;gj;jp nra;tjw;F jpl;lkplg; gad;gLk; xU MRP-
II software MFk;.

Unit – III
CNC PART PROGRAMMING AND
RAPID PROTOTYPING
1. W
What is CNC part program?
xU ghfj;jpd; ,Wjpahd tbtj;ij ngWtjw;F machine
control unit (MCU) %yk; epiwNtw;wg;gl Ntz;ba fl;lisfs;
mlq;fpa tpgug; gl;bay; NC part program vdg;gLk;.
2. List out the data required for part programming.
1) Specification of coordinate system
2) Specification of axes
3) Specification of machines
4) Specification of reference points
5) Specification of tools
6) Method of holding work pieces
7) Data tables and books
8) Sequence of operation

Q & A.13
3. How axes are specified in NC system?
 Z-axis : Z-mr;rpd; efh;thdJ spindle mr;R jpirapNyh
my;yJ spindle mr;Rf;F ,izahfNth ,Uf;Fk;.
 X-axis : Cutting tool my;yJ workpiece efUk; jpir X mr;rhf
Fwpf;fg;gLk;. ,J Z- mr;Rf;F nrq;Fj;jhf ,Uf;Fk;.
 Y-axis : ,J X kw;Wk; Z mr;R ,uz;bw;Fk; nrq;Fj;jhf
mikAk;. ,jd; jpirahdJ right hand Cartesian coordinate
systemj;ij mbg;gilahff; nfhz;L jPhkhdpf;fg;gLk;.
4. Define zero point.
CNC machinefspy;> toold; efh;Tfs; coordinate system %yk;
fl;Lg;gLj;jg; gLfpwJ. Coordinate systemj;jpd; Mjpg;
Gs;spahdJ zero point Mf fUjg;gLfpwJ.
5. Differentiate : Fixed zero point and floating zero point.
 khw;wp mikf;f ,ayhj tifapy; xU epiyahd ,lj;jpy;
Fwpf;fg;gl;bUg;gJ fixed zero point vdg;gLk;.
 Workpiecef;F Vw;g> machine slided; cjtpahy; cutting
toolI efh;j;jp Njhw;Wtpf;fg;gLtJ floating zero point
vdg;gLk;.
6. What is machine zero point or machine datum?
,J machine cw;gj;jpahsh; %yk; tiuaWf;fg;gLk;
epiyahd point MFk;. ,JNt machine controllerd;
coordinate systemj;Jf; fhd zero point MFk;.
7. What is workpiece zero point?
,e;j point MdJ machine zero pointIg; nghWj;J
workpiece coordinate systemj;ij jPh;khdpf;fpwJ. ,e;j point
MdJ part program %yk; Njh;e;njLf;fg;gl;L> machine
controllerf;F input Mf nfhLf;fg;gLk;.
8. What is tool zero point?
WorkpieceI machining nra;Ak;NghJ> machining nra;ag;gl
Ntz;ba ghijapy; tool nry;YkhW kpfj;Jy;ypakhf
fl;Lg;gLj;jg;gl Ntz;Lk;. ,jw;F tool turrety; cs;s xU
Gs;sp reference point Mf vLj;Jf; nfhs;sg;gl Ntz;Lk;.
,JNt tool zero point vdg;gLk;.

Q & A.14
9. What is machine reference point or home position?
Machine slidefs; kw;Wk; toold; efh;Tfis mstpLk;
systemj;ijf; fl;Lg; gLj;JtjpYk; callibration nra;tjpYk;
machine reference point my;yJ home position gad;gLfpwJ.
,J cw;gj;jpahsh; %yk; jPh;khdpf;fg;gLfpwJ.
10. Mention the two types of NC dimensioning.
 Absolute dimensioning: ,e;j Kiwapy;> workpiecey; cs;s
xU Gs;spapd; mr;Rj; J}uq;fs; vg;nghOJk; xU Mjpg;
Gs;spiag; nghWj;Nj Fwpf;fg;gLk;.
 Incremental dimensioning:
,e;j Kiwapy;> workpiecey;
cs;s xU Gs;spapd; mr;Rj;J}uq;fs; vg;nghOJk;> me;jg;
Gs;spf;F Kd;ghf cs;s kw;nwhU Gs;spia
mbg;gilahff; nfhz;L Fwpf;fg; gLk;.
11. List out the formats used in NC part programming.
1) Fixed sequential format
2) Fixed sequential format with tab ignored
3) Tab sequential format
4) Word address format
5) Word address format with TAB separation and variable
word order
12. Mention the latest format used in NC part programming.
 Word address format with TAB separation and variable word
order vd;w format jw;Nghija etPd CNC controllerfspy;
ngUk;ghYk; gad;gLj;jg; gLfpwJ.
 ,jpy; xt;nthU wordk; TAB %yk; gphpf;fg; gl;bUf;Fk;.
xU Blocky; cs;s wordfis ve;j orderYk; khw;wp
vOjyhk;.
13. What are G-codes(preparatory functions)?
G-codefs; vdg;git machine mr;Rfspd; efh;T kw;Wk;
mjNdhL njhlh;Gila nray;ghLfis Nkw;nfhs;tjw;fhf
ifahsg;gLk; preset functionfs; MFk;. xU blocky;
nfhLf;fg;gLk; fl;lisfis Vw;gjw;F jFe;jhw;Nghy;
machine controllerI ,e;j functionfs; jahh; nra;fpd;wd.

Q & A.15
14. What are modal and non-modal G-codes?
 Modal G-codefs; controllerf;F settingfshf nray;gLk;.
,e;j G-codefs; xUKiw nfhLf;fg;gl;L tpl;lhy;> mNj
groupIr; rhh;e;j kw;nwhU G-code %yk; ePf;fg;gLk; tiu
njhlh;e;J ,af;fj;jpy; ,Uf;Fk;.
 Nod-modal G-codefs; mJ ,lk;ngw;Ws;s blocky; kl;LNk
,af;fj;jpy; ,Uf;Fk;.
15. What are miscelleneous functions?
Misscelleneous functionfs; machining toold; rpy controlfis
,af;fp> machined; ,af;fj;ij fl;Lg;gLj;JfpwJ.
miof;fg;gLk; functionI Nkw;nfhs;Sk; jpwid Fwpg;gpl;l
machine tool ngw;wpUf;f Ntz;Lk;.
16. Write the functions of the G-codes G21, G28, G71, G76.
G21 – Metric Input system; G28 – Return to Zero (Home)
G71 – Multiple turning cycle; G76 – Multiple thread cutting cycle
17. Give the functions of the M-codes M06, M30, M70, M98.
M06 – Tool change ; M30 – Program end and rewind;
M70 – X axis mirror ON; M98 – Subprogram Call
18. What is diameter programming?
Diameter programing Kiwapy;> Mu msTfis Fwpg;gjw;F
gjpyhf> tpl;l (diameter) msTfis Fwpf;FkhW> X- mr;R
jpirapy; midj;J efh;TfSk; ,uz;L klq;fhf
Fwpf;fg;gLk;. ,e;j Kiw nghJthf turning centrefspy;
gpd;gw;wg;gLfpwJ.
19. Define tool offset.
Tool tip position kw;Wk; turret datum Mfpatw;wpw;F
,ilNaAs;s J}uk; tool offset vdg;gLk;.
20. Give the syntax for tool (T-word) function.
T-word MdJ Tmmnn vd;w formatIf; nfhz;bUf;Fk;.
,jpy; Kjy; ,uz;L ,yf;fq;fs; (mm) turret stationIAk;>
filrp ,uz;L ,yf;fq;fs; (nn) tool offset cs;s
,lj;ijAk; Fwpf;fpwJ. Offset register number 00 vdf;
Fwpg;gpl;L offsetI jtph;f;fyhk;.

Q & A.16
21. What are the methods of specifying spindle feed in NC
programmin?
1) G97 – Constant surface speed 2) G98 – Constant RPM
Example:
G96 S200 (Spindle speed is set at 200 m/min)
G97 S2500 (Spindle speed is set at 2500 rpm)
22. How feed is specified in NC programming?
Feed ,uz;L formatfspy; Fwpg;gplg;gLk; :
1) G98 – Feed in mm/min 2) G99 – Feed in mm/rev.
Example:
G98 F2.5 (2.5 mm / minute)
G99 F1 (0.01 mm / revolution)
G99 F1.0 (1.00 mm / revolution)
G99 F100 (1.00 mm / revolution)
23. What is the difference between G00 and G01?
 midj;J mr;Rthf;fpYk; xUNru mjptpiuthf toolI
efh;j;Jtjw;F G00 gad;gLfpwJ.
 njhlh;r;rpahd xU Neh;f;Nfhl;Lg; ghijia cUthf;F
tjw;F G01 gad;gLj;jg; gLfpwJ.
24. List out the various interpolation methods in NC.
 Linear interpolation
 Circular interpolation
 Helical interpolation
 Parabolic interpolation
 Cubic interpolation
25. What is linear interpolation?
njhlh;r;rpahd xU Neh;f;Nfhl;Lg; ghijia cUthf;Ftjw;F
Linear interpolation gad;gLj;jg; gLfpwJ. nfhLf;fg;gl;l
feed ratey; linear interpolationI nray;gLj;Jtjw;D G01
fl;lis gad;gLfpwJ.
26. What is circular interpolation? Give its syntax.
tisthd arcfis cUthf;Ftjw;F ciruclar interpolation
gad;gLj;jg; gLfpwJ.
Syntax: G02 X_ Z_ R_ F_ (or) G03 X_ Z_ R_ F_

Q & A.17
 G02 – Circular Interpolation (Clockwise)
G03 – Circular Interpolation (Counter-clockwise)
X, Z - coordinate values; F- Feed rate; R-Radius
27. What is canned cycle?
 xU Fwpg;gpl;l thpirapy; toold; efh;Tfis jpUk;g jpUk;g
ngWtjw;fhf> controller system memoryy; Vw;fdNt
Nrkpj;J itf;fg;;gl;Ls;s fl;lisfspd; njhFg;Ng
canned cycle my;yJ fixed cycle vdg;gLk;.
 jpUk;g jpUk;g kw;Wk; nghJthf Nkw;nfhs;sg;gLk;
machining operationfSf;F canned cyclefs;
gad;gLj;jg; gLfpd;wd.
28. Mention the syntax for threading cycle.
Syntax : G92 X_ Z_ F_
G92 – Thread cutting canned cycle
X, Z – Coordinate values; F – Feed rate (pitch of the thread)
29. Give the syntax for stock removal cycle.
Syntax : G71 U_ R_
G71 P_ Q_ U_ W_ F_
,jpy;>
G71= Stock removal cycle (or) Multiple turning canned cycle
U = xt;nthU passf;Fkhd depth of cut
R = Return passd; NghJ workpiecey; ,Ue;J tool tpyfpr;
nry;y Ntz;ba J}uk;
P = Machining nra;ag;gl Ntz;ba workpieced; gug;igf;
Fwpg;gpLk; Kjy; blockd; sequence number
Q = Machining nra;ag;gl Ntz;ba workpieced; gug;igf;
Fwpg;gpLk; filrp blockd; sequence number
U = X jpirapy; nfhLf;fg;gLk; finishing allowance
W = Z jpirapy; nfhLf;fg;gLk; finishing allowance
F = Feed rate
30. Mention the syntax for multiple threading cycle.
Syntax : G76 X_ Z_ A_ I_ K_ D_ F_
G76 = Multiple thread cutting canned cycle
X = Core diameter of the thread

Q & A.18
 Z = Length of the thread
A = Angle of the thread
I = Thread taper (usually zero)
K = Total depth of the thread in microns
D = Depth of first cut in microns
F = Feed rate (pitch)

31. What is peck drilling?

Peck drillingf;F G74 code
gad; gLj;jg;gLfpwJ. DrillI
workpiecey; ,Ue;J ghJfhg;ghd J}uj;jpy; epWj;jpa gpwF
drilling cycleI miof;f Ntz;Lk;. gpd;G drill MdJ
xt;nthU incremental depth msTf;Fk; drill nra;J gpd;G
chipI ntspNaw;Wtjw;F gpd;Ndhf;fp jpUk;g tUk;.
Programy; nfhLf;fg; gl;bUf;Fk; Z depth msT tiu ,J
jpUk;g jpUk;g eilngWk;.
32. Give the syntax for peck drilling cycle.
Syntax : G74 X_ Z_ K_ F_
G74 – Peck drilling canned cycle
X = Finish diameter
Z = Finish Z – depth
K = Peck depth
F = Feed
33. What is tool length compensation?
midj;J toolfSk; mjdjd; ,lj;jpy; nghUj;jg;gl;l
epiyapy; xU tool presetter %yk; mstplg; gLfpd;wd. xU
episahd datumj;jpw;Fk; toold; ePsj;jpw;Fk; ,ilaAs;s
NtWghL tool length compensation vdg;gLk;.
34. What is subprogram?
Sub program vd;gJ tof;fkhd part programIg; Nghd;w
midj;J mk;rq;fisAk; nfhz;l jdpahd program MFk;.
mbf;fb gad;gLj;jg;gLk; rpy operationfs; kw;Wk;
operationfspd; thpirfs; Mfpait xU jdpg;gl;l program
number cld; sub programfshf memoryy; Nrkpj;J
itf;fg;gLk;.

Q & A.19
35. What is the difference between subroutines and macros?
 Subroutinefs; xU Fwpg;gpl;l main program cld;
njhlh;Gila jw;fhypfkhd subprogamfs; MFk;.
 Macro vd;gJ controller memoryy; epue;jukhd Nrkpj;J
itf;ff; $ba sub programfs; MFk;. vdNt> ,tw;iw
ve;j programYk; mioj;J gad;gLj;jyhk;.
36. Give the syntax for subroutine calling.
Syntax : M98 Prrrnnnn
M98 – Subrouting calling
rrr- subroutine vj;jid Kiw jpUk;g jpUk;g nray;gl
Ntz;Lk; vd;gijf; Fwpf;Fk; vz;
nnnn- nray;gLj;jg; gl Ntz;ba subroutined; milahs vz;
37. How macros are called in NC program?
Syntax : G65 P4322 A_ B_ C_ . . . . . .
P4322 miof;fg;gl Ntz;ba sub program number MFk;.
A, B, C Mfpait argumentfis epakpg;gjw;F gad;gLj;jg;
gLk; word addressfs; MFk;.
38. What is mirror imaging?
rkr;rPh; tbtk; nfhz;l ghfq;fSf;fhd part program
vOJk; NghJ> ngUk;ghyhd program blockfs; rpwpa
khWjy;fSld; jpUk;g jpUk;g tUk;. Mirror imaging
trjpiag; gad;gLj;jp ,e;j programfs; vspikahf;fg;
gLfpd;wd. Mirroring nra;Ak;NghJ> ve;j mr;irg; nghWj;J
mirroring nra;ag;gLfpwNjh me;j mr;irg; nghWj;j
midj;J msTfSk; sign khw;wk; nra;ag;gLfpwJ.
39. Define pocketing.
xU work pieced; rkjsg; gug;gpy; ,Ue;J Fwpg;gpl;l
Moj;jpw;F Njitahd tbtpy; metalI ntl;b ePf;Fk;
nray;Kiw pocketing or pocket milling vdg;gLk;.
40. What is Rapid Prototyping (RP)?
Subtractive my;yJ additive manufacturing njhopy;
El;gj;ijg; gad;gLj;jp jhdfNt nghUl;fis tpiue;J
cw;gj;jp nra;Ak; Kiwf;F rapid prototyping vd;W ngah;.

Q & A.20
41. What is subtractive manufacturing?
xU KOikahd solid blocky; ,Ue;J materialI gbg;gbahf
ntl;b ePf;Ftjd; %yk; Njitahd Kg;ghpkhd tbt
nghUl;fis cUthf;Fk; Kiw subtractive manufacturing
vdg;gLk;.
42. What is additive manufacturing?
Liquid, powder my;yJ nky;ypa sheet tbt nghUl;fis
layerfshf xd;wpd;kPJ xd;W mLf;fp> mtw;iw xd;whf
,izg;gjd; %yk; Njitahd Kg;ghpkhd tbt
nghUl;fis tpiuthf cUthf;Fk; Kiw additive
manufacturing vdg;gLk;.
43. List out the various prototyping technologies.
 Selective laser sintering (SLS)
 Fused deposition modelling (FDM)
 Stereolithography (SLA)
 Laminated object manufacturing (LOM)
 Electron beam melting (EBM)
 3D printing (3DP)
 Laser Engineered Net Shaping (LENS)
44. List out the materials used in rapid prototyping.
Metal powders, Thermoplastics, Photopolymer, Paper,
Titanium alloys, etc.
45. List out the applications of rapid prototyping.
 Rapid manufacturing  Visualization
 Metal casting  Architecture
 Education  Geospatial
 Healthcare  Entertainment
 Retail  Biotechnology
 Jewelry  Footwear
 Industrial design  Automotive
 Aerospace  Archaeology
 Dental and medical industries
46. List out the advantages of rapid prototyping.
1) Designy; cs;s jtWfis vspjhf fz;lwpayhk;.

Q & A.21
 2) Designy; khw;wj;ij vspjhf Vw;gLj;jyhk;.
3) nghUspd; cz;ikahd ,Wjp tbtj;ij mwpayhk;.
4) cw;gj;jjp Neuk; kw;Wk; nryT FiwT.
5) nghUspd; juk; Nkk;gLj;jg;gLk;.
6) User kw;Wk; designerf;F ,ilNa rpwe;j njhlh;G cUthFk;.
47. List out the advantages of Stereolithography.
 kpf mjpfkhd accuracy
 kpfr; rpwe;j surface finish
 cgfuzq;fspd; tpiy kw;w nray;Kiwfisf; fhl;bYk;
FiwT.
 vspa nray;Kiw.
 nghUl;fs; machining nra;tjw;F Vw;w fbdj;jd;ikAld;
,Uf;Fk;.
 Master patternfshf nghUl;fisg; gad;gLj;jyhk;.
48. List out the advantages of FDM.
 vspa kw;Wk; rj;jkpy;yhj nray;Kiw
 Ntfkhd nray;Kiw
 nghUl;fs; mjpf typik nfhz;ljhf ,Uf;Fk;.
 gy;NtW tifahd plasticIAk; gad;gLj;jyhk;.
 cw;gj;jp nryT FiwT.
49. Give the advantages of SLS.
 Supportfs; Njitg;gLtjpy;iy
 Final curing Njitapy;iy
 gy;NtW tifahd powderfisAk; %yg;nghUl;fshfg;
gad;gLj;jyhk;.
 rpf;fyhd tbtKs;s nghUl;fisAk; cw;gj;jp nra;a
KbAk;.
50. List out the advantages of 3D printing.
 ntt;NW materialfis cs;slf;fpa ve;j xU
nghUisAk; xNu processy; nra;ayhk;.
 rpf;fyhd Kg;ghpkhz tbtk; nfhz;l nghUl;fisAk;
vspjhf cUthf;fyhk;.
 nghUl;fis gy tz;zk; nfhz;ljhfTk; cUthf;fyhk;.
 kpf tpiuthd nray;Kiw MFk;.

Q & A.22
  Equipment tpiy FiwT.
 gad;gLj;JtJ vspJ.
51. Define rapid tooling.
Rapid prototype njhopy;El;gk; kw;Wk; tof;fkhd tooling
Kiwfisf; nfhz;L> mouldfis mjptpiuthf cw;gj;jp
nra;Ak; nray;Kiw Rapid Tooling (RT) vdg;gLk;.
52. List out the advantages of rapid tooling.
 Tooling Neuk; FiwT
 Fiwe;j nryT
 Design epiyapNyNa toold; nray;jpwid
Nrhjidaplyhk;.
 Designy; cs;s jtWfis vspjpy; rhp nra;ayhk;.
 rpf;fyhd tbtq;fisAk; cUthf;fyhk;.

Unit – IV
COMPUTER INTEGRATED MANUFACTURING,
FLEXIBILE MANUFACTURING SYSTEMS,
AUTOMATIC GUIDED VEHICLE AND ROBOT
1. W
Define CIM.
CAD/CAM nray;ghLfs; kw;Wk; cw;gj;jpj; njhlh;ghd
midj;J tzpfr; nray;ghLfs; Mfpait mlq;fpaNj
Computer Integrated Manufacturing vdg;gLk;.
2. W
What is the concept of CIM?
xU epWtdj;jpd; cw;gj;jp njhlh;ghd midj;J nray;ghL
fisAk; computer system cjtpAld; xUq;fpizj;J>
mtw;iw Nkk;gLj;jp> midj;J nray;ghLfSk; jhdhfNt
Nkw;nfhs;sg; gLk; tifapy; nra;tNj CIMd; mbg;gil
Nehf;fk; MFk;.
3. W
What is CIM wheel?
CIM wheel vd;gJ xU CIM systemj;jpy; cs;s
nray;ghLfis Fwpg;gJ MFk;.

Q & A.23
4. W
List out the benefits of CIM.
1) Machined; gad;ghL mjpfhpf;fpwJ.
2) labourfspd; vz;zpf;if FiwfpwJ.
3) nghUspd; cw;gj;jp Neuk; FiwfpwJ.
4) In-process inventoryd; msT FiwfpwJ.
5) SchedulingI Njitf;Nfw;g khw;wp mikj;Jf; nfhs;syhk;.
6) Scrap kw;Wk; rework FiwfpwJ.
7) njhopw;rhiyapd; jpwd; mjpfhpf;fpwJ.
8) ghJfhg;ghd #oy; Vw;gLj;jg; gLfpwJ.
5. W
What is integrated CAD/CAM?
CAD/CAM njhopy;El;gk; %yk; design kw;Wk; manufacturing
nray;ghLfs; xUq;fpizf;fg;gLfpwJ. ,JNt integrated
CAD/CAM vdg;gLk;.
6. W
What is FMS?
Flexible Manufacturing System (FMS) vd;gJ KOtJk;
jhdpaq;fp Kiwapy; ,aq;Fk; xU GT machine cell MFk;.
,jpy; gy machine toolfs;> automated material handling
kw;Wk; storage system Mfpait xd;Wld; xd;W ,izf;fg;
gl;L xU central computer %yk; fl;Lg;gLj;jg;gLk;.
7. List out the components of FMS.
1) Processing stations or work stations
2) Material handling and storage system
3) Computer control system
4) Human labour
8. List out the various FMS layout configurations.
1) Inline layout 2) Loop layout 3) Ladder layout
4) Open field layout 5) Robot centered layout
9. State the difference between inline layout and loop layout?
 Inline layouty;> machinefs; kw;Wk; handling system
Mfpait xU Neh;f;Nfhl;by; mikf;fg; gl;bUf;Fk;.
 Loop layouty;> tl;l tbt (loop) ghijapy; work
stationfs; mikf;fg;gl;L> mNj tbtpy; mikf;fg;gl;l
part transport system %yk; work part ifahsg;gLfpwJ.

Q & A.24
10. How FMS is classified?
1) Flexible turning cell (FTC)
2) Flexible Manufacturing Cell (FMC)
3) Flexible Transfer Line (FTL)
4) Flexible Machining System (FMS)
11. What is flexible turning cell?
,J xU CNC turning centre kw;Wk; xU parts storage system
Mfpatw;iwf; nfhz;lJ MFk;.
12. What is flexible manufacturing cell?
,e;j mikg;ghdJ> automatic material handling kw;Wk;
automatic tool changer trjpfSld; $ba ,uz;L my;yJ
%d;W CNC machinefisf; nfhz;bUf;Fk;.
13. What are the applications of FMS?
1) Machining operations such as milling, turning, drilling, etc.
2) Assembly of parts 3) Sheet metal press working
4) ForgingWelding 5) Inspection and testing
14. List out the benefits of FMS.
1) Machined; gad;ghL mjpfhpf;fpwJ.
2) Njitahd machinefspd; vz;zpf;if FiwfpwJ.
3) kdpjh;fspd; jiyaPL FiwfpwJ.
4) Work-in-process inventory FiwfpwJ.
5) Manufacturing lead time FiwfpwJ.
6) Manufacturing control Nkk;gLj;jg; gLfpwJ.
7) nghUspd; juk; Nkk;gLj;jg; gLfpwJ. Scrap FiwfpwJ.
8) Njitahd floor space FiwfpwJ.
15. What is intelligent manufacturing?
ComputerI mbg;gilahff; nfhz;l Artificial Intelligence
(AI) El;gq;fis gad;gLj;jp nghUl;fis cw;gj;jp nra;tNj
Intelligence Manufacturing System vdg;gLk;.
16. Define Artificial Intelligence (AI)?
nghJthf kdpj mwpNthL njhlh;Gila nray;fis
nra;aty;y xU rhjdj;jpd; jpwd; Artificial Intelligence

Q & A.25
 vdg;gLk;. Reasoning, planning kw;Wk; problem solving
Mfpait ,j;jifa nray;ghLfspy; mlq;Fk;.
17. What is an expert system?
Expert system vd;gJ> Fwpg;gpl;l gpur;rpidia jPh;f;Fk;
Jiwapy;> xU expertIg; Nghd;w nray;ghl;Lj; jpwd; nfhz;l
computer program MFk;.
18. Define AGV?
Automated guided vehicle vd;gJ
xU material handling
cgfudk; MFk;. ,J jdpahf ,af;fg;gl;L> factory floord;
kPJ tiuaWf;fg;gl;l xU ghijapy; nry;YkhW top
elj;jg;gLfpwJ.
19. List out the components in AGV.
1) Vehicle guidance system 2) Vehicle routing system
3) Traffic control system
20. Mention the technologies used for guidance in AGV.
 Guide wire method
 Paint strip method
 Self guided vehicles
21. List out the types of AGV.
1) Towing vehicles 2) Unit load carriers
3) Pallet trucks 4) Fork trucks
5) Light load vehicles 6) Assembly line vehicles
22. List out the applications of AGV.
1) Driverless train operations 2) Storage and distribution
3) Assembly line application 4) Flexible manufacturing system
5) Office mail delivery 6) Hospital material transport
23. List out the benefits of AGV.
1) Dispatching, tracking kw;Wk; monitoring rpwg;ghf
fl;Lg;gLj;jg; gLfpwJ.
2) njhopw;rhiyapd; tsq;fis gadspfj;jf;f Kiwapy;
gad;gLj;j ,aYk;.
3) nghUl;fspd; efh;it rpwg;ghf fl;Lg;gLj;j ,aYk;.
4) nghUl;fspy; ghjpg;G Vw;gLtJ jtph;f;fg; gLfpwJ.

Q & A.26
 5) nghUl;fspd; efUk; ghijia vspjhf khw;wyhk;.
6) Location kw;Wk; positional accuracy mjpfk;.
7) Njitahd floor space Fiwf;fg; gLfpwJ.
8) Work-in-process inventory Fiwf;fg; gLfpwJ.
24. Define robot.
Robot vd;gJ gy;NtW tifg;gl;l nray;fis Nkw;nfhs;
tjw;fhf> nghUl;fs;> ghfq;fs;> toolfs; my;yJ ,ju rpwg;G
tif rhjdq;fis efh;j;Jtjw;nfd tbtikf;fg;gl;l> gy
nray;fis nra;aty;y xU manipulator MFk;.
25. What are the basic elements in robot?
1) Base 2) Manipulator 3) End effectors
4) Actuators 5) Transmission elements 6) Control system
7) Sensors 8) Interfaces
26. What are end effectors?
End effoector vd;gJ robot wrist cld; ,izf;fg;
gl;bUf;Fk;. ,e;j end effector xU gripper MfNth tool
MfNth ,Uf;fyhk;.
27. List out the various robot configurations.
 Polar coordinate configuration
 Cylindrical coordinate configuration
 Cartesian coordinate configuration
 Jointed arm configuration
 SCARA (Selective Compliance Assembly Robot Arm) configuration
28. Mention the various robot motions.
1) Vertical traverse 2) Radial traverse 3) Rotational traverse
4) Wrist swivel 5) Wrist bend 6) Wrist yaw
29. Mention the methods of robot programming.
1) Manual method 2) Walkthrough method
3) Leadthrough method 4) Off-line programming
30. List out the advantages of off-line programming.
 Robotf;F fw;Wf; nfhLg;gjhy; Vw;gLk; Neu ,og;G
jtph;f;fg; gLfpwJ.

Q & A.27
  Robot NtnwhU Ntiyia nra;J nfhz;bUf;Fk;NghNj
off-line programming nra;a ,aYk;.
 Robot kw;Wk; mjd; cgfuzq;fspd; gad;ghL
mjpfhpf;fpwJ.
 CAD / CAM database kw;Wk; jfty; ikaj;Jld; robotI
xUq;fpizf;f KbAk;.
31. List out the various robot sensors.
1) Vision sensors 2) Tactile sensors
3) proximity sensors 4) Voice sensors
32. What are the uses of vision sensors?
 Conveyory; ,Ue;J ghfq;fis fz;lwpe;J vLf;fpwJ.
 xU Fwpg;gpl;l ghfj;ij milahsk; fz;lwpfpwJ.
 nghUl;fis NrhjidapLfpwJ.
 Assemly nray;ghLfspy; rhpahd alignmentf;F cjTfpwJ.
33. What are the uses of tactile and proximity sensors?
 Assembly kw;Wk; inspection nray;ghLfspy; Tactile
sensorfs; gad;gLfpd;wd.
 xU nghUshdJ kw;nwhU nghUSf;F mUfpy;
cs;sjhf vd;gij czh;tjw;F proximity sensorfs;
cjTfpd;wd.
34. What are the types of grippers used as end effectors?
1) Mechanical grippers 2) Vacuum grippers
3) Magnetic grippers 4) Expanding grippers
5) Adhesive gripper 6) Hook gripper
35. List out the tools used as end effectors in robot.
Spot welding gun, arc welding tool, spray painting gun,
rotating spindle for drilling, grinding, and similar operations,
assembly tool, heating torch, ladle, water jet cutting tool, etc.

36. List out the characteristics of robot applications.

 mghafukhd Ntiyfs;
 xNu Ntiyia jpUk;g jpUk;g nra;jy;
 ifahsf; fbdkhd Ntiyfs;
 Multishift Ntiyfs;
 mbf;fb khwhj Ntiyr; #oy;
Q & A.28
37. List out the industrial applications of robot.
1) Material transfer 2) Machine loading 3) Welding
4) Spray coating 6) Assembly 6) Inspection

Unit – V
CONCURRENT ENGINEERING,
QUALITY FUNCTION DEPLOYMENT,
PRODUCT DEVELOPMENT CYCLE,
AND AUGMENTED REALITY
1. W
Define sequential engineering.
Sequential engineering vd;gJ>nghUl;fis tbtij;jy;>
cw;gj;jp nray;Kiwfis cUthf;Fjy;> quality kw;Wk;
testing nray;Kiwfis eph;zapj;jy; Mfpait xd;wd; gpd;
xd;whf eilngWk; xU goikahd eilKiw MFk;.
2. W
Define concurrent engineering.
xd;wpize;J nrayhw;Wk; xU FOtpidf; nfhz;L> nghUis
cw;gj;jp nra;Ak; nray;Kiwfis Nkk;gLj;Jk; xU etPd
KiwNa concurrent engineering MFk;.
3. W
What is the need of concurrent engineering?
 ngUfp tUk; cyfshtpa Nghl;b.
 mbf;fb khWfpd;w Efh;Nthhpd; Njitfs;.
 nghUspd; FWfpa MAl;fhyk;.
 Ntfkhf tsh;e;J tUk; Gjpa kw;Wk; etPd
njhopy;El;gq;fs;.
4. W
List out the benefits of concurrent engineering.
1) kpfr;rpwe;j design ngwg;gLfpwJ.
2) Designy; cs;s gpiofis vspjpy; fz;lwpe;J rhp nra;ayhk;.
3) nghUis cUthf;Ftjw;fhd Neuk; FiwT.
4) Fiwthd cw;gj;jp nryT.
5) mjpf cw;gj;jp tPjk;.
6) nghUspd; juk; Nkk;gLj;jg;gLk;.

Q & A.29
 7) nghUspd; ek;gfj;jd;ik Nkk;gLk;
8) thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.
5. W
Define Quality Function Deployment (QFD) ?
Quality Function Deployment (QFD) vd;gJ> xU nghUis
cUthf;Ftjw;fhd midj;J epiyfspYk;> thbf;if
ahsh;fspd; Njitfis mg;nghUspd; gz;Gfshf khw;wp
mikf;Fk; xU nray;Kiw MFk;.
6. W
What are the phases in QFD?
1) Product planning 2) Product design
3) Process design 4) Process control
7. What is House of Quality (HOQ) ?
House of Quality (HOQ) vd;gJ thbf;ifahshpd; Njitfs;
kw;Wk; nghUspd; nray;jpwd;fs; Mfptw;wpw;F ,ilNaAs;s
njhlh;gpid tpsf;Fk; xU glk; MFk;.
8. List out the advantages of QFD.
 thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.
 ,ilg;gl;l tbtikg;G khw;wq;fs; FiwAk;.
 nghUis cUthf;Ftjw;fhd nryT FiwAk;.
 Gjpa nghUis tbtikg;gjw;fhd Neuk; FiwAk;.
 Team workI Nkk;gLj;Jk;.
 nghUspd; juk; Nkk;gLk;.
 Rejection kw;Wk; rework FiwAk;.
 tpw;gid mjpfhpf;Fk;.
9. What is Failure Modes and Effects Analysis?
Failure Modes and Effects Analysis (FMEA) vd;gJ
nraypog;Gf;F rhj;jpakhd fhuzpfs;> nghUspd;
nray;ghl;by; mtw;wpd; tpisTs;; kw;Wk; nraypog;ig
Kd;$l;bNa jtph;g;gjw;fhd eilKiwfs; Mfpatw;iw
fz;lwpa cjTk; nray;Kiw MFk;.
10. When to use FMEA?
 Gjpa nghUl;fis cUthf;Fk;NghJ
 xU nghUspy; khw;wq;fis Vw;gLj;Jtjw;F Kd;G
 xU nghUspy; Fiwia fz;lwpe;j gpd;G
 Gjpa nfhs;iffis mwpKfg;gLj;Jk;NghJ
Q & A.30
  thbf;ifahsh;fsplk; ,Ue;j mjpf Gfhh;fs; tUk;NghJ
 tpw;gidf;F gpd;ghd nryT tof;fj;ij tpl mjpfkhf
,Uf;Fk;NghJ
11. What is RPN?
RPN vd;gJ Risk Priority NumberIf; Fwpf;Fk;. ,J failure
modefis thpirg;gLj;j FMEAy; gad;gLfpwJ.
RPN = (Severity) x (Probability) x (Detection).

12. List out the benefits of FMEA.

 nghUspd; ek;gfj;jd;ik kw;Wk; juk; Nkk;gLk;.
 thbf;ifahshpd; jpUg;jp Nkk;;gLk;.
 Team workI Nkk;gLj;Jk;.
 nghUspd; cw;gj;jp Neuk; kw;Wk; nryT FiwAk;.
 nghUspd; tbtikg;G khw;wk; kw;Wk; mJ njhlh;ghd
nryT FiwAk;.
 Failure kw;Wk; warranty nryTfs; FiwAk;.
 epWtdj;jpd ,yhgk; mjpfhpf;Fk;.
13. Define value engineering.
Value engineering (VE) vd;gJ xU nghUis tbtikf;Fk;
NghJ mjd; kjpg;ig (value) Nkk;gLj;Jtjw;fhf
Nkw;nfhs;sg;gLk; Kiwahd mZFKiw MFk;.
14. Define value.
xU nghUspd; kjpg;ghdJ mjd; nray;ghL kw;Wk; tpiy
Mfpatw;wpw;F ,ilNaahd tpfpjk; MFk;. vdNt> xU
nghUspd; nray;ghl;il Nkk;gLj;JtJ my;yJ tpiyia
Fiwg;gjd; %yk; mjd; kjpg;ig mjpfhpf;fyhk;.
15. List out the types of values?
1) Cost value 2) Use value 3) Esteem value
4) Exchange value 5) Time value 6) Place value

16. Mention any two techniques used for identification of

poor value areas.

1) Value tests 2) Function – cost matrix approach

Q & A.31
17. List out the benefits of value engineering.
1) xU nghUSf;fhd nryT FiwAk;.
2) nghUspd; nray;ghl;L tPjk; Nkk;gLk;.
3) nghUspd; juk; Nkk;gLk;.
4) cw;gj;jp nryT FiwAk;.
5) nghUs; tPzhtJ jtph;f;fg;gLk;.
6) FO czh;T kw;Wk; xOf;fk; Nkk;gLk;.
7) thbf;ifahsh; - tpw;gidahsh; cwT Nkk;gLk;.
8) xU nghUspy; cs;s ghfq;fspd; vz;zpf;if FiwAk;.

18. Define DFMA.

xU nghUspd; tbtikg;G kw;Wk; cw;gj;jp nray;Kiwia
vspikahf;fp nryitf; Fiwf;Fk; topKiwfis
fz;lwpAk; KiwNa DFMA vdg;gLk;.
19. List out the benefits of DFMA.
1) xU nghUspy; cs;s ghfq;fspd; vz;zpf;if FiwAk;.
2) nghUspd; juk; Nkk;gLk;.
3) cw;gj;jp nryT kw;Wk; Neuk; FiwAk;.
4) nghUs; tPzhtJ jtph;f;fg;gLk;.
5) FO czh;T kw;Wk; xOf;fk; Nkk;gLk;.

20. Mention the activities in product development cycle?

1) Developing product concept 2) Designing the product

3) Planning 4) Manufacturing the part
5) Marketing 6) Servicing
21. List out the stages in product life cycle.

1) Introduction 2) Growth 3) Maturity 4) Decline

22. Liast out the stages in new product development
process.

1) Idea generation 2) Idea screening

3) Concept testing 4) Business analysis
5) Product development 6) Test marketing
7) Commercialization

Q & A.32
23. What is Augmented Reality?
Augmented reality (AR) vd;gJ gadhshpd; cz;ikahd
#oypd; kPJ computer %yk; cUthf;fg;gl;l cs;sPLfis
nghUj;Jk; njhopy;El;gk; MFk;. ,k;Kiwapy;> graphics,
sound kw;Wk; touch feedback Mfpait ,aw;if #oYld;
nghUj;jg;gLfpwJ.
24. List out the display devices used in AR.

Head-mounted display, eyeglasses, Google Glass, HoloLens,

Contact lenses, Virtual retinal display.
25. What are the software used in AR?
glj;jpy; Njhd;Wk; nghUspd; ,lk; kw;Wk; Njhw;wj;ij
tpthpg;gjw;F Augmented Reality Markup Language (ARML)
vd;w data standard gad;gLj;jg; gLfpwJ. CloudRidAR,
ARToolKit, Mobinett AR, Wikitude, kw;Wk; Meta Nghd;w
software development kitfSk; gad;ghl;by; cs;sd.

26. List out the important fields of application of AR.

1) Architecture 2) Visual art 3) Education

4) Video games 5) Industrial design 6) Medical
7) Military 8) Broadcast

Q & A.33
32062 COMPUTER AIDED DESIGN AND MANUFACTURING
MODEL QUESTION PAPER – I
Time: 3 Hrs Max Marks : 75
[N.B: (1) Answer any five questions in each PART – A and PART – B
Q.No.8 in PART – A and 16 in PART – B are compulsory.
(2) Answer division (a) or division (b) of each question in
PART – C.
(3) Each question carries 2 marks in PART – A, 3 marks in
PART – B and 10 marks in PART – C.]

PART – A

1. Define CAD.
2. Define IGES standard.
3. List out the benefits of CAM.
4. What is canned cycle?
5. List out the advantages of FDM.
6. What is the need of concurrent engineering?
7. Define DFMA
8. What is the concept of CIM?
PART – B

9. State the features in OpenGL.

10. List out the benefits of CAPP.
11. Write short notes on JIT.
12. Explain three dimensional printing.
13. List out the benefits of AGV.
14. List out the various robot sensors.
15. Explain product life cycle.
16. What is peck drilling? Give the syntax.

QP.1
 PART – C

17.(a) Explain 2D and 3D transformations.

(Or)
(b) Discuss solid modelling with an example. State its merits and
demerits.

18.(a) Explain the various coding structures used in parts classification

and coding.
(Or)
(b) Explain with a neat diagram the structure of a CAPP system

19.(a) Write a part program for thread cutting operation in a CNC lathe.
(Or)
(b) Explain the selective laser sintering process. Mention its
advantages and disadvantages.

20.(a) Explain about the FMS components.

(Or)
(b) Explain the configurations of robot.

21.(a) Explain the basic steps in Failure Mode and Effects Analysis.
(Or)
(b) Explain the new product development process with a sketch.

QP.2
32062 COMPUTER AIDED DESIGN AND MANUFACTURING
MODEL QUESTION PAPER – II
Time: 3 Hrs Max Marks : 75
[N.B: (1) Answer any five questions in each PART – A and PART – B
Q.No.8 in PART – A and 16 in PART – B are compulsory.
(2) Answer division (a) or division (b) of each question in
PART – C.
(3) Each question carries 2 marks in PART – A, 3 marks in
PART – B and 10 marks in PART – C.]

PART – A

1. Define graphics standard.

2. What is Group Technology?
3. Define JIT.
4. What is canned cycle?
5. Define AGV.
6. What is House of Quality.
7. Define FMEA.
8. What is FMS?
PART – B

9. List out the benefits of CAD.

10. What are the advantages of FEA?
11. What are the objectives of PPC?
12. Explain the two types of NC dimensioning.
13. List out the applications of rapid prototyping.
14. List out the types of grippers used in robot.
15. List out the benefits of value engineering.
16. What is master production schedule?

QP.3
 PART – C

17.(a) (i) Explain Shigley’s design process.

(ii) Explain constructive solid geometry.
(Or)
(b) (i) Briefly explain the Ohsuga model.
(ii) Explain the OpenGL pipeline process.

18.(a) (i) Explain the generative type CAPP.

(ii) Explain materials requirements planning.
(Or)
(b) (i) Explain the CODE system.
(ii) Explain shop floor control system.

19.(a) (i) Explain about the datum points and reference points in CNC.
(ii) Explain stereolithography process with a simple sketch.
(Or)
(b) (i) Write a part program to explain mirroring operation in CNC
machining centre.
(ii) Briefly explain rapid tooling.

20.(a) (i) Write short notes on (a) Flexible manufacturing cells

(b) Flexible transfer lines.
(ii) Explain the working principle of AGV
(Or)
(b) (i) Explain the intelligent manufacturing system.
(ii) Explain the industrial applications of robot.

21.(a) (i) Define QFD. Explain the phases in QFD.

(ii) Explain the stages in product life cycle.
(Or)
(b) (i) Explain the important guidelines for DFMA.
(ii) Explain the applications of Augmented Reality.

QP.4