*TYPES OF MILLING MACHINES:- 1)Knee and Column type :- a. Horizontal. b. Vertical c.

Universal d.2) Turret Type Production Type:- a. Simplex b. Duplex c. 3) Triplex Special Type a.
Rotary table b. Drum type c. Copy milling d. Planetary milling machine.4) Planner Type milling
*GEAR MANUFACTURING METHODS: 1) Casting 2)Forging 3)Extrusion and cold-drawing
4)Powder metallurgy 5)Blanking 6)Gear Machining - Hobbing - Shaping - Milling – Broaching
*FUNCTIONS OF CNC MACHINE COMPONENTS: 1) Machine Control Panel – A machine Control
Panel is a flat area where controlling, monitoring, or managing instruments are displayed, serving
as the direct interface between the operator and the NC system. 2) Programmable Logic
Controller (PLC) – A PLC is an industrial solid-state computer that matches the NC to the machine,
which follows a pre-programmed sets of rules and carry out outputs based on inputs to control
system and make logic-based decisions for the CNC machine. It is used to minimize manual
operation and can survive harsh conditions such as extreme heat, cold, dust, and moisture.
3) Servo Control Unit – The servo control unit is responsible for precise position control as it
receives the position feedback signals for the actual movement of the machine tool axes from the
feedback devices. It generates suitable signals as command values, which are interfaced with the
axes and the spindle motors. 4) Feedback Devices – The feedback devices, which is also referred
to as the measuring system, consist of position and speed transducers that act as sensors to
monitor the current position of the cutting tool at any instant.
WORKING OF ABRASIVE JET MACHINING:

In abrasive-jet machining (AJM), a high-velocity jet of dry air, nitrogen, or carbon dioxide containing
abrasive particles is aimed at the workpiece surface under controlled conditions. The impact of the
particles develops a sufficiently concentrated force to perform operations The gas-supply pressure is on
the order of 850 kPa, and the abrasive-jet velocity can be as high as 300 m/s and is controlled by a valve.
The nozzles are usually made of tungsten carbide or sapphire, both of which have abrasive Wear
resistance. The abrasive size is in the range from 10 to 50 um
Ultrasonic Machining:- High power sine wave generator :-
This unit converts low frequency (60
Hz) electrical power to high frequency
(20kHz) electrical power. Transducer
:-The high frequency electrical signal
is transmitted to traducer which
converts it into high frequency low
amplitude vibration. Transducer
converts electrical energy to
mechanical vibration. Tool holder. OR
Horn:-. The tool holder holds and
connects the tool to the transducer
Tool :- Tools are made of relatively
ductile materials like Brass, Stainless
steel or Mild steel so that Tool wear
rate (TWR) can be minimized
Describe Automatic tool changer (ATC) of CNC machine

Concept of Automatic tool changer (ATC): 1. Tool changing in CNC machines is carried out
automatically by using Automatic tool changer according to the sequence of operations given in the part
program 2. Tool magazine is provided with various tools mounted sequentially and identified by specific
tool number which helps for tool changing using ATC Function of automatic tool changer: 1. It will
improve the production rate and tool carrying capacity of the machine. 2. It will help to save time
required for changing tools as per number of operations to be performed on the work piece. 3. It will
automatically unload the tool from the spindle of machine and load the new cutting tool from tool
magazine using tool changing arm.

Radial hobbing

• In radial hobbing the feed is given to the hob such that it moves radially towards the centre of
blank. • Radial feeding is suitable for cutting worm wheels having a helix angle of less than 6 or
7 degrees. • Radial feed stops when the hob reaches the full depth of cut. • Radial hobbing may
affect the accuracy of tooth profile of final cut gear.
DRAW S SETUP DIAGRAM OF EDM (ELECTRO DISCHARGE MACHINING ) :-
Discharge Current Range: The
capacitor discharge is repeated at
rates between 200 and 500 kHz, with
and currents from 0.1 to 500 A. Voltage
Range: voltages usually ranging
between 50 and 380 V. Type of
Dielectric: The most common
dielectric fluids are mineral oils,
although kerosene and distilled and
deionized water also are used in
specialized applications. Type of
Electrode material: Electrodes for
EDM usually are made of graphite,
although brass, copper, or copper-
tungsten alloys, Tungsten-wire
electrodes also are used

Justify the need of group technology in today's manufacturing system

Group Technology (GT) is a manufacturing philosophy that emphasizes the organization of parts into
families based on their similarities in design and manufacturing characteristics. This concept remains
relevant in today's manufacturing systems due to several reasons: 1. Efficient Production Planning and
Control: Grouping similar parts into families streamlines production planning and control. It allows for
the application of standardized processes, reducing setup times and improving efficiency in scheduling
production runs .2. Reduced Setup Time and Costs: By categorizing parts into families with shared
characteristics, GT facilitates the use of standardized setups and tools. This leads to reduced changeover
times between different parts, minimizing downtime and cutting costs associated with retooling.
3. Enhanced Inventory Management: Grouping parts into families aids in inventory management by
allowing manufacturers to apply common stocking policies, reduce stock levels, and better predict
material requirements for each part family. 4. Facilitates Cellular Manufacturing: GT forms the basis for
cellular manufacturing, where machines are organized into cells based on part families. Cells are self-
contained units that specialize in producing specific part families, promóting efficiency and minimizing
material movement. 5. Simplifies Manufacturing Processes: Similar parts grouped together benefit from
shared processes and tooling, enabling standardization in manufacturing methods. This simplifies
training requirements and allows for more consistent quality across the production of similar parts.
6. Supports Flexibility and Agility: Despite the emphasis on standardization, GT also allows for flexibility
within part families. Manufacturers can accommodate variations within families more easily while
maintaining the benefits of standard processes. 7. Improved Quality and Consistency: By focusing on
standardized processes and setups, GT contributes to better quality control and consistency in
manufacturing, reducing errors and rework
Cutter radius Compensation : Cutter compensation is used to offset the center of the
cutter, and shift it the distance of the radius, to the specified side of the programmed path. Complex part
geometries having angled lines, lines tangent to arcs, and lines intersecting arcs involve substantial
trigonometric computations to determine the center of the cutter. Cutter compensation involves
programming the part geometry directly instead of the tool center. The cutter compensation commands
are Cutter Comp. Left (G41), Cutter Comp Right (G42) and Cutter Comp Cancel (G40).

EXPLANE ABSOLUTE AND INCREMENTAL CO-ORDINATE SYSTEM SYSTEM IN CNC

MACHINE WITH SUITABLE EXAMPEL

Absolute coordinates refers to a Cartesian System that uses X-axis and Y-axis to establish a point some
distance from a common origin.in other words the system has a fixed origin. Incremental Coordinates s
do not use the point of origin or the part datum to move machine to the next position. These
coordinates reset to (0, 0) after every point. The next position is calculated starting at (0,0). Incremental
Coordinates are modal and will cancel absolute co ordinates.The G Code G90 is used to define the
absolute positioning system. When G90 is active the machine will read all dimensions and movements
from the working datum position.
DRAW SET UP DIAGRAM OF ECM PROCESSES SHOWING ALL THE ELEMENTS.
STATE THE FUNCTION OF EACH ELEMENT
Functions of each element:- [1]
Fixture :- To hold the work piece
rigidly and securely [2] DC
Supply :- To supply current to
cathode and anode [3] Tank :- To
store the electrolyte [4] Tool
(Cathode) :- To remove the
material by controlled
dissolution of anode [5] Servo
system :- To circulate the
electrolyte

DRAW INTERNAL MECHANISM OF UNIVERSAL DIVIDING HEAD AND LABEL THE

PARTS
OPEN LOOP CONTROL SYSTEM :- •open loop system is suitable foe simple and low accurate
applications where feedback not sequened it is useful for simple machines like electrical cloth dryer,
conventional machines etc.

Closed loop Control System. :- This system is similar But it Consists of two to open loop Cant Cal. Cal
System additional devices fasm of feedback the actual teansduces and in the Compatatos Show in fig.
Compteansduces feedbacks the actual Slide displacement to Compacator This system is buitable for CNC
machines, wher accucocy is important