1)What are the basic components of the NC system and explain the function of

each component?
The basic components of NC system are:

1. Programmer: The programmer is responsible for creating a program of

instructions that the machine will execute. The program typically contains
commands for the machine to move the cutting tool along specific axes change
speeds and control other important parameters.
2. Control unit: The control unit is the brain of the NC machine. It receives the
program instructions from the programmer interprets them and sends them to the
servomechanisms that control the machine's movements. The control unit is
responsible for precise control of the spindle speed axis movements automatic tool
changers and other key functions.
3. Servomechanisms: The servomechanisms consist of electric motors and sensors
that control the machine's movements. The sensors continuously monitor the
position of the machine's components and send feedback to the control unit. The
feedback allows the control unit to make real-time adjustments to the machine's
movements and ensure precise positioning.
4. Feedback devices: Feedback devices include linear and rotary encoders
potentiometers and other sensors that detect the actual position of the machine's
components. The feedback is used by the control unit to ensure that the machine
moves precisely to the desired location and maintains accuracy throughout the
cutting process.
5. Machine tool: The machine tool is the physical machine that performs the
cutting drilling milling or other operations required to create the final part. The
machine tool may consist of a lathe milling machine drill press or other specialized
equipment.
6. Cutting tool: The cutting tool is the component that performs the actual metal-
removal process. It can be a drill bit milling cutter or other tool and is selected
based on the specific requirements of the part being produced.

2) Sketch and explain the DNC setup.

The DNC (Direct Numerical Control) setup is a crucial component of flexible
manufacturing systems. It allows computerized numerical control (CNC) machines
to communicate with a central computer that controls the entire system.
The DNC setup consists of a central computer (a server) that manages and controls
the CNC machines. The CNC machines are connected to the server through a
network or a cable. The server sends programs and commands to the CNC
machines which execute them to perform the necessary tasks.
The DNC setup enables the manufacturing process to be optimized and
streamlined. The central computer can quickly download programs and
instructions to the CNC machines which means that changes can be made on the
fly and the production can be quickly adjusted to accommodate new demands.
In a flexible manufacturing system the DNC setup is essential because it enables
the entire production process to be automated and managed from a central location.
The system can be easily adapted to new products and production runs without
significant downtime or reconfiguration.
Overall the DNC setup is an integral part of flexible manufacturing systems and it
plays a critical role in improving production efficiency and flexibility.

3) Discuss the several word functions in Numerical Control systems. Discuss

the advantages of DNC over NC/CNC.

1. Variables: Variables in numerical control systems are used to store values

that are used in calculations or decision-making processes. Variables can be
used to store various values such as tool offsets position coordinates feed rates
spindle speeds etc. These values can be changed or modified as needed
allowing for more flexibility in the machining process.
2. Functions: Functions in numerical control systems are pre-programmed
sequences of operations that perform specific tasks. These tasks can include
tool changes spindle speed changes coolant on/off etc. Functions can be
programmed to execute automatically or can be manually activated by the
operator
3. Loops: Loops in numerical control systems are used to repeat a sequence of
operations a specific number of times. This allows for the repetition of complex
machining operations without the need to manually input each command. Loops
can also be used to create patterns or shapes that require repetitive movements.
4. Conditional statements: Conditional statements in numerical control systems
are used to make decisions based on specific conditions. These conditions can
include tool wear workpiece dimensions cutting conditions etc. Conditional
statements allow for adaptive machining and can help to prevent errors and
reduce tool wear.
5. Program subroutines: Program subroutines in numerical control systems are
sections of code that can be called repeatedly from within a larger program.
Subroutines can be used to simplify programming tasks reduce program size
and complexity and allow for easier modification of the program.

Here are some more advantages of DNC (Direct Numerical Control) over
NC/CNC (Numerical Control/Computer Numerical Control):

1. Centralized Programming: DNC helps in centralized programming where the

program is created once and is then copied to multiple machines. This saves
time for the operator and increases efficiency.
2. Increased Accuracy: DNC systems offer increased accuracy and precision
since the program is generated from a central computer which eliminates
programming errors and variations.
3. Reduced Downtime: With DNC operators can conveniently retrieve the
necessary programs from a central location thereby reducing downtime.
 4. No Need for Large Memory: DNC systems don't require large memory
storage as the program is stored in a central computer and is transmitted to the
machine only when needed.
5. Real-Time Monitoring: With DNC the central computer can monitor the
machine's operations in real-time making it easy to track the machine's
performance and make necessary corrections immediately.
6. Cost-Effective: DNC is a cost-effective solution compared to NC/CNC
machines as it eliminates the need for standalone controllers.
7. Increased Flexibility: DNC systems offer more flexibility as the program can
be modified easily and quickly.
In conclusion DNC provides numerous advantages over NC/CNC including
centralized programming increased accuracy reduced downtime no need for
large memory real-time monitoring cost-effectiveness and increased flexibility.

4) Describe various G and M codes used in CNC machines

here are some more G and M codes commonly used in CNC machines:
G74: Peck drilling cycle
G80: Cancel cycle
G81: Drill cycle; drilling a hole
G82: Drill cycle; drilling a hole with a dwell period at the bottom
G83: Peck drilling cycle for deep holes
G84: Tapping cycle for right-hand threaded holes
G85: Boring cycle with no dwell
G86: Boring cycle with a dwell
G90: Absolute positioning mode
G91: Incremental positioning mode
G92: Set current position to specified coordinates
G94: Feed rate per revolution
G98: Set initial level in canned cycle
 G99: R-point level in canned cycle

M00: Program stop

M02: Program end
M03: Spindle on clockwise rotation
M04: Spindle on counterclockwise rotation
M05: Spindle off
M07: Coolant on
M08: Coolant on
M09: Coolant off
M30: Program end with rewind and stop
These are just a few examples of the many G and M codes that exist in CNC
machines. It's important for operators to familiarize themselves with the codes
that are specific to their machine and application in order to efficiently and
accurately run their program.

5) Describe the axis representation system used for CNC Milling machines.
Discuss the various interpolation methods used in NC machines.

The axis representation system used for CNC Milling machines is a Cartesian
coordinate system comprising of three axes: X Y and Z. These axes represent the
horizontal (left-right vertical (up-down and depth (in-out) directions of the milling
tool.

The X-axis is the horizontal axis and runs from left to right. It is parallel to
the worktable. The Y-axis is the vertical axis and runs up and down
perpendicular to the worktable. The Z-axis runs in and out perpendicular to
both the X-axis and Y-axis and moves the milling tool up and down.

The three axes are controlled by stepper motors that move the toolhead
precisely and accurately to the desired position. These axes enable the
machine to move the milling tool in any direction making it possible to
create complex shapes and designs.

To operate the machine the user inputs the coordinates for the desired tool
path into the computer's software program. The software then translates the
coordinates into machine language and sends commands to the stepper
motors to move the toolhead in the desired direction along the specified
path. The result is a precise and accurate cut or shape.

Interpolation is a method used in CNC machines to determine the path that

the cutting tool will follow. There are various interpolation methods used in
CNC machines including straight-line interpolation circular interpolation
and helical interpolation.

1. Straight-Line Interpolation - This method is used to move the tool along a

straight line path from one point to another. Linear interpolation moves the
tool in a straight line at constant velocity between two programmed points.
This method is quick and efficient and is suitable for simple machining
operations.

2. Circular Interpolation - This method is used when the cutting tool needs to
move along a circular path. Circles can be programmed to have different
radii starting and ending points and number of revolutions. The cutting tool
follows a circular path with the center being the midpoint between the start
and end points.

3. Helical Interpolation - This method combines circular and linear

interpolation. The cutting tool moves along a path that is a combination of a
linear and a circular path. Helical interpolation is used for creating spiral
paths or for creating threads on cylindrical surfaces.

4. Spline Interpolation - This method is used to create complex curved paths.

Spline interpolation uses a curve that is defined by a set of data points. The
curve is then fit to the data points using a mathematical algorithm.

5. Arc-Fitting Interpolation - This method is used to create smooth curved

paths. Arc-fitting interpolation uses a series of data points to create a series
of small arcs. These arcs are then combined to create a smooth curved path.
 In conclusion CNC machines use different interpolation methods to control
the movement of cutting tools. Each method has its advantages and
disadvantages and the choice of method depends on the specific application
and the desired cutting path.

6) Discuss the objectives of CAQC. Explain the different computer aided

inspection methods.

The objectives of the Computer-Aided Quality Control (CAQC) in flexible

manufacturing system are:

1. To improve the quality of the products by detecting and eliminating defects at an

early stage before they become costly errors.
2. To reduce the inspection time by using automated inspection techniques.
3. To enhance the production efficiency by reducing the time spent on rework.
4. To reduce the cost of production by minimizing the number of rejected products.
5. To enhance the competitive advantage of the manufacturing firm by ensuring
that their products meet industry standards and customer expectations.
6. To promote customer satisfaction by providing high-quality products that meet
their requirements.

By achieving these objectives CAQC helps manufacturing firms to achieve their

ultimate goal of maximizing profits in their operations.

there are several computer-aided inspection methods used in manufacturing

and quality control. Some of the most common ones include:

1. Coordinate Measuring Machines (CMM): CMMs are used for dimensional

inspection and can precisely measure the dimensional attributes of mechanical
parts. They use probes to touch the surface of the part and generate data points
which are compiled into a 3D image of the part.
2. Automated Optical Inspection (AOI): AOI uses cameras and lighting to inspect
the surface of parts and can quickly identify defects such as scratches dents and
missing features. It is commonly used in the inspection of printed circuit boards
and other electronic components.
3. X-ray Inspection: X-ray inspection is used for non-destructive testing of parts
and can detect internal defects such as cracks and voids. It is commonly used in the
inspection of castings and other metal parts.
4. Laser Scanning: Laser scanning is used to capture the surface geometry of parts
and is particularly useful for inspecting complex geometries that are difficult to
measure with traditional methods. It can also be used to capture 3D images of large
assemblies.
5. ultrasonic Testing: Ultrasonic testing uses high-frequency sound waves to detect
defects in parts. It is commonly used in the inspection of welds and other critical
joints.
These computer-aided inspection methods are widely used in the manufacturing
industry to ensure that parts and components meet the necessary quality standards.
They can improve the accuracy and speed of inspections while reducing the need
for expensive and time-consuming manual inspections.

7) Explain the salient features of any two CAM software that are being
currently used in the industry. What factors may influence the selection
of particular software?

1) Intuitive modeling features

Design and produce, this is the main answer to which a CAD/CAM software
worthy of the name must respond. It is therefore important that it offers highly
relevant features to cover all the user’s needs. For the woodworking industry, such
features include material removal, configuration of assemblies between parts,
parametric 3D modeling, as well as advanced software customization to allow for
greater benefit and ease of use. And the list goes on.

2) Real-time visualization of the changes made

real time and to make changes to dimensions without having to check each
element. Therefore, the operation of the chosen design rules, as well as the
conformity of the rendering based on the customer’s wishes, are verified on the
spot and with reliability. Not to mention that drawings, bills of materials, and
machining programs are also updated automatically.