Jan, 2004 ‘Timed Hrs Machine Toots 2) culty of Engineering ‘Attemp¢ all questions 1. a) Briefly expfain how numeticat contro! operates, b)Ifa CNC machine is designed to use the following fied eycles:- -Diilliag eyele ~ Taping cycle + Circular pocket cycle - Finishing longitudinal ring eycle Write down a suitable FORMAT for each-eyele together witha diagrammatic, sketch showing the coordinates, ©) Mlustrate and describe in detail the ntain components of a CNC turning centre with ‘closed loop control, Show the interrelation botween the components, 2.8) Construct the part programme for machining the part shown ia fig. 1 on CNC ‘achiaing center. The part program Z zero is'at 200 men ebove the un machined part surface, while the tooling datum is at 100 mm above the pact program r ‘The tool length offset of the diferent tools measured from the tooling datum are given below: “HSS No. 3 center dell located in turet No, 1 with 35 mm tool length offset HSS dei! mm diam. located in turret No.2 with 75mm tool length offset HSS dell 14mm diam. located in turet No, 3 with 80mm tool length offset - Bail mill 12.mm diam. located in turret No.5 with 60mm tool length offset Assuming suitable cutting eonditions, given thatthe machine has the following format: WarxyzassincaanstTeMa 4 ‘The work pigce row material is ‘steel 37 block of 109 * 100 *33mm 4X Sheough holes @ & Figure | g3 The component given i fig? is o be produced from a C45 bar of 63 mm diemetcr on a ‘arming center with the FORMAT:- N4 G2X 2443 1K 443 14 S472 M2 Assuming reasonable feeds, speeds, tools and thai the machine is equipped with diameter and tool length offset: 4) deseribe the method of determiming the zero datum ») construc the part program j+-——88___., a axa = Se Figure? 4. The part shown in Fig. 2 will be machined on a cam automated turet mechine with 10 KW power and 60 % efficiency,Given that: + The unit cutting power is 05 KW/Cm3/min ~ 3 hundredth are used for any non cutting operation. ~ The raw meteral is in 2 form of bar of 60 mum diameter and 6 mm length. ~The bar setting requires 10 min The too! setting requires 60 min, every $00 produced parts on a turret, Itis required to: ~ 8) Prepare the sequence of operations with the tooling layout andthe proper ‘machining values, +b) Caloulate the production rte and the eam divisions for producing the part. Good Luck Prof, Dr. Eng: Monir Koura De. Eng, M.L. ZamzameM yee ESN ONL = Jan. 2003 B.Sc. Design & Production Ain Shams University Time 4 Hirs Machine Tools (2) Faculty of Engineering ieee oo onena saan seeee==Ssene EER SssssmeeeC Es Attempt all questions ‘Assume any missing data Ia) What are the differences between CNC machine tool and Ordinary Meckine Tool? What is the meaning of NC part program? What is the differences between the mechanization and the utomation? 1-0) why the part programmer must lea manual programming through G-M ooding, although there “are tltematives to manual programming ? What are the alternatives? 1-0) Weite a detail notes on the following:- +X, and Z tool length offsets in CNC Turning Centre ~ Cutter diameter offset and wear compensation ~ Axes designation ia ISO standard for CNC 1-4) Ifa CNC machine is designed to use @ rectangular pocket eycle , Write down a suitable FORMAT for the cyote together with a diagrammatic sketch showing, the coordinates, 2- Construct the pat program for machining the part shown in fig. 1, using SAE {4540 Alloy stel forged plate 100x#0x 22 mm asthe raw material. The CNC milling machine has the following format- NB G22G.2¥3.273.2 15.2 82 K3.2F4 $4 72M ‘The machining sequence will be as follows = 8) Mill top surface (1) 1) Mill the stepped surface (2) ©) drill the 4 oles 125 (3) d) Mill the rectangular pocket 66:2615(4) ©) Mill the large hole 265 (5). sven that the machine is equipped with the following tools- ~ ©. carbo insert shel end mil 50 man diam, ive teeth, located in turret No.1 ~ HSS slot dill 6 mm dia, located in turret No. 2 i" fo =HSS end mill 12 mm dizi located in turrel No.3. ~ HSS end mill 3 mma diam located in turret No. 6 ~ Dail § mm diam located in turret No. 4 ~ Drill 12 mm diam located in turret No. 5 Assume thatthe top surface ofthe cow material is at 200 mm below Z zero, and the ‘machine support the tool length and diametec compensation 23