MT II - 2 Marks With Answers
MT II - 2 Marks With Answers
Metal cutting or machining is the process of by removing unwanted material from a block
of metal in the form of chips.
2. What are the important characteristics of materials used for cutting tools?
The time period between two consecutive resharpening, with which the cuts the material
effectively is called as tool life.
The various angles of tools are mentioned in a numerical number in particular order. That
is known as tool signature.
5. What is the effect of back rack angle and mention the types?
Back rake angle of tool is increases the strength of cutting tool and cutting action. It
2. Negative Rake
1. Positive rake angle. angle.
Joining of side and end cutting edges by means of small radius in order to increase the
tool life and better surface finish on the work piece.
7. What are all conditions for using positive rake angle?
Orthogonal cutting: The cutting edge of tool is perpendicular to the work piece axis.Oblique
cutting: The cutting edge is inclined at an acute angle with normal to the cutting
Cutting ductile materials with low speed and small rake angle of the tool.
10. What are the favorable factors for continuous chip formation?
Machine ability is defined as the ease with which a material can be satisfactorily
machined.
The material of work piece is stressed beyond its yield point under the compressive force.
This causes the material to deform plastically and shear off. The plastic floe takes place in a
localized region is called shear plane.
The sheared material begins to along the cutting tool face in the form of small pieces is
called chip.
a.Continuous chip.
b.Discontinuous chip.
14. Write the factors affecting the tool life or Write the Taylor’s tool life equation.
Taylor’s equation VT n = C
i.Cutting speed
iii.Tool Geometry
iv.Tool material
vi.Work material
Side relief angle: It is the angle between the portion of the side flank immediately below the
side cutting edge and a line perpendicular to the base of the tool, and measured at right angle
to the side flank.
End relief angle: It is the angle between the portion of the end flank immediately below the
end cutting edge and a line perpendicular to the base of the tool, and measured at right angle
to the angle.
16. What are the importances of Nose Radius?
Nose radius is favorable to long tool life and good surface finish. A sharp point on the end
of a tool is highly stressed, Short lived and leaves a groove in the path of cut. There is an
improvement in surface finish and permissible cutting speed as nose radius is increased from
zero value.
17. What are the differences between orthogonal cutting and oblique cutting?
The direction of chip flow is perpendicular to The direction of chip flow is angled to
The chip coils in a tight flat spiral The chip flows sideways in a long.
The chip coils in a helix and curl around the work and the tool and may injure the
operator in case of continuous chip. A chip breaker is a metal piece attached to the tool,
breaks the chip and reduces the difficulties.
Cutting power: The cutting power or the specific energy consumption , is the product of
the cutting speed and the cutting force.Specific metal removal rate : The amount of metal
removal per unit power consumption is called “specific metal removal rate” .
.
21.What are the major types of tool wear?
Cutting conditions,
5.Low ductility.
A wedge shaped tool is made to move relative to the workpiece. As the tool makes
contact with the metal, it exerts a pressure on it resulting in the compression of the metal near
the tool tip. This induces shear type deformation within the metal and it starts moving
upwards along the top face of the tool. As the tool advances, the material ahead of it is
sheared continuously along plane called the shear plane.
The surface along which the chip moves upwards is called Rake angle and the other
surface which is relieved to avoid rubbing with the machined surface is called Flank surface
27. Define - Rack angle and clearance angle.
The angle between the rake surface and the normal is known as Rake angle, and the angle
between the flank and the horizontal machined surface is known as the relief or clearance
angle.
28. Name the two systems used in metal cutting to designate the tool shape:
In the ASA system, the angles of tool face, that is, its slope, are defined in two orthogonal
planes, one parallel to and the other perpendicular to, the axis of the cutting tool, both planes
being perpendicular to the base of the tool.
Nose radius is favourable to long tool life and good surface finish.Asharp point on the end
of a tool is highly stressed, short lived and leaves a groove in the path of cut. There is an
improvement in surfacefinish and permissible cutting speed as nose radius is increased from
zero value.Too large nose radius will induce chatter.
The total cutting time accumulated before tool failure occurs is termed as tool life.
33. Write the criteria commonly used for measuring tool life.
The two most commonly used criteria for measuring the tool life are
Process variables
Tool material
Cutting.
1. What is a Lathe?
Lathe is a machine tool which removes the metal from a piece of work to the required
shape and size.
Headstock carries a hollow spindle with nose to hold the work piece. To Mount the driving
and speed changing mechanisms.
3. What is an apron?
The integral part of several gears, levers and clutches mounted with the saddle for moving
the carriage along with lead screw while thread cutting.
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Heavier and Larger workpiece chucking can be done. More rigid, hence it withstands heavy
cuts.
8.Name any four tool holding devices used in capstan and turret lathe.
Semi automatic
3. Tool room lathe 4. lathe
5.Automatic lathe
The lathe in which all the machining operations are performed automatically and loading
and unloading of work piece, coolant on or off is performed manually
12.State the various feed mechanisms used for obtaining automatic feed?
4.Apron mechanism
Centering, straight turning, rough turning, finish turning, shoulder turning, facing,
chamfering, knurling, etc.
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The ratio of the difference in diameters of tapers its length k= D-dd-smaller dia
D-larger dia
15.State the purpose of providing lead cam in single spindle automatic screw cutting
machine?
The turret slide travel is controlled by a lead cam. The lead cam gives a slow forward and
fast return movement to the turret slide.
The advantages of a sliding head automatic lathe is that long slender work pieces can be
machined with very good surface finish, accuracy and concentricity in sliding head automatic
lathes.
3.Rigid construction.
It is used for producing small jobs, screws, stepped pins, pins, bolts etc.
Automatic lathes or simply automats are machines tools in which all the operations
required to finish off the work piece are done automatically without the attention of an
operator.
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22.State the purpose of providing lead cam in single automatic screw cuffing machine?
The turret slide travel is controlled by a lead cam. Cam gives a slow forward and fast
It is used for producing small jobs, screws, stepped pins, pins, bolts etc.
The advantage of a sliding head automatic lathe is that long, slender work pieces can be
machined with very good surface finish, accuracy and concentricity in sliding head autornatic
lathes.
25. What are the four major parts of swiss type automatic lathes?
Simple design of
3. Micrometer tool setting 4.cams
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The principle of the multi spindle automate is that it has a tool slide working on the jobs
on all spindles simultaneously.
The operating mechanism for sliding, feeding are actuated by cams through levers and gears.
Maximum size of the work diameter swing over cross slide and over bed. Number of feeds
for the carriage
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These are designed for machining long accurate parts of small diameter, such as 4 to 25
mm. An exclusive feature of these machines is the longitudinal travel of the headstock, or of
a quill carrying the rotating work spindle.
Centering, Boring, Knurling, Cutting off, Reaming, Thread cutting, Drilling and spot
facing.
The ratio between the cutting stroke time and the return stroke time is called as cutting
ratio.
Cutting ratio m=
Type of driving
1.Maximum stroke length. 2.mechanism.
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Planer- The work piece reciprocates while the tool is Stationary. Shaper – The tool
reciprocates while the work Stationary.
The working principle is similar to that of a planer. But it has two reciprocating table. In
that one table is working with work the other is loaded and unloaded
More number of single spindle with essential speed and feed are mounted side by side on
one base and have common work table, is known as the gang- drilling machine.
A tap is a tool which is used for making internal threads in a machined component.
The boring machine is designed for machining large and heavy work piece in mass
production work of engine frame, Cylinder, machine housing etc.
8. What is the main difference between boring bar and boring tool?
Boring bar:
The tool which is having single point cutting edge known as boring bar. Boring tool:
The tool which is having multi point cutting edge known as boring tool.
This is a modified form of a milling machine It is provided with two spindles, one of
which is in the horizontal plane while the other is carried by a universal swiveling head.
3.Less wear on feed screw and nut due to the absence of pre loaded.
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Plain or Lab milling is the operation of producing flat horizontal surface parallel to the
axis of the cutter using a plain or slab milling cutter.
Indexing is the process of dividing the periphery of a job in to equal number of divisions.
Cam milling is the operation of producing cams in a milling machine by the use of a
universal dividing head and a vertical milling attachment.
Advantages;
1.the threads will be smoother and more accurate than those cut in a lathe.
Limitations:
2.Threads milling cannot be used for making thread with more than 30 helix
angle.
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1.Double housing
3.Pit planer
4.Edge planer
1.Bed
2.Table
3.Columns
4.Cross rail
5.Tool head
Drilling is the process of producing hole on the work piece by using a rotating cutter
called drill.
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2.Table size of maximum dimensions of a job can mount on a table in square meter
21.List any four machining operations that can be performed on a drilling machine?
1.Drilling
2.Counter sinking
3.Tapping
4.Trepanning
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1.In plain milling machine the table is provided with three movements, longitudinal,
cross&vertical. In universal milling machine in addition to these three movements, there is a
forth movement to the table. The table can be swiveled horizontally & can be fed at angles to
the milling machine spindle.
2.The universal milling machine is provided with auxiliaries such as dividing head, vertical
milling attachment, rotary table etc. Hence it is possible to make spiral, bevel gears, twist
drills, reamers etc on universal milling machine.
3.
1. Arbors 2. Adaptors Collets
1.Vertical milling
2.Universal milling
4.Rotary
5.Slotting
6.Rack milling
Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter
angles.
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1.Cutter with higher rake angle can be used. This reduces power requirements.
2.Cutter wear is less because chip thickness is maximum at the start of cut.
2.Face milling.
3.Angular milling.
4.Gang milling.
5.End milling.
6.Gear cutting.
Indexing is the process of dividing the periphery of a job into equal number of divisions.
a) Plain milling machine, b)vertical milling machine, c) universal milling machine Plano
miller
Special types
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Work is feed against the rotating cutter Work moves parallel to the cutter rotation
Thickness of the chip is minimum in the Thickness of the chip is maximum in the
initial stages and increases maximum at initial stages and minimum at the end of
Cutter lifts the work, so requires more Cutter holds the work. Requires less
Several drill spindles are mounted in a drill head and driven by a common motor using set
of gear with different speeds and drills. This machine is used to drill more number of holes in
the work at a time. The feed is given either rising the table and lowering the spindle head.
Drilling: A process of initiating a hole or enlarging a hole with a tool called Drill. Boring:
The process of enlarging a hole that has already drilled using a boring tool is called as boring.
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Table type, Floor Type, Planer Type, Multi head type Vertical boring machine
Jig boring machine is a specially designed machined machine tool used for precision
location and manufacturing of holes in the precision equipments like, jigs, fixtures, dies,
gauges.
Counter boring is a operation of enlarging the end of the hole through a certain distance to
form a seat for the bolts and nuts have been seated.
Stroke length,
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Hydraulic mechanism
In shaping machine metal is cut during the forward stroke and the return stroke no metal
is removed.. It is known as idle stroke. To reduce the total machining time the idle stroke
time should be reduced. So the return stroke is made faster than the cutting stroke. This is
done by a mechanism called quick return mechanism.
Pit planer
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1. What is broaching?
Advantages:
1.Roughing, semi finishing & finishing cuts are completed in one pass of the broach
Limitation:
2.Job work or batch work is not advisable due to the high tool cost.
4.What are the different operations that can be performed on a broaching machine?
1.Broaching splines
The rate of production is higher when compared to forced cutter method. It is a simple
flexible and accurate method of generating gears.
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1.To remove small amount of metal from work pieces & finish then to close tolerances.
The machining accuracy of holes produce by this machine tool lies with in a range of
0.0025 mm.
Grade or hardness indicates the strength with which the bonding material holds the
abrasive grain in the grinding wheel.
The process of loading &breaking away the glazed surface so that new sharp abrasive
particles are again present to work for efficient cutting is called dressing.
Truing is a process of trimming the cutting surface of the wheel to run true with the axis.
Lapping is a surface finishing process used for producing geometrically accurate flat,
cylindrical &spherical surfaces.
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1.Plain or simple.
2.Universal.
3.Optical
3.Gear broaching.
4.Template method.
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1.Gear shaping used for generating both internal & external spur gears.
Gear
1.Gear shaving. 2.burnishing.
The centre less grinder operates with two wheels as the cutting wheel, to remove the
excess stock and a regulating wheel which is used to control the speed of rotation of the work
and the rate of feed.
No tendency for chatter and deflection of the work piece. Easy size control of the work.
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Honing ids also a surface finishing process like grinding, which uses a “hon” tool that
consists of stones to abrade the metals.
Polishing is the surface finishing operation performed by a polishing wheel, for the
purpose of removing appreciable metal to take out scratches, hole marks, Pits and other
defects from rough surfaces.
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Buffing is used give much high lustrous, reflective finish that can not be obtained by
polishing. The buffing process consists of applying a very fine abrasive with rotating wheel.
involutes.
Gear blank is rotated every tooth is over- Gear blank is not indexed.
indexed
Each module this process requires a set of One cutter is enough for more number of
With a particular module of DP cutter, Gears having same module of DP but different number
of teeth can be cut accurately.
Only one cutter is used for cutting all spur gears of same pitchBoth internal and external
gears can be cut.
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25.
Hobb operates several teeth at a time Milling cutter cuts one tooth at a time
It is not necessary to disengage the cutter It is necessary to disengage the cutter and
26.What is sawing?
Sawing is one of the basic metal cutting processes, in which the cutting off the metal is
done by using saws.
Surface broaching
Keyway broaching
Spline broaching.
Gear broaching.
The centre less grinder operates with two wheels as the cutting wheel, to remove the
excess stock and a regulating wheel which is used to control the speed of rotation of the work
and the rate of feed.
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Indexing is the process of dividing the periphery of a job into equal number of divisions.
Polishing is the surface finishing operation performed by a polishing wheel, for the
purpose of removing appreciable metal to take out scratches, hole marks, Pits and other
defects from rough surfaces.
Buffing is used give much high lustrous, reflective finish that can not be obtained by
polishing. The buffing process consists of applying a very fine abrasive with rotating wheel.
With a particular module of DP cutter, Gears having same module of DP but different number
of teeth can be cut accurately.
Only one cutter is used for cutting all spur gears of same pitch
ABRASSIVE APPLICATION
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36. What are the disadvantages of using abrasives again and again?
Contamination of wears materials clogging the nozzle and the cutting unit orifices.
MACHIN/
RAPID
5. What is CNC?
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.
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Part program is a high level language containing the instructions for machining a part to
various standard words, codes and symbols.
Post processing is a computer program that takes a generalized part program output and
adopts it to a particular machine control unit and machine tool combination. It is the basic
intelligence required to change the program into computer language.
End of
Preparatory function Feed function Tool function block
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.
Canned cycle simplifies and shortens the programming in such way whenever any one of
the operation is required.
13.What are the major areas to be considered in the design of NC machine tools?
ii.Location of transducer
iii.Slideways
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14.How the heat effect on the machine bed, tool holder can be taken care?
` iv.The hollow cross section for beds, bases and columns with a number of ribs welded with
the walls cater for the rigidity as well as opening for inspection, lubrication and collection of
chip coolants.
viii.Avoiding direct as well as local sources of heat such as sunlight and electrical motors.oil
pumps respectively.
x.Proper alignment of the machine elements relative to each other while in operation as well
as in stationary conditions
In general machine tools are provided with tables, slides, carriages etc., to carry the work
pieces or cutting tools etc., These parts are sliding in nature and mounted on the ways that are
fixed on the other parts (column, housing, bed or knee) of the machines known as sliding
ways.
Conventional sliders operating under sliding friction do not have a constant coefficient of
friction and the highest value of co-efficient tends to be at the lowest rates of slide velocity.
This phenomenon given to the familiar “stricking” of oil lubricated slideing surfaces when
the fine adjustment is needed, a jerky action when movement takes place at low velocities.
The term “stick-slip” is used to describe these situations.
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iii.Rotax Tychoway
Sufficient damping.
Reversibility
No stick slip in the sliding metal to metal contact is substituted by rolling contact
The control unit should be situated so that it is convenient for the machine operator to
operate the machine from the central place. A control unit should:
i.Indicate the current status and position of various machine tool features and give feedback
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21.What are the various types of DC motors used in a CNC machine tool?
i.In general the advantages of permanent magnet DC motor over winded field motors are:
ii.Indicate the current status and position of various machine tool features and give feedback
i.AC spindle motors are now preferred for the main drive by CNC machine tool designers due
to a variety of reasons as follows:
ii.AC motors are reliable than DC motors under several operating conditions
iii.AC motors are being free of brushes and other wearing parts do not require frequent
maintenance
iv.The unique stator cooling system in AC motors result in high speed output characteristics
with compact size
v.AC drive units provide stable and smooth operation with reduced vibration and noise from
low speed to high speed.
In slide way system plastic or non metallic inserts are used. These insets are bonded to the
underside of the sliding members. They can be of thermoplastics (Turcute-B) or
thermosetting (SKC-3, Moglice) types. It is found that for these coated slide ways the static
coefficient is less that the dynamic coefficient of friction
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25. Discuss the advantages of plastic inserts for slide ways of machine tools?
Plastic inserts / composites are made of two or more materials in which one reduces
coefficient of friction. The other increases strength, wear resistance and load bearing
capacity. They also have self lubricating capacity. They can take up dirt, dust particles and
eliminate scoring. Another advantage is the case with a worn out strip can be replaced
without the need of any scraping or machining of bedways.
The concept of the ATC is that the range of tools for a specified job shall be made
available for automatic selection and positioning . ATC can be :
i.Drum type – for holding small number of tools store in periphery of drum
ii.Chain type – for more number of tools (30 – 40 or more tools can be used)
27. Why are the balls re-circulating screws used in CNC machines?
Ball screws are primarily employed in feed mechanism in machine tools. The advantages
are as follows:
i.In the ball screw the lead between the threads of the screw and the nut is not transmitted by direct
contract, but through spherical balls. Balls rotate between the helical grooves of the screw
and nut in a manner that function in a ball bearing. An essential feature is the provision of
recirculation of balls.
iii.Higher transmission efficiency allows larger thrust loads to be carried with less torque
iv.By preloading the assembly, clearances and consequent backlash can be eliminated. The
accuracy of ball screw is high.
i.Tool magazines must be capable of holding enough tools needed for performing complete
operation for work pieces on the machining centers
ii.As the magazine gets larger, the space needed is more and more expensive and hence the
magazine has to be compact and as simple as possible
iii.Interchange of tools should not interfere with the workpiece space and tool space. This means
that the tool magazine should be located outside the working space of the machine tool
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iv.Easier and safer manual exchange of tools in the tool magazine during loading and
unloading should be facilitated
v.All preparatory works for tool exchange should be made during machining
intersecting axis
For machines with automatic pallet changer (ATC) the table is replaced by pallet. The
pallet when transferred from the pallet changer on the machine gets located and clamped with
heavy clamping force either hydraulically or mechanically. The function of pallet changer is
to interchange the pallet on the machine which has the finished component and the other
pallet with newly loaded component.
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During different machining process, various jaw positions of chuck are used and these are
mounted on the main spindle. The distance of the face side of the work piece from the
machine datum differs depending on the jaw surface, which is used for chucking. This has to
be considered while programming. It is desirable to offset the origin of the coordinate system
into the work piece zero point W instead of the machine. Reference point, which is the useful
origin of the machine.
These are the commands which prepare the machine for the different modes of movement
like positioning, contouring, thread cutting etc., the preparatory functions always precede the
dimension word.
Function Meaning
G04 Dwell
33.Describe the general form of a program line and explain each term
The tool path of the CNC machine is described in machine tools. The general form is as
follows: (some of the terms are optional)
N.. G.. X.. Y.. Z.. A.. B.. C.. F.. S.. T.. M..
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Where,
S- Spindle speed
It is the origin of the co-ordinate system with the lathe. It is on the mounting flange of the
main spindle and the turning axis. It cannot be changed by the user of the machine. It is fixed
by the manufacturer and programmed into the computer. The point generally has the
coordinates X=0, Z=0
The position of the reference point R is determined by the manufacturer. The value of the
machine reference coordinates X and Z are fixed and cannot changed by the user.
A canned cycle is a combination of machine moves that performs any one particular
machining function such as drilling, milling, boring, tapping, dwell etc.,
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All CNC machines are equipped with the decimal point input. In order to simplify
program input the leading zero can be omitted. Ex. 12.145 instead of 0012.145
Consecutive zeros after decimal point need not be entered 12 instead of 12.000 and
40.What is tool length offset? Where do you store tool length offsets?
i.In addition to the other data, tool length information as to be input to enable the computer to
calculate the toll path. In case of the machining centers tools are preset using a pre setting
device. With preset tools the tool tip position has to be programmed in the tool reference
point. Some machines have an automatic tools presetting device which can be mounted on
the machine tool itself. This slide position information will be used by the computer to
determine the slide displacements for particular tool path.
ii.Another method is to hold the blank in the chuck and jog the tool to touch the diameter and a
face of the work piece. The diameter and length information can then be input into the
memory of the machine.
The carbide insert used in turning operation has a certain corner radius and the carbide tip
tool will break or melt when working. These radii are standardized according to ISO.
Program sections required more than one can be defined as subroutines and stored in the
control. They can be called several times in part programs. Geometric values, feed rates,
spindle speeds etc., are defined in subroutines as parameters. These parameters are assigned
actual values before the subroutines are called making it possible to adopt dimensions and
technological data to the actual work piece. A typical application for subroutines is the
machining of similar parts with different dimensions.
Machining cycles are technology based subroutines for often needed machining
operations such as deep hole drilling, pocket milling etc., in modern CNC systems standard
cycles are available for various types of drilling/boring and milling patterns. The machining
cycles are programmed in the usual NC programming language.
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A presetting device is used to preset axial and radial positions of the tip on the tool
holder. Once this is done the tool holder is ready to be mounted on the machine or tool
magazine and produce a known dimension. The amount of compensation can be quickly
decided with the presetting device. Accuracies in the order of 0.0002 mm can be quickly and
easily maintained.
“The setting of tools in advance at a place away from the machine tool on offline in
special holders is known as preset tools.” The tools are carefully positioned in the holder so
that when the holders are clamped in the machine tool, their effective cutting positions will
correspond to these cutting positions assumed while preparation of part programmed.
The multi hole “plug – board” concept has proved very successful in this type of fixtures.
Its special advantage is that a work holding fixture can be built with absolute positional
accuracy by simple pegging of a few fixture elements. The multi hole grid system enables
different jig and fixture combination to be assembled for a wide range of work pieces.
Block is the basic unit of a part program input to the control. It contains adequate
information for the machine to perform a movement and for functions.
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Preparing a program sheet where each block will contain the sequence number, details of
operation and basic information such as preparatory feed codes, feed rate, miscellaneous M
code
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Input translation
Arithmetic calculations
Post processors
APT Compact II
ADAPT PROMPT
CINTURN
EXAPT II
Auxiliary
3.Post processor statements 4.statements
2 ½ axis machine implies that machine movements are in planes parallel to the X- Y plane
3 axes machine implies that machine movements are in all the 3 axes (X, Y and Z)
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