KARPAGAM INSTITUTE OF TECHNOLOGY Seeraplayam, Coimbatore 641105.

AE 2307 CAD/CAM LABORATORY RECORD BOOK

KARPAGAM INSTITUTE OF TECHNOLOGY Seeraplayam, Coimbatore 641105.

Certified that this is the bonafide record of work done by Mr/Ms__________________________________________Regd.No.______________________ in the AE 2307 CAD/CAM Laboratory of B.E Aeronautical Engineering of this institution as prescribed by Anna University Chennai for III year V semester during academic year of 2013-2014

Staff in charge

Head of the Department

Submitted for the University practical Examination of Anna University Chennai conducted on __________________

Internal Examiner

External Examiner

INDEX
Page S.No 1 2 3 4 5 6 7 8 9 10 Date Contents No Design and modeling of rectangular plate with hole Design and analysis of Truss Design and analysis of Beam distributed load Design and modeling of Spar components Design and modeling of Aerofoil structures Design and modeling of Cut Section for wings Design and modeling of Machine component Design and modeling of Machine components CNC program for step turning operation CNC program for taper turning operation Marks Signature

SUMMERY OF EXPERIMENTS
Marks Expt No. 1 2 3 4 5 6 7 8 9 10 Name of the Experiment Experiment Date Practical Class Assessment Record Viva Voice Total Initial of Faculty

Design and modeling of rectangular plate with hole Design and analysis of Truss Design and analysis of Beam distributed load Design and modeling of Spar components Design and modeling of Aerofoil structures Design and modeling of Cut Section for wings Design and modeling of Machine component Design and modeling of Machine components CNC program for step turning operation CNC program for taper turning operation

DESIGN AND MODELING OF RECTANGULAR PLATE WITH HOLE Aim: To draw the design and modeling of rectangular plate with hole using the Solid Works package Problem Description: A simple rectangular steel plate with a circular hole at centre having dimension 200 X 100 X 20 mm is constrained as shown in Fig (1).

Fig.1 Rectangular plate with hole Commands used: Rectangle Circle Extrude Remove material Procedure: 1) 2) 3) 4) 5) 6) Open the software tool Solid Works package. Set the units and limits for the display screen Use the Rectangle command and draw as per the given dimensions Draw the circle by the given dimensions Extrude the dimensions for the rectangular job Save the diagram in specified directory

Result: Thus the required drawing was designed and modeled as per the given dimension and verified.

DESIGN AND ANALYSIS OF TRUSS Aim: To design and analysis of truss using an ANSYS Software. Problem Description: Determine the nodal deflections, reaction forces, and stress for the truss system shown below Fig 2 (E = 200GPa, A = 3250mm2)

Fig.2 Truss structure Procedure: The procedure involves three steps and they are Preprocessing, Solution and Post processing. Preprocessing 1. Specify the title 2. Set preferences 3. Define element types 4. Define real constants 5. Define material properties 6. Create a model using modeling command 7. Create an element between nodes.

Solution 8. Apply displacement constraints and pressure loads 9. Solve using Current LS Post Processing 10. Enter general post processor and read the results 11. Plot the Von misses equivalent stress 12. Plot the deformed shape 13. Exit the ANSYS program.

Result: Thus the required drawing was designed and modeled as per the given dimension and verified.

DESIGN AND ANALYSIS OF BEAM DISTRIBUTED LOAD

Aim: To design analysis of beam distributed load an ANSYS Software

Problem Description: A simple, stress analysis is to be done on cantilever beam as shown in Fig 3. The given material properties are, 1. Elastic modulus 2. Poissons ratio = = 70000 MPa 0.33

Fig .3 Cantilever Beam Approach and Assumptions: Assume plane stress for this analysis. Since the pipe having thickness, and one end is fixed and other end is loaded vertically downward with a load of 100 N. Our approach is to use 3D elastic straight pipe element type and mesh it manually with element length of 20 mm. (Alternatively, we could enter the number of divisions we want in the line. For element length of 20 mm, we could enter 25 divisions.) Procedure: The procedure involves three steps and they are Preprocessing, Solution and Post processing. Preprocessing 1. Specify the title 2. Set preferences 3. Define element types 4. Define real constants

5. Define material properties 6. Create a model using modeling command 7. Mesh using manual size command Solution 8. Apply displacement constraints and vertically downward load 9. Solve using Current LS Post Processing 10. Enter general post processor and read the results 11. Plot the deformed shape 12. Plot the Nodal solution per node 13. Plot the stress by Von-misses criteria 14. Exit the ANSYS program.

Result:
Thus the required drawing was designed and modeled and analyzed .

DESIGN AND MODELLING OF SPAR COMPONENTS Aim: To draw the design and modeling of spar components using the Solid Works package Problem Description: A simple Spar component having dimension length of 500 mm is constrained as shown in Fig (4).

Fig.4 spar component Commands used: Lines Circle Extrude Edge Fillet

Procedure: 1) 2) 3) 4) 5) 6) 7) Open the software tool Solid Works package. Create the new file and save it in the directory Set the units and limits for the display screen Use the line command and as per the given dimensions Draw the spar assembly by the given dimensions Mark the dimensions for the Spar Save the diagram in specified directory

Result: Thus the required drawing was designed and modeled as per the given dimension and verified.

DESIGN AND MODELING OF AEROFOIL STRUCTURES Aim: To draw the Design and Modeling of Aerofoil structures using the Solid works package Problem Description: An Aerofoil Structure having coordinate points of 65412 is constrained and statically loaded as shown in Fig (5).

Fig. 5 Aerofoil Structure Commands used: Dots Spline Coordinate points

Procedure: 1.Open the Solid works package. 2.Create the new file and save it in the directory 3.Set the units and limits for the display screen 4.Use the point command and draw as per the given dimensions 5.Draw the drawing by the given dimensions 6.Save the diagram in specified directory

Result : Thus the required drawing was designed and modeled as per the given dimension and verified.

DESIGN AND MODELING OF CUT SECTION OF WING Aim: To draw the Design and Modeling of cut section of wings using the Solid works package Problem Description: The Cut section of wing Structure having coordinate points of 65412 is constrained as shown in Fig (6).

Fig. 6 Cut Section wing

Commands used: Spline Coordinate points Plane Loft

Procedure 1. 2. 3. 4. 5. 6. 7. Open the Solid works package. Create the new file and save it in the directory Set the units and limits for the display screen Use the line command and draw the as per the given dimensions Draw the diagram by the given dimensions Mark the dimensions for the riveted job Save the diagram in specified directory

Result : Thus the required drawing was designed and modeled as per the given dimension and verified.

DESIGN AND MODELING OF MACHINE COMPONENT Aim: To draw the Design and Modeling of machine components using the Solid works package Problem Description: A simple mechanical component shell as shown in Fig (7).

Fig. 7 Flange Approach and Assumptions: Remove the material from selected face, Create a hallow block from solid block Procedure 1. 2. 3. 4. 5. 6. Result Thus the required drawing was designed and modeled as per the given dimension and verified. Open the solid works package. Create the new file and save it in the directory Select the plane and draw 2D sketch Extrude the 2D Sketch Sketch the cut profile Select solid feature and remove the material.

DESIGN AND MODELING OF MACHINE COMPONENTS Aim: To draw the Design and Modeling of machine components using the Solid works package Problem Description: An Flange coupling as shown in Fig (8).

Fig .8 Flange coupling

Procedure 1. 2. 3. 4. 5. 6. Result Thus the required drawing was designed and modeled as per the given dimension and verified. Open the solid works package. Create the new file and save it in the directory Select the plane and draw 3D sketch Select the assembly Mating the sketches Save the assembly.

CAM PART Computer-aided manufacturing Computer-aided manufacturing (CAM) is the use of computer-based software tools that assist engineers and machinists in manufacturing or prototyping product components. Its primary purpose is to create a faster production process and components with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is a programming tool that makes it possible to manufacture physical models using computer-aided design (CAD) programs. CAM creates real life versions of components designed within a software package G-codes G-Code, or preparatory code or function, are functions in the Numerical control programming language. The G-codes are the codes that position the tool and do the actual work, as opposed to M-codes, that manages the machine; T for tool-related codes. S and F are toolSpeed and tool-Feed, and finally D-codes for tool compensation. The programming language of Numerical Control (NC) is sometimes informally called G-code. But in actuality, G-codes are only a part of the NC-programming language that controls NC and CNC machine tools. A basic list of `G' operation codes is given below. These direct motion of the tool. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. G00 - Rapid move (not cutting) G01 - Linear move G02 - Clockwise circular motion G03 - Counterclockwise circular motion G04 - Dwell G05 - Pause (for operator intervention) G08 - Acceleration G09 - Deceleration G17 - x-y plane for circular interpolation G18 - z-x plane for circular interpolation G19 - y-z plane for circular interpolation G20 - turning cycle or inch data specification G21 - thread cutting cycle or metric data specification G24 - face turning cycle G25 - wait for input #1 to go low (Prolight Mill)

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61.

G26 - wait for input #1 to go high (Prolight Mill) G28 - return to reference point G29 - return from reference point G31 - Stop on input (INROB1 is high) (Prolight Mill) G33-35 - thread cutting functions (Emco Lathe) G35 - wait for input #2 to go low (Prolight Mill) G36 - wait for input #2 to go high (Prolight Mill) G40 - cutter compensation cancel G41 - cutter compensation to the left G42 - cutter compensation to the right G43 - tool length compensation, positive G44 - tool length compensation, negative G50 - Preset position G70 - set inch based units or finishing cycle G71 - set metric units or stock removal G72 - indicate finishing cycle (EMCO Lathe) G72 - 3D circular interpolation clockwise (Prolight Mill) G73 - turning cycle contour (EMCO Lathe) G73 - 3D circular interpolation counter clockwise (Prolight Mill) G74 - facing cycle contour (Emco Lathe) G74.1 - disable 360 deg arcs (Prolight Mill) G75 - pattern repeating (Emco Lathe) G75.1 - enable 360 degree arcs (Prolight Mill) G76 - deep hole drilling, cut cycle in z-axis G77 - cut-in cycle in x-axis G78 - multiple threading cycle G80 - fixed cycle cancel G81-89 - fixed cycles specified by machine tool manufacturers G81 - drilling cycle (Prolight Mill) G82 - straight drilling cycle with dwell (Prolight Mill) G83 - drilling cycle (EMCO Lathe) G83 - peck drilling cycle (Prolight Mill) G84 - taping cycle (EMCO Lathe) G85 - reaming cycle (EMCO Lathe) G85 - boring cycle (Prolight mill) G86 - boring with spindle off and dwell cycle (Prolight Mill) G89 - boring cycle with dwell (Prolight Mill) G90 - absolute dimension program G91 - incremental dimensions G92 - Spindle speed limit G93 - Coordinate system setting G94 - Feed rate in ipm (EMCO Lathe) G95 - Feed rate in ipr (EMCO Lathe) G96 - Surface cutting speed (EMCO Lathe) G97 - Rotational speed rpm (EMCO Lathe) G98 - withdraw the tool to the starting point or feed per minute

62. 63.

G99 - withdraw the tool to a safe plane or feed per revolution G101 - Spline interpolation (Prolight Mill)

M-Codes M-Codes control machine functions and these include, 1. M00 - program stop 2. M01 - optional stop using stop button 3. M02 - end of program 4. M03 - spindle on CW 5. M04 - spindle on CCW 6. M05 - spindle off 7. M06 - tool change 8. M07 - flood with coolant 9. M08 - mist with coolant 10. M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill) 11. M09 - coolant off 12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill) 13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill) 14. M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change 15. M17 - subroutine end 16. M20 - tailstock back (EMCO Lathe) 17. M20 - Chain to next program (Prolight Mill) 18. M21 - tailstock forward (EMCO Lathe) 19. M22 - Write current position to data file (Prolight Mill) 20. M25 - open chuck (EMCO Lathe) 21. M25 - set output #1 off (Prolight Mill) 22. M26 - close chuck (EMCO Lathe) 23. M26 - set output #1 on (Prolight Mill) 24. M30 - end of tape (rewind) 25. M35 - set output #2 off (Prolight Mill) 26. M36 - set output #2 on (Prolight Mill) 27. M38 - put stepper motors on low power standby (Prolight Mill) 28. M47 - restart a program continuously, or a fixed number of times (Prolight Mill) 29. M71 - puff blowing on (EMCO Lathe) 30. M72 - puff blowing off (EMCO Lathe) 31. M96 - compensate for rounded external curves 32. M97 - compensate for sharp external curves 33. M98 - subprogram call 34. M99 - return from subprogram, jump instruction 35. M101 - move x-axis home (Prolight Mill) 36. M102 - move y-axis home (Prolight Mill) 37. M103 - move z-axis home (Prolight Mill)

CNC PROGRAM FOR STEP TURNING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: FANUC programming software Program: N10 G21 G90; N20 G28; N30 M06 T01; N40 M03; N50 G00 X33 z0; N60 G01 Z0 F75; N70 X-1; N80 Z1; N90 X33; N100 G28 U0 W0; N110 M06 T02; N120 G71 U0.5 R1; N130 G71 P140 Q190 U0.2 W0.2 F75 N140 G012 X25; N150 Z-20 N160 X30; N170 Z-50; N190 G01 X33; N200 G28 U0 W0; N210 G28 U0 W0; N220 G78 P140 Q190; N230 G28 U0 W0; N240 M05; N250 M30;

Result: Thus the program was written and executed successfully using FANUC.

CNC PROGRAM FOR TAPER TURING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: FANUC programming software Program: 000001 N10 G21 G90; N20 G28 U0 W0; N30 M06 T01; N40 M03 S2000; N50 G00 X33 Z2; N60 G01 Z0 F75; N70 X-1; N80 Z1; N90 X33; N100 G28 UO WO; N110 M06 T02; N120 G71 U0.5 R1; N130 P140 G180 U0.2 F75; N140 X25; N150 X30 Z-20; N160 Z-50; N170 X32; N180 Z-60; N190 G00 ZO; N200 G28 UO WO; N210 M06 T03; N220 G70 P140 Q180; N230 G28 UO WO; N240 M05; N250 M30;

Result: Thus the program was written and executed successfully using FANUC.