MODEL ANSWERS

COMPUTER INTEGRATED MANUFACTURING

CODE: 15ME62T
VI SEMESTER DIPLOMA EXAMINATION APRIL/MAY 2020

NOTE: (i) Answer any SIX questions from Part – A

(ii) Answer any SEVEN questions from Part – B

PART – A

Question 01. Define CIM and list the scope of CIM. 5-Marks
Answer 01. Define CIM: Computer-integrated manufacturing (CIM) is the manufacturing
approach of using computers to control the entire production process. CIM is the integration of
total manufacturing enterprise by using integrated systems and data communication coupled
with new managerial philosophies that improve organizational and personnel efficiency.
Scope of CIM: Computer-integrated manufacturing system not only includes all of the
engineering functions of CAD/CAM, but also includes the firm’s business functions that are
related to manufacturing. The scope of CIM compared to the limited scope of CAD/CAM as
shown in the figure below.

Figure 01. Scope of CIM

The concept of CIM is that, all of the firm operations related to production are
incorporated in an integrated computer system to assist, augment and automate the operations.
The computer system is networked throughout the firm, touching all activities that support
manufacturing. In this system, the output of one activity serves as input to the next activity,
through the chain of events that starts with the sales order to the shipment of the product.

Question 02. List the applications of CNC System. 5-Marks

Answer 02: Almost every manufacturing industry uses CNC machines. With increase in the
competitive environment and demands, the demand of CNC usage has increased to a greater
extent. The machine tools that come with the CNC are late, mills, shaper, welding etc. The
industries that are using CNC machines are automotive industry, metal removing industries,
industries of fabricating metals, electrical discharge machining industries, wood industries etc.
It can be used for the applications like- Flame cutting or Plasma cutting, Punching, Laser
Cutting, Forming, Grinding operations, Milling operations, Routing operations etc.
 The following parts are usually made in practice on the CNC Machines:

1. Aerospace equipment’s.
2. Automobile Parts
3. Complex shapes.
4. Electronic industry uses CNC e.g. Printed circuit board.
5. Electrical industry uses CNC e.g. Coil winding.
6. For small to medium batch quantity.
7. Where the tool storage is a problem.
8. Where much metal needs to be removed.
9. For parts subjected to regularly design changes.
10. When the inspection is required 100%.
11. When lead time does not permit the conventional tooling manufacture.
12. Where repetitive operations are required on the work.

Question 03. Factors considered in the designing the guide ways. 5-Marks
Answer 03. Following are the factors to be considered while designing guide ways:
 Rigidity
 Damping capability
 Geometric and Kinematic accuracy
 Velocity of slide
 Friction characteristics
 Wear resistance
 Provision for adjustment of play
 Position in relation to work area
 Protection against swarf and damage

Question 04. Explain Hydrodynamic bearing with a neat sketch. 5-Marks

Answer 04: These are journal bearing with a thin film of oil between the spindle and the
journal. These are used where load carrying capacity is low and frequent start and stop is not
required.
Here the load on the bearing is supported by a continuous film of lubricant, usually oil
which avoids direct contact between the journal and the bearing. Motion of the journal inside the
bearing creates necessary pressure for the film to sustain the load.

Figure 02. Principle of hydrodynamic bearing

 In the startup stage, when the journal rotates, the radial load applied to the bearing
through the journal forces journal towards the center in the direction of the load. The converging
wedge shaped area above the region of contact draws the oil, resulting in pumping action, which
generates an oil film pressure. So, the journal will be lifted off from the bearing. The film
thickness must be sufficient to eliminate metal to metal contact during running. The clearance in
the range of 0.001 to 0.002 times the bearing diameter.

Question 05. Explain the tool compensations in CNC Machine. 5-Marks

Answer 05. Tool Compensations in CNC Machines:
(i)Tool length compensation:
Tool length compensation is required to take care of tool of different lengths used in
machining. This is the distance between the gauge line on the spindle nose and the tip of the
cutter. It is essential to establish the length of each tool and store that in the system memory
against the corresponding tool number before starting the actual cutting.
(ii) Tool radius compensation:
During a turning or milling operation, an equidistant path of the tool tip centre or cutter
centre has to be calculated and the dimensions have to be given to this tool path. This feature
permits programming the drawing dimensions of the work piece and allow the calculations of
the equidistant tool path to the control system. The actual tool radius is not specified in the
program at all, this compensation can be given to the left of the work piece (G41) or to the right
of the work piece (G42) G40 cancels G41 or G42.

Question 06. State the benefits of Computer Aided Process Planning (CAPP). 5-Marks
Answer 06. The benefits of CAPP are as follows:
1. Process rationalization
2. Increase productivity of planners
3. Reduced time
4. Increased legibility
5. Incorporation of other Application programmers
6. It reduces skill of the planner
7. It reduces manufacturing cost
8. The inventory is minimum
9. The quality of the products is high
10. It can meet the demands of the customers

Question 07. List the important benefits or use of robots in CIM. 5-Marks
Answer 07. Important uses of Robots:
General characteristics of industrial work situations that promote the use of industrial robots
1. Hazardous work environment for humans
2. Repetitive work cycle
3. Difficult handling task for humans
4. Multi shift operations
5. In frequent change over
6. Part position and orientation are established in the work cell
1. Material handling applications- Material transfer – pick-and-place, palletizing
Machine loading and/or unloading
2. Processing operations- Spot welding and continuous arc welding, Spray coating
Other – water jet cutting, laser cutting, grinding
3. Assembly and inspection
Question 08. Explain briefly automatic tool changer (ATC). 5-Marks
Answer 08. Automatic Tool Changer:
The CNC machines are designed to perform a number of operations in a single setting
of the job. A number of tools may be required for making a complex part. In a manual machine,
the tools are changed manually whenever required. In a CNC machine, tools are changed
through program instructions. The tools are fitted in a tool magazine or drum. When a tool
needs to be changed, the drum rotates to an empty position, approaches the old tool and
pulls it. Then it again rotates to position the new tool, fits it and then retracts. This is a typical
tool changing sequence of an automatic tool changer (ATC). The concept of the ATC is that the
range of tools for a specific job shall be made available for automatic selection and positioning.
ACT can be – Drum type and Chain Type
Drum Type: The disc type rotates to get the desired tool in position with the tool change arm.
Larger the diameter of the disc/drum more the number of tools it can hold. It carries about 12 to
50 tools.
Chain Type: When the number of tools is more than 50, chain type of magazines are used.
In chain magazines the tools are identified either by their location in the tool holder or by
means of some coding on the tool holder.
As soon as the tool selection command is received by the system, the selected tool
comes to a fixed place known as tool change position. The selected tool is transferred to the
spindle from magazine after the previous tool is transferred to the magazine from spindle.
This is called tool change cycle. The tools from the magazines and spindle are exchanged by
a tool changer arm.

Question 09. Explain five levels of automation. 5-Marks

Answer 09. Five levels of Automation:
1. Device level: This is the lowest level in our automation hierarchy. It includes the
actuators, sensors and other hardware components that comprise the machine level. The devices
are combined into the individual control loops of the machine, for example, the feedback control
loop for one axis of a CNC machine or one joint of an industrial robot.
2. Machine level: Hardware at the device is assembled into individual machines.
Example: CNC machine tools and similar production equipment, industrial robots and powered
conveyors. Control functions at this level include performing the sequences of step in the
program of instructions in the correct order and making sure that each step is properly executed.
3. Cell or System level: This is the manufacturing cell or system level, which operates
under instructions from the plant level. A manufacturing cell or system is a group of machine or
work stations connected and supported by a material handling system, computer and other
equipment appropriate to the manufacturing process. Production lines are included in this
level. Functions include part dispatching and machine loading, coordination among machine and
material handling system, and collecting and evaluating inspection data.
4. Plant level: It is factory or production system level. It receives information from the
corporate information system and translates them into operational plans for production. Its
function include order processing, process planting, inventory control, purchasing material
requirements planning, shop floor control and quality control.
5. Enterprise level: This is the highest level consists of corporate information system.
It is concerned with all of the functions necessary to manage the company, like marketing
and sales, accounting, design, research, aggregate planning and master production
scheduling.
 OR

Figure 03. Five levels of automation and control in manufacturing

PART – B
Question 10(a). Compare between fixed, programmable and flexible automation system.
6-Marks
Answer 10(a). Automation System:
The relative positions of the three types of automation for different production
volumes and product varieties are depicted in the following figure.
1. Fixed automation
2. Programmable automation
3. Flexible automation
Fixed automation: It is a system in which the sequence of processing (or assembly) operations
is fixed by the equipment configuration. The operations in the sequence are usually simple. It
is the integration and coordination of many such operations into one piece of equipment that
makes the system complex
Programmable Automation: In this, the production equipment is designed with the
capability to change the sequence of operations to accommodate different product
configurations. The operation sequence is controlled by a program, new programs can be
prepared and entered into the equipment to produce new products.
A manufacturing system designed with the capability to change the sequence of operations to
accommodate different product configurations
Flexible Automation: It is an extension of programmable automation. A flexible automated
system is one that is capable of producing a variety of products (or parts) with virtually no
time lost for changeovers from one product to the next.

Figure 04. Automation System for different levels

Question 10 (b). What are the essential need of CIM. 4-Marks
Answer 10(b). Following are the essential needs of CIM:
1. To increase the manufacturing efficiency.
2. To improve the scheduling flexibility in the long term.
3. Integration of automated assignment and reporting of factory floor operations.
4. For product design.
5. For manufacturing planning.
6. For manufacturing and inventory control.
7. To increase the accuracy in the production.
8. To reduce the wastage to the zero level.
9. To maintain quality control.
10. Update financial accounts.
11. To have the high degree of integration in business functions.
12. To have enterprise resource planning.
13. For material requirement planning.
14. Customer order management.

Question 11 (a). Explain Distributed Numerical Control (DNC). 5-Marks

Answer 11(a). Direct Numerical Control can be defined as a type of manufacturing system in
which several NC or CNC machines are controlled remotely from a Host/Main frame
computer or direct numerical control (DNC)
Direct numerical control (DNC) is defined as a system which integrates a number of
machines by controlling it through a central computer by direct connection.
The central computer is designed to provide instructions to each machine tool on
demand. The central computer also receives data back from the machines. Thus, there is a
two way information exchange between the central computer and each of the machine
tool.

Figure 05. DNC System

The part-program is downloaded to the machines directly (thus omitting the tape reader)
from the computer memory. The basic DNC system requires following basic component are
Main frame computer, Memory, Communication network, NC machine tool. The
communication network can be done either through connecting the remotely located computer,
with lengthy cables to the individual machine control directly or connecting the main frame
computer with a small computer at individual operator’s station known as satellite computer.
DNC system is expensive and is preferably used in large organizations.
Question 11(b). Compare between point to point versus straight cut control system. 5 Marks
Answer 11(b). (i) Point to point control system:
It is the tool positioning system, In this point to point, the main objective of the machine
tool is to move the cutting tool to a predefined location. The path and speed by which the
movement of the movement of the tool is accomplished is not important in PTP. Once the
tool reaches the desired location, the machining operation is performed at that position.
For example, in NC drilling machines, the spindle is positioned at a particular location
on a work piece by PTP control and then drilling is performed at that point, and so forth.
Since there is no cutting action between holes, there is no need to control the relative motion of
the tool and work piece between hole location as shown in the figure.

Figure 06. Point to point control system

(ii) Straight cut control system:

This system is capable to move the cutting tool parallel to one of the major axis at a
controlled rate suitable for machining. Therefore these are suitable for milling operations to
fabricate a rectangular work piece. In this system it is not possible to combine movements in
more than a single axis direction hence, the angular cuts are not possible.

Figure 07. Straight cut control system

Question 12 (a). Explain re-circulating ball screw and nut mechanism in CNC machines
with a neat sketch. 5-Marks
Answer 12(a). Re-circulating ball screw and Nut:
This is an improved form of screw and nut mechanism. Hardened steel balls are
introduced between the screw and nut and there is a rolling action during the movement of the
screw. In re-circulating ball screw and nut hardened steel balls are introduced in the thread
portion of the screw and nut to replace sliding friction by rolling friction. There is an
endless stream of re-circulating steel balls.
 Figure 08. Re-circulating ball screw and nut
Following are the features of this system:
1. Lower frictional resistance
2. Low energy consumption
3. Minimum temperature rise
4. Higher efficiency
5. No stick-slip action
6. Higher traverse speed
7. Longer life with minimum wear
For the continuous Re-circulating of the balls during the axial movement of the nut, a
channel is cut internally or mounted externally. For the accurate movement, the
backlash effect should be reduced. This is achieved by pre-loading of the nut. The
efficiency of the system is 90%. Two types of thread forms are used. Balls rotate
between the screw and nut. For returning of the balls, an external tube and insert channel
types of arrangement are used.

Question 12(b). Sketch and explain the principle of Hydrostatic bearing. 5-Marks
Answer 12(b). Hydro-static bearing:
The spindle is supported in the bearing relatively, thick film of oil is supplied under the
pressure, it is similar to that used in the bearings for linear movements. The oil is pressurized by
a pump external to the bearing. These are used only temperature affects causes problems in pate
of accuracy.

Figure 09. Principle of hydrostatic bearing

Advantages:
 High running accuracy
 High damping properties
 High wear resistance
Question 13(a). Explain Static, Dynamic and Thermal loads in machine structure. 6-Marks
Answer 13(a).
Static load:
The static load develops on the machine structure due to weights of slides and work
pieces, and the forces due to cutting action. The structure should have adequate stiffness and
proper structural configuration to keep the deformation of the structure within the permissible
limits due to the static load.
Dynamic load:
The dynamic load is constantly changing forces acting on the structure while movement
is taking place. These forces cause the whole machine system to vibrate. The origin of
vibration are due to the
 Unbalanced rotating parts
 Improper meshing of gears
 Bearing irregularities
 Interrupted cuts while machining (in case of milling)
The effect of these vibrations on machine structure can be reduced by
 Reducing the mass of the structure
 Increasing the stiffness of the structure
 Improving the damping properties
Thermal load:
Thermal gradients existing within the machine tool due to due to varying temperature
levels at different positions causes thermal stress.
This is the thermal distortion of the machine structure due to local heat sources. They
cause thermal gradients in the machine structure and also deformation of various parts which
leads to considerable inaccuracy.
These sources thermal loads are
 Electric motors
 Friction in mechanical drives and gear boxes
 Spindle and other moving parts
 Friction in bearing and guide ways
 Machining processes
 Temperature of surrounding objects

Question 13(b). Explain tool monitoring system. 4-Marks

Answer 13(b). Tool monitoring System:
(i) Direct tool monitoring:
In this system, monitoring of the tool conditions is done directly by using a touch probe
by checking the tool edge position and checking for the existence of a tool edge. It is also called
off-line tool monitoring system. This system will not give any alarm to an operator to change the
tool. Decision making system is the manual one.
(ii) Indirect tool monitoring:
In this system, the tool condition is checked indirectly by monitoring the change in
certain parameters whose value when affected reflects the condition of the tool. Some of the
parameters used to monitor the tool conditions are tool life, power of spindle or feed drive,
forces due to cutting, noise emission during cutting. It is also called on-line tool monitoring
system. This system gives an alarm to an operator to change the tool. Decision making system is
the control system.
Question 14(a). Explain with sketch methods of dimensioning for part production on CNC
machines. 6-Marks
Answer 14(a). Methods of dimensioning:
(i) Absolute dimensioning:
The absolute dimensioning is the most common method of dimensioning the drawings.
In this system, all the dimensions are measured from a single reference line called datum. The
advantage of this system is if any one hole is wrongly located, the other holes remain unaffected.
In a part program, the address G90, the preparatory function is used to specify the absolute
dimensioning system.

Figure 10. Absolute dimensioning

(ii) Incremental dimensioning:
In incremental dimensioning, the dimensions value can readable directly. The origin or
the reference edge continuously changes from one point to another point. The basic limitation of
this system is if any one hole is wrongly located, the reset of the holes will also get affected. The
preparatory function G91 is used to specify incremental dimensioning.

Figure 11. Incremental Dimensioning

Question 14(b). Define the following: (i) Machine Zero and (ii) Work piece Zero 4-Marks
Answers 14(b). (i) Machine Zero: At this point coordinates of all axes are zero. Tool moves
with respect to this point and position of all axes can be seen on computer screen. Machine
zero point is decided by manufacturer of machine
(ii) Work piece Zero: For preparing a program, first tool path is prepared according to
operation sequence and then coordinates of all points are determined. These coordinates are
determined by considering an original point on the job where all the axes intersect and
coordinates of that point are zero. This original point is known as Work Zero point.
Question 15(a). List five applications of Group Technology. 5-Marks
Answer 15(a). Applications of GT
(i) Product design
(ii) Tooling and setups
(iii) Material handling
(iv) Production and inventory control
(v) Employee satisfaction
(vi) Process planning procedures

Question 15(b). Explain circular interpolation functions in CNC machines. 5-Marks

Answer 15(b). Circular Interpolation:
If the cutting tool is required to move along an arc, circular interpolations G02 or G03
are used to execute the instructions. G02 is used if the direction of interpolation is clockwise and
G03 is used for counter clockwise interpolation. The following information is required for
writing an instruction block for circular interpolation
i. G – code depending on the direction of interpolation
ii. Co-ordinates of the target point
iii. Co-ordinates of the centre point of the arc
iv. Feed rate of the cutting tool
The instruction blocks for the circular interpolation clockwise
G02 X__Y__I__J__F__EOB Or G02 X__Y__R__F__EOB
The instruction blocks for the circular interpolation counter clockwise
G03 X__Y__I__J__F__EOB Or G03 X__Y__R__F__EOB

Question 16(a). State the advantages of FMS. 5-Marks

Answer 16(a). Advantages of FMS:
Successfully implemented FMS offer several advantages. Some of them are given below:
1. Increased machine utilization
2. Reduced inventory
3. Reduced manufacturing lead time
4. Greater flexibility in production scheduling
5. Reduced direct labor cost
6. Increased labor productivity
7. Shorter response time
8. Consistent quality
9. Other FMS benefits include:
 Reduced factory floor space.
 Reduced number of tools and machines required.
 Improved product quality.
 Easy expandability for additional processes or added capacity.

Question 16(b). Explain with diagram retrieval type of CAPP System. 5-Marks
Answer 16(b). Retrieval type of CAPP system:
This approach use a group technology (GT) code to select a generic process plan from
the existing master process plans generally developed for each part family and edits to suit the
requirements of the part. Retrieval approach is implemented with GT coding system and each
group has a master plan
 Figure 12. Retrieval type of CAPP System
However the retrieval approach is impractical in the situations where small batches of
widely varying parts are produced and this method also fails to capture real knowledge or
expertise of process planners and there is a danger of repeating mistakes from earlier plans that
were stored in the data base.

Question 17(a). Explain about six degrees of freedom in order to set the motions in robots.
6-Marks
Answer 17(a). Six degrees of freedom in Robots:
There are six basic motions, or degree of freedom by which a robot can have a
capability to move end effectors through required sequence of motions. These six basic motions
consist of three arm and body motions and three wrist motions as follows:
Arm and body motions:
1. Vertical traverse: Up and down motions of arm caused by pivoting the entire arm about
a horizontal axis or moving the arm along a vertical slide.
2. Radial traverse: Extension and retraction of the arm i.e. in and out movement
3. Rotational traverse: Rotation about the vertical axis i.e. right or left swivel of the robot
arm.
Wrist motions:
4. Wrist swivel: Rotation of wrist
5. Wrist bend: Up and down movement of wrist, which also involves a rotational
movement
6. Wrist yaw: Right or Left swivel of the wrist

Figure 13. Typical six degrees of freedom in robot motion

Question 17(b). List the various methods by which robots can be programmed. 4-Marks
Answer 17(b). Following are the different methods of programming the robots -
1. Manual method
2. Walk through method
3. Lead through method
4. Offline programming

Question 18. Write a part program for the following component as shown in the figure in
absolute mode. 10-Marks
Answer 18.

Raw material size: ϕ 100 X 120

20mm inside the chuck
All dimensions are in mm only
NOTE: By considering the given diameter, program should be in steps turning.

% 100
N10 G90 G00 X100 Z00 S1000 M03 M08 T01 LF
N20 X30 Z00 F50 LF
N30 G01 X30 Z-30 LF
N40 G00 X60 Z-30 LF
N50 G01 Z-60 LF
N60 G00 X100 LF
N70 X100 Z00 LF
N80 X26 Z00 LF
N90 G01 X30 Z-2 LF
N100 G00 X30 Z00 LF
N110 X60 Z00 LF
N120 X54 Z-30 LF
N130 G01 X60 Z-33 LF
N140 G00 X60 Z-30 LF
N150 G00 X100 Z-30 LF
N160 G00 X100 Z-60 LF
N170 X94 Z-60 LF
N180 G01 X100 Z-63 LF
N190 G00 X100 Z-60 LF
N200 X100 Z00 M05 M09 M30 LF
Que 19. Write a CNC milling part program for the given figure using subroutine.10-Marks
Answer 19.

Main Program
N10 G90 G00 X20 Y20 M03 S1000 T02 LF
N20 L20 LF
N30 G00 X50 Y50 LF
N40 L20 LF
N50 G00 X80 Y80 LF
N60 L20 LF
N70 G00 X00 Y00 M02 M05 LF
N80 M30 LF

Sub-routine Call L20

N10 G91 G01 X20 Y00 Z-5 F50
N20 G01 X00 Y20
N30 G01 X-20 Y00
N40 G01 X00 Y-20
N50 G90 G00 Z5
N60 M17

Certificate:
This is to certify that the model answers prepared by me for the subject 15ME62T are
from the Text Books prescribed by BTE. The valuer may also consider the most relevant and
alternate answers for the questions and also for programs from the other Text Books prescribed
by BTE.

NAGARAJ. N
Selection Grade Lecturer
A.P.S. Polytechnic (203)
Bengaluru
Mob. #: 98445 14727
E-mail: nnr4aps@gmail.com
 SCHEME OF VALUATION
COMPUTER INTEGRATED MANUFACTURING
CODE: 15ME62T
VI SEMESTER DIPLOMA EXAMI NATION APRIL/MAY 2020

NOTE: (i) Answer any SIX questions from Part – A

(ii) Answer any SEVEN questions from Part – B

Q. No Scheme of Valuation Max

Marks
PART - A
1 Definition 2 ½ marks and Scope 2 ½ marks 5
2 Applications of CNC System each 1 mark 5
3 Factors considered for designing Guide Ways each 1 mark 5
4 Hydrodynamic bearing Explanation 2 ½ marks 5
Sketch 2 ½ marks
5 Tool Compensations 5
(Tool length 2 ½ marks & Tool radius 2 ½ marks)
6 Benefits of CAPP (Any five) 5
7 Important benefits of use of Robots in CIM (Any five) 5
8 Explain about ATC 5
9 Five levels of Automation (Each level 1 Mark) 5
PART - B
10 (a) Each automation system 2 Marks 6
10 (b) Essential needs of CIM (Any four each 1 mark) 4
11 (a) Explain DNC 5
11 (b) Point to Point control system 2 ½ marks and 5
Straight cut control system 2 ½ marks
12 (a) Explanation 2 ½ marks and Sketch 2 ½ marks 5
12 (b) Explanation 2 ½ marks and Sketch 2 ½ marks 5
13 (a) Explanation Static, Dynamic and Thermal Load (Each 2 marks) 6
13 (b) Explain tool monitoring system (Direct & Indirect, Each 2 marks) 4
14 (a) Absolute dimensioning 2 ½ marks and 6
Incremental dimensioning 2 ½ marks
14 (b) Machine zero 2 ½ marks and Work piece zero 2 ½ marks 4
15 (a) Applications of Group Technology (Each 1 mark) 5
15 (b) Explanation Clock wise 2 ½ marks & Counter clock wise 2 ½ marks 5
16 (a) Benefits of FMS (Each 1 marks) 5
16 (b) Explanation 2 ½ marks and Sketch 2 ½ marks 5
17 (a) Six degrees of freedom in Robot –sketch 3 marks, explanation 3 6
marks
17 (b) List of Program methods 4
18 First two block of program 2 marks, Middle part program 6 marks 10
and two end blocks of Part program 2 mark
19 Main Program 5 marks and Sub-Program 5 marks 10

NAGARAJ. N
Selection Grade Lecturer
A.P.S. Polytechnic (203)
Bengaluru
Mob. #: 98445 14727
E-mail: nnr4aps@gmail.com