REPUBLIC OF CAMEROON REPUBLIQUE DU CAMEROUN

Peace – Work – Fatherland Paix – Travail – Patrie

------------------------ ------------------------
MINISTRY MINISTRE
OF HIGHER EDUCATION DE L’ENSEIGNMENT SUPERIEUR
----------------------- ------------------------
NATIONAL COMMISION FOR THE ORGANISATION COMMISION NATIONALE D’ORGANISATION
OF THE EXAMS DES EXAMENS
------------------------ -----------------------

National Exams of Higher National Diploma – 2016 Session

Specialty/Option: Mechanical Fabrication Ceof: 5
Paper: Case Study Duration: 6 hours

AUTHORIZED DOCUMENTS
Only the non-programmable type Scientific Electronic calculators are acceptable. No
document is authorized except those given by the invigilators and the following.
Any mechanical design handbook
AFNOR and NORELEM documents
Drawing instruments
RECOMMENDATIONS
Before you start this paper, check to be sure that you have been given sheets 1/1__ to__/__ with an
A3 tracing paper

I. PRESENTATION OF PAPER

This paper of the case study is divided into three main parts:
⮚ Advanced manufacturing;
⮚ Manufacturing Analysis;
⮚ Jigs and Fixtures design.

WORK DESCRIPTION
A newly created company in the republic places a command of 15000 SPECIAL SCREW. They
further explain that 125 pieces must be realised per month so as to catch the death limit of 10 years.
You are asked to study the realization of those pieces.
I. ADVANCED MANUFACTURING (20mks)

Section A – Understanding Advance Manufacturing

❖ Define the following expressions (1×6=6mks)
a) CNC
b) CAM
c) CADD
d) CIM
e) FMS
f) CAE
❖ Using Numerical Control Machine, You are asked to realise surfacing and the contouring
operation on the work-piece provided on the page 4 using absolute programming on the CNC
milling machine. (14mks)
⮚ Write out the coordinates for surfacing and contouring.
⮚ Programme the workpiece for the surfacing in two passes (2mm finishing)
⮚ Continue with the contouring
 CUTTING CONDITIONS AND TOOLS AVIALABLE IN THE STORE
N° ROOMS DESIGNATIONS SPINDLE SPEED FEED (F...)
(S…)
T1 D1 Facing milling cutter of Ø45 in Hss 900 180
T2 D2 Facing milling cutter of Ø70 in Hss 800 80
T3 D3 Center drill Ø4 in Hss 1050 1750
T4 D4 Drill Ø10 in Hss 800 150
T5 D5 Drill Ø6 in Hss 1100 250
T6 D6 milling cutter of Ø12 in Hss 270 90
T7 D7 milling cutter of Ø40 in Hss 350 120
T8 D8 milling cutter of Ø15 in Hss 1400 150

II. MANUFACTURING ANALYSIS (40marks)

Given that your workshop is well equipped with all necessary machine tools, fixtures,
cutting tools, measuring instruments and control equipments, make sure you realise the following
tasks using the tables handed to you by the examiners.
 Establish the manufacturing analysis study of the special screw as represented on the
detailed and manufacturing drawing by filing the following:
i. Pre-processed graphs (functional dimensional linkage graphs) (6mks)
ii. Inventory of machining restriction(6mks)
iii. Table for machining restriction(6mks)
iv. Table for machining levels(6mks)
v. Table for grouping of phases(6mks)
vi. The phase contract for realising
a. surface F1 and D2(5mks)
b. Surface D1, D3, A1, D4, F4 & F5(5mks)
III. JIGS AND FIXTURES DESIGN (40marks)

If on a given phase you are to realize surfaces D3. You are required to design to scale 1 on A 3
tracing paper, a drilling fixture that will permit the mounting while respecting judiciously all
specifications indicated (support plane on surface F1; orientation (short centering) on surface D2;
stop in surface D5 and axial tightening against surface D5):
Your drawing should be done in thin pencil lines;
The piece should be in red lines;
The machined surfaces should be in thick red lines.
NB: Show at least two views.
Your design should show clearly:
- All dimensional and geometrical specifications;
- All tolerances and fits;
- Position and immobilization of the work during machining;
- Work piece extraction system, after machining each piece.

MARKS DISTRIBUTION
- Plan support. (5mks)
- Orientation. (4mks)
- Tightening. (6mks)
- Stop point. (4mks)
- Construction of body (frame). (5mks)
- Holding of the body with the machine table. (5mks)
- Functioning. (6mks)
- Nomenclature. (5mks)
 ADVANCED MANUFACTURING
PROGRAMMING FUNCTIONS
PREPARATORY FUNCTIONS
COD REVOCATION DESCRIPTION
E
G00 G00-G02-G03 Rapid linear interpolation
G01* G00-G02-G03 Rapid linear interpolation at programmed speed
G02 G00-G01-G03 Clockwise circular interpolation at a programmed tangential speed
G03 G00-G01-G03 Anti-Clockwise circular interpolation at a programmed tangential
speed
G04 End of block Programmed waiting with F address
G09 End of block Precise stop at end of block with link to the next block
G12 End of block Excess speed by handle
G16* End of block Definition of tool axis using PQR address
G17* G18-G19 XY plane choice for circular interpolation and radius correction
G18 G17-G19 ZX plane choice for circular interpolation and radius correction
G19 G18-G17 YZ plane choice for circular interpolation and radius correction
G40 G41-G42 Annulations of tool correction on R
G41 G40-G42 Correction of tool radius on the left of the profile
G42 G40-G41 Correction of tool radius on the right of the profile
G45 End of block Pocket cycle
G51 End of block Validation of the mirror function using axes address
G52 End of block Absolute programming of dimensions with respect to measuring origin
G53 G54 Invalidation of shifts PREF and DEC1
G54* G53 Invalidation of shifts PREF and DEC1
G59 End of block Shift of programmed origin, adds onto shift validated by G54
G70 G71 Entries in inches
G71* G70 Metric entries
G77 End of block Unconditional call of a subprogram or a series of sequences with return
G79 End of block Conditional or unconditional skip of a sequence with return
G80* G81 to G89 Annulations of machining cycle
G81 G80-G82 to G89 Center drilling cycle
G82 G80 to G81 Cycle for room drilling (internal grooving)
G83 to G89
G83 G80 to G82 Drilling cycle for a through-hole
G84 to G89
G84 G80 to G83 Tapping cycle
G84 to G89
G85 G80 to G84 Boring cycle
G86 to G89
G86 G80 to G86 Boring cycle (tilted spindle)
G87 to G89
G87 G80 to G86 Drilling with chip breaker
G88 to G89
G89 G80 to G88 Boring cycle with time delay at hole limit
G90* G91 Programming in absolute with respect to programme origin
G91 G90 Relative programming with respect to block origin
G92 End of block Pre-selection of programme origin
 G94* G93 Feed in mm/min
*Functions that are initialized when the machine is turned on, or when the machine is reset.

PROGRAMMING FUNCTIONS
PREPARATORY FUNCTIONS
CODE FUNCTION REVOCATION DESCRIPTION
BEFORE AFTER
M00 × Action on DCY Programmed stop
M01 × Action on DCY Optimal stop
M02 × % or EOR End of part programme
M03 × M04-M05-M00-M19 Clockwise rotation of spindle
M04 × M03-M05-M00-M19 Anticlockwise rotation of spindle
M05* × M03-M04 Spindle stop
M06 × Feed back Change of tool
M08 × M00-M09 Coolant flow
M09* × M08 Stop of coolant flow
M48* × M49 Validation of spindle potentiometers
M49 × M48 Inhibition of potentiometer

OTHER FUNCTIONS
S spindle speed
F Feed
T Tool number
D Tool correction number
 PROGRAMMING SHEET NO I
LINES FOR PROGRAMMING COMMENTS
 PROGRAMMING SHEET NO II
LINES FOR PROGRAMMING COMMENTS
REP. NBR. DESIGNATION MATERIAL OBSERATION

NOMENCLATURE
DIMENSION LINK GRAPH

Ox Direction
 Oy Direction

Oz Direction

TABLE OF ELEMENTARY OPERATIONS

REFERENCE FUNCTIONAL EXIGENCES TECHNOLOGICAL EXIGENCES FUNCTIONAL OPERATIONS

SURFACE

√ IT OTHERS NBR SYMBOLISATION

 TABLE OF ASSOCIATION OF SURFACES

SURFACES TO BE CUTTING TOOL NEW DESIGNATION

ASSOCIATED
 TABLE OF MACHINING RESTRICTIONS

A o RESTRICTIONS (CONTRAINTS)
ss p Di Geometrical Technological Economic
o e m Minor Finishing
∕∕ Others Repeat Operation Burr
ci r en machining tool
at a si
e ti on
d o al
S n
ur
fa
ce
s

TABLE FOR GROUPING OF PHASES

 (GANTT GRAPH)

LEVEL ELEMENTARY OPERATIONS

10

11

12

13

14

15

DRAFT OF MACHINING SEQUENCE

PHASE DESIGNATION SURFACES MACHINED
REF
10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

HIGHER NATIONAL DIPLOMA Time: 06 hours

 Coef: 05
MINESUP PHASE CONTRACT I
Session:
Phase No: Machine tool used:

Referential:

MACHINING OPERATIONS TOOLS CUTTING ELEMENTS

Cs N F a Lc
Ref. Description Cutting Verification m/mm Rev/mn mm/rev mm Mm

HIGHER NATIONAL DIPLOMA Time: 06 hours

 Coef: 05
MINESUP PHASE CONTRACT II
Session:
Phase No: Machine tool used:

Referential:

MACHINING OPERATIONS TOOLS CUTTING ELEMENTS

Cs N F a Lc
Ref. Description Cutting Verification m/mm Rev/mn mm/rev mm Mm