P. 1
AE2307 Lab Manual

AE2307 Lab Manual

|Views: 188|Likes:
Published by Nishant Mayekar

More info:

Published by: Nishant Mayekar on Sep 20, 2011
Copyright:Attribution Non-commercial

Availability:

Read on Scribd mobile: iPhone, iPad and Android.
download as DOC, PDF, TXT or read online from Scribd
See more
See less

08/27/2012

pdf

text

original

AE 2307 CAD / CAM LABORATORY

DEPARTMENT OF AERONAUTICAL ENGINEERING

LAB MANUAL

Its primary purpose is to create a faster production process and components with more precise dimensions and material consistency. Although major applications of CNC even today continue to be in machining. which in some cases. CAM is a programming tool that makes it possible to manufacture physical models using computer-aided design (CAD) programs. Manufacture of these cams/ templates is costly and slow.CAM PART PART -1 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. These motions and switching functions are input in the form of alphanumeric instructions. it finds applications in other processes such as sheet metal working. It has now evolved into a mature technology known as Computer Numerical Control (CNC). uses only the required amount of raw material (thus minimizing waste). simplified generic tooling even for the most complex jobs and accurate construction are some of the salient features of CNC. any process that can be visualized as a sequence of motions and switching functions can be controlled by CNC. non-traditional machining and inspection. CAM creates real life versions of components designed within a software package CNC Technology Numerical Control (NC) is a software-based machine tool control technique developed at Massachusetts Institute of Technology (MIT) in early 1960s. independent axes coordinated through software. Unlimited muscle power. while simultaneously reducing energy consumption. CNC Machining Automats and Special Purpose Machines (SPMs) require special cams/ templates and clutch settings for each part. In fact. Robots and Rapid Prototyping machines are also CNC controlled. CNC is the basis of flexible automation which helps industries cut down time-to-market and enables launch of even low volume products. . unmanned operation.

changing over from one part to the other on these machines also consumes considerable time. The high cost and long time of these hard automated machines to produce parts can be justified only in mass production. tool makers today require EDM only for producing inaccessible regions. The programming language of Numerical Control (NC) is sometimes informally called G- . The G-codes are the codes that position the tool and do the actual work. tiny features and desired surface quality. S and F are tool-Speed and tool-Feed. These in conjunction with advanced cutting tools have made High Speed Cutting (HSC) of hard materials a reality. that manages the machine. sharp corners. NC programming and verification in another place and actual machining in yet another place. or preparatory code or function. Intricate aerospace parts are realized through 5 axis CNC machining. Internet technology in a global village enables designing in one place. Therefore. Advantages of CNC  Flexibility  Accuracy  Speed  Simplified fixturing and generic cutting tools  Storage of machining skill in NC programs  Less skilled operators will do  Less fatigue to the operators G-codes G-Code. T for tool-related codes. are functions in the Numerical control programming language. as opposed to M-codes. CNC machining has become a standard means to produce dies and molds. and finally D-codes for tool compensation. rigid and accurate CNC machines and sophisticated CAM packages. generation of NC programs and change over from one product to the other are easy and fast as it does not require any mechanical change. With the advent of fast.Furthermore.

3D circular interpolation counter clockwise (Prolight Mill) G74 . 16. 29.Clockwise circular motion G03 . 9. 10.deep hole drilling.wait for input #1 to go high (Prolight Mill) G28 . 18.cutter compensation cancel G41 . 27.set metric units or stock removal G72 . 11.indicate finishing cycle (EMCO Lathe) G72 .disable 360 deg arcs (Prolight Mill) G75 . 31. 36.pattern repeating (Emco Lathe) G75. positive G44 . 20. 26. 24. 17.Acceleration G09 . These direct motion of the tool. 35. A basic list of `G' operation codes is given below.x-y plane for circular interpolation G18 .wait for input #1 to go low (Prolight Mill) G26 . 13.1 .tool length compensation. 4.thread cutting functions (Emco Lathe) G35 . 2.return from reference point G31 . 14.tool length compensation.thread cutting cycle or metric data specification G24 . 32.cutter compensation to the left G42 . But in actuality.face turning cycle G25 . 28.Linear move G02 .turning cycle contour (EMCO Lathe) G73 . 25. 30. 1. G00 . 3.enable 360 degree arcs (Prolight Mill) G76 . 37. 39.y-z plane for circular interpolation G20 .1 .Deceleration G17 .wait for input #2 to go high (Prolight Mill) G40 .set inch based units or finishing cycle G71 . 40. G-codes are only a part of the NC-programming language that controls NC and CNC machine tools.Dwell G05 .3D circular interpolation clockwise (Prolight Mill) G73 . 15.cut-in cycle in x-axis . 8.Pause (for operator intervention) G08 .wait for input #2 to go low (Prolight Mill) G36 . negative G50 . 19.Counterclockwise circular motion G04 . 7.turning cycle or inch data specification G21 .z-x plane for circular interpolation G19 . 12.return to reference point G29 . cut cycle in z-axis G77 .code.cutter compensation to the right G43 . 6. 21.Rapid move (not cutting) G01 . 34.facing cycle contour (Emco Lathe) G74.Preset position G70 .Stop on input (INROB1 is high) (Prolight Mill) G33-35 . 38. 5. 23. 33. 22.

49. 56.turn on accessory #1 (120VAC outlet) (Prolight Mill) 11. 43. M06 .Spindle speed limit G93 .incremental dimensions G92 . 60. M08 .turn on accessory #2 (120VAC outlet) (Prolight Mill) . 57.Feed rate in ipm (EMCO Lathe) G95 . 58.taping cycle (EMCO Lathe) G85 . 55.Feed rate in ipr (EMCO Lathe) G96 .coolant off 12.41. 50. M07 .spindle on CCW 6.spindle off 7.withdraw the tool to a safe plane or feed per revolution G101 .spindle on CW 5. M09 . 42. 61. M05 .fixed cycle cancel G81-89 .Spline interpolation (Prolight Mill) M-Codes M-Codes control machine functions and these include. M10 . M00 .program stop 2. 54.boring with spindle off and dwell cycle (Prolight Mill) G89 .boring cycle with dwell (Prolight Mill) G90 . 45. 48. 52. 47. M09 .reaming cycle (EMCO Lathe) G85 . 53.Surface cutting speed (EMCO Lathe) G97 . 62. 46.flood with coolant 9.peck drilling cycle (Prolight Mill) G84 .withdraw the tool to the starting point or feed per minute G99 .fixed cycles specified by machine tool manufacturers G81 . M02 .drilling cycle (Prolight Mill) G82 . G78 .Rotational speed rpm (EMCO Lathe) G98 .optional stop using stop button 3. M08 .boring cycle (Prolight mill) G86 . 59.multiple threading cycle G80 .drilling cycle (EMCO Lathe) G83 .turn off accessory #1 (120VAC outlet) (Prolight Mill) 13. M04 .straight drilling cycle with dwell (Prolight Mill) G83 . M03 . 44.Coordinate system setting G94 . M01 .end of program 4.tool change 8. 1.absolute dimension program G91 .mist with coolant 10. 51. 63.

30. 36. 29. There is no need for a y-axis because the tool moves in a plane through the rotational center of the work. 15.subprogram call M99 . 35. 22. 16. 26.Write current position to data file (Prolight Mill) M25 . 17.Chain to next program (Prolight Mill) M21 .tailstock forward (EMCO Lathe) M22 .put stepper motors on low power standby (Prolight Mill) M47 . 27.compensate for rounded external curves M97 .subroutine end M20 . 23.puff blowing on (EMCO Lathe) M72 . 31.set output #2 on (Prolight Mill) M38 . .turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change M17 . 34.move z-axis home (Prolight Mill) CNC PROGRAMMING · The coordinates are almost exclusively cartesian and the origin is on the workpiece.puff blowing off (EMCO Lathe) M96 .move x-axis home (Prolight Mill) M102 . the carriage/length axis is the z-axis. 33.restart a program continuously.compensate for sharp external curves M98 .tailstock back (EMCO Lathe) M20 . 20.open chuck (EMCO Lathe) M25 . or a fixed number of times (Prolight Mill) M71 . 28.close chuck (EMCO Lathe) M26 . M11 . 32.set output #2 off (Prolight Mill) M36 . · For a lathe.end of tape (rewind) M35 . the infeed/radial axis is the x-axis. 19.set output #1 on (Prolight Mill) M30 . 25. 24. 37. jump instruction M101 .move y-axis home (Prolight Mill) M103 .return from subprogram.14. 18. Coordinates on the work piece shown below are relative to the work.set output #1 off (Prolight Mill) M26 . 21.

These machines are often set and operated by the same person. however the knowledge base is broader compared to the older production machines where intimate knowledge of each machine was considered essential. The part may be designed and the tool paths programmed by the CAD/CAM process. where the operator will supervise a small number of machines (cell).CNC lathe / CNC turning center CNC lathes are rapidly replacing the older production lathes (multispindle. . They are designed to use modern carbide tooling and fully utilize modern processes.The machine is controlled electronically via a computer menu style interface. and the resulting file uploaded to the machine. etc) due to their ease of setting and operation. The setter/operator needs a high level of skill to perform the process. and once set and trailed the machine will continue to turn out parts under the occasional supervision of an operator. the program may be modified and displayed at the machine. along with a simulated view of the process.

G00 X26 Z-3. G00 X0 Z1.EX NO :1 DATE: CNC PROGRAM FOR FACING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X25 Z90. M05. G28 U0 W0. G21. M30. G00 X26 Z1. G00 X26 Z1. G00 X0 Z-3 F5. G98. Result: Thus the program was written and executed successfully using FANUC . G50 S1000. G28 U0 W0.

G50 S1000. G00 X0 Z1. G00 X26 Z1. Result: Thus the program was written and executed successfully using FANUC . M05. G00 X26 Z-3.EX NO : DATE: CNC PROGRAM FOR TURNING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X25 Z90. M30. G28 U0 W0. G98. G00 X0 Z-3 F5. G28 U0 W0. G21. G00 X26 Z1.

G50 S1000. G28 U0 W0. Result: Thus the program was written and executed successfully using FANUC . G94 X0 Z-1 F5. M05. Z-6. X14 . X11 . Z-7. X13 . Z-4. M30.EX NO : DATE: CNC PROGRAM FOR BOX TURNING & FACING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X25 Z90. G21. X9 . G00 X15 Z1. Z-10. G90 X15 Z-50 F5. X10 . G98. X8 . Z-2. Z-3. Z-8. G90 X10 Z-30 F5 . Z-5. Z-9. X12 . G28 U0 W0.

X20 R-2. G00 X25 Z0. G00 X20 Z-22. G90 X23 Z-39 F25. M30. G90 X10 Z-10 R-1 F25 . G28 U0 W0. G90 X20 Z-29 R0. G98. G50 S1000.5 F25. G00 X20 Z-15 . X14 Z-10. X18 Z-10.5.EX NO : DATE: CNC PROGRAM FOR TAPER TURING OPERATION Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X25 Z90. X10 Z-10 .5. G00 X19 Z-22 R0. X10 R-2 . Result: Thus the program was written and executed successfully using FANUC .5 . G21. G28 U0 W0.5 F25 . X15 R2. X20 R-1. X20 R-1. M05. X10 R-4 . X10 R-3 . X17 R1. X20 Z-34. X12 Z-10.5. X18 R1 . X16 R2 . X10 R-5 . X16 Z-10. X20 R-2.

G71 U0.1 F5. M05. M06 T08. G02 X20 Z-25 R10. G71 P100 Q200 U0. G70 P100 Q200 F5. M03 S1000. M06 T01. N200 G01 X20 Z-40. M30. Result: Thus the program was written and executed successfully using FANUC . G28 U0 W0. G03 X10 Z-5 R5. N100 G01 X00.5 R1. G02 X10 Z-15. G21 G98. G00 X26 Z2.1 W0. G00 X26 Z21. M05. G28 U0 W0. M03 S1000.EX NO DATE: CNC PROGRAM FOR MULTIPLE TURNING Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X26 Z70. Z00. G50 S2000. G28 U0 W0. G01 X20 Z-40.

EX NO DATE: CNC PROGRAM FOR MULTIPLE GROOVING CYCLE Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X40 Z55. G71 P100 Q200 U0. G28 U0 W0. G28 U0 W0. G21 G98. G00 X30 Z1. G00 X30 Z-17. G75 X24 Z-30 P1000 Q1750 F10. G01 X30 Z-35. G28 U0 W0.1 W0. M05. M30. G50 S2000. G01 X40 Z-45. M06 T08. M05. M06 T01. G71 U0. G70 P100 Q200 F5. G28 U0 W0. G75 R1. M03 S1200. Result: Thus the program was written and executed successfully using FANUC . G00 X40 Z1. M05.5 R1.1 F5. M06 T05. M03 S1200. G00 X30 Z2. G00 X30 Z1. N200 G01 X40 Z-45. N100 G01 X26. G01 X30 Z-2. Z00. M03 S1600.

M06 T01. G01 X-40 Y-25 . G01 X-25 Y40 . G90 G00 X-25 Y-40 . G02 X-25 Y-40 R15 . [TOOLDEF T01 D10. G01 X25 Y-40 . G02 X25 Y40 R15 . G21 G94 G40. M30 . [EDGE MOVE X-50 Y-50. G03 X40 Y-25 R15 . Result: Thus the program was written and executed successfully using FANUC . G03 X-40 Y25 R15 .EX NO : DATE: CNC PROGRAM FOR LINEAR &CIRCULAR SLOTTING Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILLET X100 Y100 Z10. G01 Z-5 F40 . G91 G28 X0 Y0 Z0 . G28 X0 Y0. M05 . M03 S1200 . G01 X40 Y25 . G91 G28 Z0. G00 Z2 . G50 S2000.

G90 G00 X0 Y0 Z2 . Result: Thus the program was written and executed successfully using FANUC . G170 R0 P0 Q1 X0 Y0 Z-5 I0. M03 S1200. G00 Z2 . G21 G94 G40 G91 G28 Z0 . G91 G28 X0 Y0 Z0 M30.EX NO : DATE: CNC PROGRAM FOR CIRCULAR POCKETING Aim: To write the CNC program for the given operation using FANUC language Requirement: Pentium IV FANUC programming software Program: [BILET X100 Y100 Z10 . [EDGE MOVE X-50 Y-50 . G171 P75 S1500 R75 F25 B2000 J100 . [TOOLDEF T01 D10 .2 K25 .2 J0. M05 . M06 T01. G50 S3000. G28 X0 Y0.

engineering analysis. solid modeling systems ensure that all surfaces meet properly and that the object is geometrically correct. . For every company that uses CATIA for product design. because it simulates an object internally and externally. Unlike wireframe and surface modeling. CATIA was created by Dassault Systems of France CATIA is used by the automotive and aerospace industries for automobile and aircraft product and tooling design. product visualization and visualization of scientific research CATIA. Solid models can be sectioned (cut open) to reveal their internal features. which stands for Computer Aided Three-dimensional Interactive Application. there are hundreds of suppliers to those companies that also use CATIA. which tests to see if two or more objects occupy the same space. CATIA is found in a variety of industries throughout the world. Solid models allow for interference checking. and they can be stress tested as if they were physical entities in the real world. computer graphics and animation. Some of these industries include. Primary uses of solid modeling are for CAD. medical testing. is the most powerful and widely used CAD (computer aided design) software of its kind in the world. Aerospace. There are thousands of companies the world over using CATIA. rapid prototyping.PART –II CAD PART Solid Modeling Solid modeling is the most complicated of the CAD technologies. A mathematical technique for representing solid objects.

working with private industry. Medical. Consumer Goods. Mold and Die. Electronics.CATIA has played a major role in NASA's design of the Space Shuttle. Furniture. Automotive. aircraft carriers. tanks and various other forms of weaponry. and Shipbuilding. . uses CATIA for the design of "jet-fighter" aircraft. The military. Machinery.Appliances. helicopters. Architecture. Construction.

.

Experiment no: 1 DESIGN AND MODELLING OF RECTANGULAR PLATE WITH HOLE Aim: To draw the design and modelling of rectangular plate with hole using the CATIA package Commands used: • Lines • Rectangle • Circle • Extrude • Pocketing • Edge Fillet Tools required CATIA package Procedure 1) Open the software tool CATIA 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 line command and draw as per the given dimensions 5) Draw the circle by the given dimensions 6) Mark the dimensions for the riveted job 7) Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified .

Experiment no: 2 Design and MODELLING OF SPAR COMPONENTS Aim: To draw the design and modelling of spar components using the CATIA package Commands used: • Lines • Circle • Extrude • Pocketing • Multicopy • Edge Fillet Tools required CATIA package Procedure 1) Open the software tool CATIA 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 line command and as per the given dimensions 5) Draw the spar assembly by the given dimensions 6) Mark the dimensions for the riveted job 7) Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified .

Open the CATIA package. Set the units and limits for the display screen 4. 2. Create the new file and save it in the directory 3. Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified . Use the line command and draw as per the given dimensions 5. Mark the dimensions for the riveted job 7.Experiment no: 3 Design and Modeling of Aerofoil structures Aim: To draw the Design and Modeling of Aerofoil structures using the CATIA package Commands used: • Dots • Spline • Coordinate points • Plane • Loft Tools required CATIA package Procedure: 1. Draw the drawing by the given dimensions 6.

Use the line command and draw the as per the given dimensions 5. 2. Set the units and limits for the display screen 4. Draw the diagram by the given dimensions 6. Create the new file and save it in the directory 3. Mark the dimensions for the riveted job 7. Open the CATIA package.Experiment no: 4 Design and Modeling of cut section of wings Aim: To draw the Design and Modeling of cut section of wings using the CATIA package Commands used: • Spline • Coordinate points • Plane • Loft Tools required CATIA package Procedure 1. Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified .

Use the line command and draw the as per the given dimensions 5. Open the CATIA package. Draw the diagram using commands by the given dimensions 6. 2. Mark the dimensions Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified . Create the new file and save it in the directory 3. Set the units and limits for the display screen 4.Experiment no: 5 Design and Modeling of machine components Aim: To draw the Design and Modeling of machine components using the CATIA package Commands used: • Lines • Groove • Shaft • Plane • Pocketing • Translate Tools required CATIA package Procedure 1.

Mark the dimensions for the riveted job 6. Open the software tool CATIA package. Create the new file and save it in the directory 3. 2. Set the units and limits for the display screen 4. Use the line command and draw the as per the given dimensions 5.Experiment no: 6 Design and Modeling of machine components (push pull rod) Aim: To draw the Design and Modeling of machine components (push pull rod) using the CATIA package Commands used: • Lines • Groove • Shaft • Plane • Pocketing • Translate Tools required CATIA package Procedure 1. Save the diagram in specified directory Result Thus the required drawing was designed and modeled as per the given dimension and verified .

Open the software tool CATIA package.Experiment no: 7 DESIGN AND ANALYSIS OF TRUSS Aim: To design and analysis of truss using the CATIA package and ANSYS software Commands used: • Lines • Arcs • Circle • Region • Hatching Tools required CATIA package and ANSYS software Procedure 1. Set the units and limits for the display screen 4. conduct the structural analysis using ANSYS Result Thus the required drawing was designed and modeled and analyzed . Create the new file and save it in the directory 3. Save the diagram in specified directory 7. Use the line command and draw as per the given dimensions 5. Mark the dimensions for the riveted job 6. 2.

Mark the dimensions for the riveted job 6. Create the new file and save it in the directory 3. conduct the structural analysis using ANSYS Result Thus the required drawing was designed and modeled and analyzed . Save the diagram in specified directory 7. Use the line command and draw the as per the given dimensions 5. 2.Experiment no: 8 DESIGN AND ANALYSIS OF BEAM DISTRIBUED LOAD Aim: To design analysis of beam distributed load the CATIA package and ANSYS software Commands used: • Lines • Arcs • Circle • Region • Hatching Tools required CATIA package and ANSYS software Procedure 1. Set the units and limits for the display screen 4. Open the software tool CATIA package.

You're Reading a Free Preview

Download
scribd
/*********** DO NOT ALTER ANYTHING BELOW THIS LINE ! ************/ var s_code=s.t();if(s_code)document.write(s_code)//-->