MEC4108: COMPUTER AIDED ENGINEERING FOR MECHANICAL

ENGINEERS

END OF SEMESTER I EXAMINATIONS

ACADEMIC YEAR 2015/2016

DATE: Friday December 11th 2015

TIME: 14:00 – 17:00 Hours

Instructions:

Attempt any five questions

Question 1.0 (20 Marks)
(a) Discuss the role of computer-aided process planning (CAPP) in CAD/CAM integration.
(4 Marks)
(b) Using appropriate illustrations, explain in details the differences between the different
computer-aided process planning methods while highlighting their advantages and
limitations. (6 Marks)
(c) Define the term “Group Technology”. Briefly identify some of the problems that need to
be considered before implementing Group Technology. (4 Marks)
(d) Briefly explain the different components of a computer-aided manufacturing (CAM)
system. (2 Marks)
(e) Discuss the steps followed in implementing a typical CAM process on a CAD/CAM
system. (4 Marks)

Question 2.0 (20 Marks)

(a) Identify and briefly describe the three basic components of a numerical control system
(4 Marks)
(b) Explain the following using illustrations: (6 Marks)
• Absolute and incremental programming
• CNC and DNC
(c) What do you understand by the term interpolation? Briefly outline and explain the
different methods of interpolation. (4 Marks)
(d) The two axes of an x-y positioning table are each driven by a stepping motor connected
to a leadscrew with a 10:1 gear reduction. The number of step angles on each stepping
motor is 20. Each leadscrew has a pitch = 5.0 mm and provides an axis range = 300.0
mm. There are 16 bits in each binary register used by the controller to store position data
for the two axes. (1) What is the control resolution of each axis? (2) What are the
required rotational speeds and corresponding pulse train frequencies of each stepping
motor in order to drive the table at 600 mm/min in a straight line from point (25, 25) to
point (100,150)? Ignore acceleration (6 Marks)
Question 3.0 (20 Marks)
(a) Using examples, explain in details the different CNC programming formats while
highlighting the advantages and disadvantages of each. (6 Marks)
(b) Using examples, explain in details the differences between G-codes and M-codes.
(4 Marks)
(c) The part shown in Figure one below is to be machined from a 5" x 4" x 2" work piece
low carbon steel. You are required to develop the following:
(1) A process plan for manufacturing the part (4 Marks)
(2) An NC part program for the part (6 Marks)
 Figure one: A sample 5" x 4" x 2" work piece drawing

Question 4.0 (20 Marks)

(a) Briefly explain some of the benefits usually cited for NC compared to using manual
alternative methods? (4 Marks)
(b) Using illustrations, explain the differences between point-to-point, straight-cut, and
continuous path motions in NC systems. Identify at least two manufacturing processes
suitable for each motion. (6 Marks)
(c) Briefly discuss at least four features of Numerical Control systems (4 Marks)
(d) A dc servomotor is used to drive the x-axis of an NC milling machine table. The motor is
coupled directly to the table leadscrew, which has 4 threads/in. An optical encoder is used
to provide the feedback measurement. It is connected to the leadscrew using a 1:5 gear
ratio (one turn of the leadscrew converts to 5 turns of the encoder disk). The optical
encoder emits 125 pulses per revolution. To execute a certain programmed instruction,
the table must be moved from point (3.5, 1.5) to point (1.0, 7.2) in a straight-line
trajectory at a feed rate of 7.5 in/min. Determine: (1) the control resolution of the system
for the x-axis; also (2) the rotational speed of the motor and (3) the frequency of the pulse
train emitted by the optical encoder when the desired feed rate is achieved. (6 Marks)

Question 5.0 (20 Marks)

(a) Identify any four factors considered in planning for NC part programs (4 Marks)
(b) Briefly explain the four categories under which the language statements in an APT
program fall. (4 Marks)
 (c) In reference to robot programming, explain the difference between powered lead through
and manual lead through. (4 Marks)
(d) The designer of a polar configuration robot is considering a portion of the manipulator
consisting of a rotational joint connected to its output link. The output link is 25 in long
and the rotational joint has a range of 75°. The accuracy of the joint-link combination,
expressed as a linear measure at the end of the link which results from rotating the joint,
is specified as 0.030 in. The mechanical inaccuracies of the joint result in a repeatability
error = ±0.030° of rotation. It is assumed that the link is perfectly rigid, so there are no
additional errors due to deflection. (a) Show that the specified accuracy can be achieved,
given the repeatability error. (b) Determine the minimum number of bits required in the
binary register of the robot's control memory to achieve the specified accuracy (8 Marks)

Question 6.0 (20 Marks)

(a) What is a flexible manufacturing system? (2 Marks)
(b) What makes an automated manufacturing system flexible? (3 Marks)
(c) Briefly explain the advantages of FMS technology compared to conventional batch
operations (5 Marks)
(c) Using illustrations, briefly explain the different Flexible Manufacturing Systems layouts
(FMS) (6 Marks)
(d) Name some of the FMS software and control functions (4 Marks)