1. (a) Briefly explain canned cycles as used in CNC programming. (2 Marks)
(b) With the aid of clear sketches, explain the process of perk drilling as a suitable process where canned cycles are applied. Write a general example of a two-line CNC program code for the process. (7 Marks) 2. The figure shows a profile to be machined on a three axes CNC milling machine. Write a CNC code to machine the profile. Use a feed rate of 50mm/min and depth of cut of 5mm. Assume material being cut is Perspex. You may refer to the table of milling G- Codes attached. (6 Marks)
3. (a) Explain any four qualities that make robots commercially and technologically important. (4 Marks) (b) With the aid of a neat sketch, show the configuration of the SCARA robot and state two suitable applications. (5 Marks)
4. (a) Briefly explain how the following benefits are achieved in FMS. Increased machine utilization (2.5 Marks) Reduced inventory requirements (2.5 Marks) (b) With the aid of a neat sketch, show the ladder layout of material handling in FMS and state two of its main advantages. (6 Marks)
TABLE: MILLING G-CODES
G code Description G00 Rapid traverse G01 Linear interpolation G02 Circular interpolation CW G03 Circular interpolation CCW G04 Dwell G17 X Y plane selection G18 Z X plane selection 1of 6 G19 Y Z plane selection G28 Return to reference position G30 2nd, 3rd and 4th reference position return G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right G43 Tool length compensation + direction G44 Tool length compensation – direction G49 Tool length compensation cancel G53 Machine coordinate system selection G54 Workpiece coordinate system 1 selection G55 Workpiece coordinate system 2 selection G56 Workpiece coordinate system 3 selection G57 Workpiece coordinate system 4 selection G58 Workpiece coordinate system 5 selection G59 Workpiece coordinate system 6 selection G68 Coordinate rotation G69 Coordinate rotation cancel G73 Peck drilling cycle G74 Left-spiral cutting circle G76 Fine boring cycle G80 Canned cycle cancel G81 Drilling cycle, spot boring cycle G82 Drilling cycle or counter boring cycle G83 Peck drilling cycle G84 Tapping cycle G85 Boring cycle G86 Boring cycle G87 Back boring cycle G88 Boring cycle G89 Boring cycle G90 Absolute command G91 Increment command G92 Setting for work coordinate system or clamp at maximum spindle speed G98 Return to initial point in canned cycle G99 Return to R point in canned cycle
END!!
2of 6 SOLUTIONS 1 A peck drill cycle is used on deep holes. The tool drills an incremental distance (Q) and then fully retracts from the hole. This breaks the chip, clears material out of the hole, and allows coolant to cool the drill and flush out the hole, reducing the chance of the tool breaking and producing a better quality hole.
3 (a) Some of the qualities that make industrial robots commercially and technologically important are the following: Robots can be substituted for humans in hazardous or uncomfortable work environments. A robot performs its work cycle with a consistency and repeatability that cannot be attained by humans. Robots can be reprogrammed. When the production run of the current task is completed, a robot can be reprogrammed and equipped with the necessary tooling to perform an altogether different task. Robots are controlled by computers and can therefore be connected to other computer systems to achieve computer integrated manufacturing. ETC
(4 Marks)
4of 6 (b) An acronym for Selectively Compliant Arm for Robotic Assembly and is a special RPP.
(Either diagram = 3 Marks)
Applications include; Electronics assembly Engraving applications due to their precision, accuracy and compact size ETC - Any reasonable applications. A manufacture will probably use one robot for many functions by just changing the tooling end. (2 Marks)
4 (a) Increased machine utilization. Reasons for this include: 24 hr/day operation, automatic tool changing machine tools, automatic pallet changing at workstations, queues of parts at stations and dynamic scheduling of production that takes into account irregularities from normal operations. It should be possible to approach 80-90% asset utilization by implementing FMS technology. (2.5 Marks) Reduced inventory requirements. Because different parts are processed together rather than separately in batches. Work-in-process (WIP) is less than in a batch production mode. The inventory of starting and finished parts can be reduced as well. Inventory reductions of 60-80% are estimated.
(2.5 Marks)
(b) No need of all details on the sketch. The ladder layout consists of a loop with rungs between the straight sections of the loop, on which workstations are located, as shown in figure. The rungs increase the possible ways of getting from one machine to the next, and obviate the need for a secondary handling system. This reduces average travel distance and minimizes congestion in the handling system, thereby reducing transport time between workstations. (ANY TWO = 2 Marks)
