CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY

GUINDY, CHENNAI – 600 032

QUESTION BANK
Course : DPMT
Semester : V
Subject : Advanced Mould Manufacturing Techniques

Section-B
(2 mark – questions)

1. What are the basic components of NC System?

Ans.: 1. Program of instructions
2. Tape punch
3. Tape reader
4. Machine control unit
5. Machine Tool.

2. What are the steps of NC Procedure to utilize numerical control in manufacturing?

Ans.:1. Process Planning
2. Part Programming
3. Tape preparation
4. Tape verification
5. Production

3. What is NC?
Ans.: NC can be defined, as a Numerical Control system in which the action of machine tool is controlled by
nos., letters, symbols and alphanumeric instruction. These symbolic input data are provided to the NC System
by punched tape, magnetic cassette, flopy disk etc.

4. What is CNC?
Ans.: Computer Numerical Control (CNC) is one in which the functions and motions of a machine tool are
controlled by means of a prepared program containing coded alphanumeric data. The program is created,
modified & stored in a computer attached with machine.

5.What is DNC?
Ans.: Direct Numerical Control (DNC) is a manufacturing system in which a large number of machines are
controlled by a computer through direct connections. All the machines are linked to a main frame computer
which sends information to individual machines as and when required.

6. What are the different types of programming techniques?

Ans.:1. Manual part programming
2. Computer assisted part programming
3. Manual Data Input

7. What do you mean by auto mode in CNC Machine?

Ans.: In this mode the program runs continuously from the start to till the end of the program and the cycle start
button is used only once.

8. What is DRY RUN mode in CNC Machine?

Ans.:This mode is used to execute a program in CNC Machine without cutting the material and we can see the
simulation of a program in graphical view.

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9.What are the different types of control system used in CNC Machines?
Ans.:
 FANUC
 Heidenhein
 Sinumeric
 HASS
 Mazatnol etc.

10.What is MPG in CNC Milling machine?

Ans.:This can also be called as hand wheel. This is used to move the required axis (X,Y,Z) Manually as per
requirement.

11.What are the type of motion control of tools in NC System?

Ans.: 1. Point to point.
2. Straight cut
3. Contouring

12.What are the components of DNC System?

Ans.: 1.Central computer
2. Shop computer
3. CNC Machines

13. What is the function of EDIT MODE in CNC machine?

Ans.:In Edit mode we can create a new program, edit program and delete program. In this mode the program is
saved automatically.

14.What are the different types of CNC Machine tools?

Ans.: 1.CNC Lathe
2.CNC Milling
3.CNC EDM
4.CNC Wire EDM
5.CNC CMM
6.CNC Sheet Metal Press
7.CNC 3D Printing
8.CNC Laser Cutting etc.

15.What are the different parts of CNC Machine?

Ans.: 1.Base
2.Bed
3.Column
4.Spindle Head
5.ATC
6.Servo Motor
7.Ball Screw
8.Coolent Tank etc.

16.What is EOB in CNC programming?

Ans.:EOB is the End-Of-Block character. It is displayed as a semicolon (;) on the screen and it signifies the end
of a program line.

17.What is absolute tool positioning system?

Ans.;An absolute tool positioning system is one in which all moving commands are referred to one reference
point, which is the origin, and is called zero point.

18.What is incremental tool positioning system?

Ans.:An incremental tool positioning system is one in which the reference point to the next instruction is the end
point of the preceding operation.

Incremental Coordinates do not use the point of origin to move the CNC machine to the next position. These
coordinates reset to (0, 0) after every point Page 2 of 8
19. Write down any four advantages of CNC Machine.
Ans.: (1) High accuracy & repeatability in manufacturing
(2) Short production time
(3) Greater manufacturing flexibility
(4) Reduced human error

20.Write down the axis and motion nomenclature for 3 axis vertical CNC Milling Machine.
Ans.: Right-hand Rule is used to designate the primary axis of the machine tool. if we hold the thumb, forefinger
and middle finger at 90to each other, this three finger is assumed to show three axis like Thumb (X-axis)
,Forefinger (Y axis), and Middle finger (Z-axis). Each finger points to +ve direction of motion of the CNC tool.
Spindle movement is taken along Z axis and table movement is taken along X & Y axis.

21. Explain the tool change command prompt used in CNC milling machine?
Ans.: M06 M-code is used to actually make the tool change. For most machining centers, M06 will cause the
tool that is in the spindle to be placed back into the magazine–and the tool in the ready position will then be
placed into the spindle.
For example, the command M06 T05 will cause tool station number 5 to rotate to the ready station, then the tool
in station 5 is placed into the spindle, and whatever tool was previously in the spindle will be placed back into the
magazine at the correct position.
A machining center is a computer-controlled machine tool that can perform multiple machining operations on a
22. What workpiece
single is meant by Machining Centre?
Ans.: The machining centre is CNC system with automatic tool changing arrangement that is designed to
perform a verity of machining operations, with large number of cutting tools.

23. What is Part Program?

Ans.: Part program is a high level language containing the instructions for machining a part to various standard
words, codes and symbols.

24. What Is Preparatory Function?

Ans.: It is word address format represented by the letter G, Followed by a numerical code for the operation of
the control unit to instruct the machine tool.

25. What is Canned Cycle?

Ans.: Canned cycle simplifies and shortens the programming in such way whenever any one of the operation is
required.

A canned cycle is a combination of machine movements that perform machining operation like drilling, milling,
boring and tapping

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26. Write down the directions of motion (axis) for a CNC Turning Centre?
Ans.: All turning centers have at least two linear axes of motion. The turret (and cutting tool) will move along with
these two axes. By linear, we mean the axis moves along a straight line. The X word controls the cross slide
movement and The Z word controls longitudinal carriage or saddle movement. The X-axis will always be the
diameter-controlling axis &The Z-axis will always be the length controlling axis.

27. What is the meaning of following G Codes: G00, G01, G02&G03 used in CNC Programming?
Ans.: 1.G00-Linear interpolation (Rapid)
2. G01-Linear interpolation (Slow)
3. G02-Circular Interpolation Clock wise
4. G03-Circular Interpolation Counter clock wise.

28. Name few work holding devices used in CNC milling machine.
Ans.: 1.Vice
2. Chuck
3. T- Bolt, Step block & Clamp
4. Milling Fixture,
5.Angle plate
6.Rotary Table etc.

29. Name few work holding devices used in CNC Lathe machine?
Ans.:1.Chuck
2.Face Plate
3.Mandrel
4.Driving plate
5.Dog
6.Angle plate
7.Lathe fixture etc.

30. Write down the few tool holding devices used in CNC Milling Machine?
Ans.: (i) Drill chuck
(ii) Adapter
(iii) Collet
(iv) Sleeve
(v) Screwed arbor etc.

31. What are the different devices used to set the work offset in CNC Milling machine?
Ans.: (i) Mechanical edge finder
(ii) Touch probe
(iii) End mill cutter
(iv) Dial indicator etc
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32. What are the different shapes of cutting tool carbide inserts used in index able carbide insert cutter body?
Ans.: (i) Square
(ii) Rectangle
(iii) Triangle
(iv) Round
(v) Trigon
(vi) Pentagonal
(vii) Hexagonal
(viii) Octagonal
(ix) Parallelogram etc.

33. Write down the MDI Command prompt for Tool change & spindle rotation in clock wise Direction?
Ans.: M06 T2;
M03 S1000;

34. What is the meaning of following CNC Address: N, T, F& S?

Ans.: N: Block Number
T: Tool Number
F: Feed rate
S: Spindle speed

35. What is Miscellaneous function (M-code)? Give two examples

Ans.:Miscellaneous function is a coded command for non machining functions like coolant ON/OFF,spindle
ON/OFF etc.
(i)M03 –Spindle ON (Clock wise)
(ii) M08-Coolant ON

36. Explain the following CNC Programming line:G00 G54 G90 X0 Y0 Z0;
Ans.G00-Rapid position
G54-Work coordinate system/work zero
G90-Absolute System
X0,Y0,& Z0- Axis positioning
The above command describes that the tool should move rapidly to work zero point fixed by operator.

37.What is floating Zero or work coordinate system(WCS)?

Ans.: A characteristic of numerical control system which allows the zero reference point to be shifted to
anywhere over the full travel of the machine slides.

38.What is fixed Zero or Machine coordinate system(MCS)?

Ans.:A fixed point on a numerically controlled system,about which all machine movements are
referenced.Machine zero point is fixed and cannot be shifted.The machine zero point is also called “Home
Position’.

39.What are the most important modes of CNC Machine operation?

Ans.: (i) MDI Mode
(ii)JOG Mode
(iii)Auto Mode

40.What is open loop control system?

Ans.:A control system in which there is no feedback from the output of the system.

41.What is closed loop control system?

Ans.:A control system where a feedback signal is used to continuously monitor the output i.e. velocity or tool
position and compare it with input data.

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42.What is ATC?
Ans.: Automatic Tool Changer is a device for automatically changing the cutting tools under the instructions
given in the part program. The required tool is automatically selected from the tool magazine and loaded on the
machine spindle.

43.What is Homming in CNC Machine?

Ans.: This process is used to refresh the machine axis. During this process the entire axis of the machine goes
to its zero position which is specified by the machine manufacturer and the machine axis value in the position
window is displaced as zero.

44. What is electric discharge machining?

Ans.:Electric discharge machining is a process of metal removal based on the principle of erosion of metals by
an interrupted electric spark discharge between the electrode tool(usually cathode) and the work piece(anode).

45. Write down the name of dielectric fluids used in CNC EDM?
Ans.: 1.Kerosene
2.Paraffin
3.Transformer oil try ethylene glycol (with water 40% by volume )
4.Deionized water. etc.

46.Give examples for electrode materials used in CNC EDM ?

Ans.:1.Copper
2.Brass
3.Graphite
4.Copper Tungsten
5.Zinc etc.

47.What is the purpose of dielectric fluid?

Ans.: The purpose of the dielectric (water or mineral oil) is to lower the temperature in the machining area,
remove the residual metallic particles, and enable sparks to be created

48.What is spark gap in EDM? How much spark gap is maintained?

Ans.: Spark gap is the distance between the electrode and the part during the process of EDM. The
spark gap is kept between 0.025-0.075 mm.

49. What is the application of EDM?

Ans.: 1.Fine cutting with thread shaped electrode.
2.Drilling of Micro holes.
3.Thread cutting
4.Helical profile milling
5.Curved hole drilling
6. Extrusion die profiles.
7. Machining of hard materials
8. Machining of Intricate mould cavities& mould parts.etc.

50. Selection of the EDM wire is based on how many factors?

Ans.:The selection of wires is dependent on following factors:
• Cutting speeds (for good cutting speeds, coated wires are used)
• Taper angles to be machined
• Tensile strength (for cutting thick workpieces, wires of high tensile strengths are used)
• Flushability.

51. What is the use of U and V axes in CNC Wire cut EDM?
Ans.: These axes provide movement to the top portion of the wire to produce taper angles of up to +/- 30
degrees. Both conical and oblique cylindrical radii can be programmed, and the size of the top and bottom radii
of the part can also be programmed.

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52. What are the applications of wire cut EDM?
Ans.;Wire cut EDM has a broad range of applications that are continuing to grow. Some of them are listed
below:
Parts with complex geometry’s
Thin or delicate parts those are susceptible to tool pressure.
Progressive, blanking and trim dies.
Extrusion dies.
Narrow slots and keyways.
Mold components.
Cutting hardened materials such as HSS, carbide, C.B.N. and P.C.D.
Electrodes (graphite or copper) for vertical EDM.
In making Fixtures, Gauges & Cams.
Machining ejector holes
shaping and cutting the ejector pin ends to follow mould cavity surface shapes.

53. Which material is commonly used to make electrode wires for wire cut EDM?
Ans.: Wire used in wire cut EDM are usually made of brass – either zinc-coated or uncoated. Brass wire can be
purchased in different hardness and different diameters. Zinc coated wire is used in machining high melting point
workpiece materials.

54.Define surface roughness.

Ans.: Every machining operation leaves characteristics evidence on the machined surface. This evidence in the
form of finely spaced micro irregularities left by the cutting tool. Each type of cutting tool leaves its own individual
pattern which therefore can be identified. This pattern is known as surface finish or surface roughness. These
irregularities combine to form surface texture.

55. What are the factors which affect the surface finish?
Ans.: 1.The machining variable which include: Cutting speed, Feed& Depth of cut.
2. The tool geometry: Nose radius, rake angle, side cutting angle & cutting edge.
3. Quality and type of machine tool used: Conventional or CNC Machine.
4. Vibrations between work piece, machine tool& cutting tool.

56.What are the machining parameters which affect the surface finish?
Ans.:1.Cutting speed
2. Feed and
3. Depth of cut.

57. What is polishing?

Ans.: Polishing is a finishing process for smoothing a work piece’s surface using an abrasive and a work wheel
or leather strop.

58.Write down the different types of polishing tools?

Ans:1. Abrasive stones
2. Emery papers
3. Diamand Needle files
4. Silicon carbide mounted wheels
5. Diamond mounted points
6. Brass rod & wood sticks
7. Diamand paste
8. Cotton
9. Polishing machine etc.

59. What is hard chrome plating?

Ans.: Hard chrome plating is a electro plating technique by which a thin layer of chromium is deposited on
metal surface or mould cavities to get wear resistance surface, surface smoothness & corrosion resistance
surface.

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60.What are the advantages of hard chrome plating on plastic mould cavities?
Ans.: (i) Wear resistance surface
(ii) Surface smoothness
(iii) Corrosion resistance
(iv) Low co-efficient of friction
(v) Little tendency for materials to adhere.
(vi) Resistance to chemical environments etc.

61. What is Chemical etching?

Ans.: Etching is traditionally the process of using strong acid or mordant to cut into the unprotected parts of a
metal surface to create a design or patterns in metal.

62.What are the techniques used to create surface texturing in moulds?

Ans.: (i) Chemical etching
(ii) Sand blasting
(iii) CNC Engraving
(iv) Electric Discharge Machining (EDM),etc.

63.What are the metals which can be etched?

Ans.: (i) All metals can be etched
(ii) Common metal is steel (chrome-nickel variety)
(iii) Cast steels can also be etched.
(iv) Non ferrous metals and alloys used in tool making can also be etched.

64.What are the surface finishing techniques used for finishing of mould cavities?
Ans.: (i) Grinding
(ii) Polishing
(iii) Buffing
(iv) Honing.

65. list out the name of mould elements, which is manufactured using CNC Lathe machine?
Ans.: (i) Locating ring
(ii) Sprue bush
(iii) Guide pillar & Guide bush
(iv) Round Core & cavity insert
(v) Core pin etc.

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