1.

0 TITLE
COMPUTER AIDED DESIGN/ COMPUTER AIDED MANUFACTURING

2.0 OBJECTIVES
 To develop the knowledge about Computer Aided Design (CAD) and Computer
Aided Manufacturing (CAM) and apply it during the manufacturing process.
 To machine product using CNC Milling machine.
 To design a basic NC program for CNC Milling.

3.0 INTRODUCTION
Manufacturing process generally can be divided into two classes which are primary
manufacturing process and secondary manufacturing process. The primary manufacturing
process are providing simple shape and size of material required by the designer. Secondary
manufacturing process provide tighter control over dimension and create the final shape. The
secondary manufacturing process mainly about the material removal process.
CNC machining is a manufacturing process which suitable for a wide range of
industries including automotive. CNC machining process starts by designing product using
Computer Aided Design (CAD) or Computer Aided Manufacturing (CAM). CAD involves
constructing computer models described by geometric parameters. CAD is used for
preliminary design and layout, developing 3-D models and interfacing with analytics and
manufacturing. In order to monitor automated machinery, computer-aided manufacturing
(CAM) uses geometrical design data. Computer numerical control (CNC) or direct numerical
control (DNC) systems are connected with CAM systems.
Coordinate systems are used to properly understand how machines perceive
programmed movement. Parts zero is the datum corresponding to the CAD drawing 0,0
coordinate used to construct g-code and complete other CAM work; in the g-code, the
X0Y0Z0 represents part zero position. Process to do such as cutting process and machining
process are being instructed by the g-code commands. G-code will contain instructions to
precisely move X (left / right), Y (front / back) and Z (up / down). G54 work offsets are CNC
control machine data registers keeping the distance from the machine 's home X, Y, Z to the
part datum. The machine operator locates XY's fixture offset by shifting the machine from its
home location to the part being machined. When identified, the G54 command transfers the
CNC machine from the machine coordinate system (MCS) to the Work Coordinate System
(WCS).
4.0 APPARATUS
 Laptop
 NC Program
 Machine controller
 Rough stock
 CNC Milling machine
 Work holding devices cutting tool

5.0 SAFETY AND EXPERIMENTAL PROCEDURE

1. Start the CATIA v5 software to create the 2D vectors or 3D solid part design
2. A rectangular block was designed using the CATIA software with dimension
100x50x25mm and student ID was created on the surface of the block.
3. The formatted CAD design file runs through a CAM software
4. The workpiece was simulated using the software where a tool path for surface
machining was created.
5. The part geometry was extracted and G-code was generated to control the CNC
machine and manipulated the tooling to produce custom-designed part
6. 'STARTFIFO' was inserted at the start of the g-code, as it was necessary for the
machine to read the instructions.
7. The machine was turned on by switching on the isolator.
8. Air supply pressure (6 bar) and machine controller were switched on.
9. G54 have been set to the CNC milling machine to set the datum which is the origin,
x=0, y=0 and z=0.
10. Once the G-code is generated, it's loaded to the CNC machine. When identified, the
G54 command transfers the CNC machine from the machine coordinate system
(MCS) to the Work Coordinate System (WCS).
11. CNC machine was prepared for the operation where the workpiece was fixed directly
into the machine onto work holding device and attached with required tooling.
12. The workpiece was set up at x=0, y=0 and z=0
 13. The start button was pushed to begin the machining process. Before this process, we
need to make sure that the door of the machine is securely closed for the machine to
operate.
14. Proper safety equipment also required such as ear protection, safety glasses, suitable
footwear such as boots during the operation of the machine
15. The machine was kept running until the machining process completed. During the
machining process, we need to keep our hands away from any moving parts of the
machine to avoid any cause of injury.
16. The amount of error need to be minimized during this operation to ensure precise
product is produced.

6.0 CONCLUSIONS

Computer numerical control, CNC, machining produces various complex parts in

hundreds of industries. Although mass production works for certain applications, for
particular uses, many industries need custom parts. The ability to accurately design and build
computer-driven parts drives many businesses to pursue CNC machining for their operations.
Anything from medical to transport and other industries depends on machining parts. Due to
the development of both computers and machines, the process allows more complex custom
designs than most manufacturing methods can accomplish.
From this lab session, it can be concluded that G-code is an important aspect for
computer aided manufacturing process. To be able understand this lab session, G-code should
be one of the way to achieve the objective of this lab session. Below are the top 15 lines of
the G-code generated through the lab session.
STARTFIFO N1 G54 G64 G40 G90 G17 G94 G49 G80 N2 M8 N3 G53 N4 T1 M6 N5 G0
X6.62 Y28.988 S1000 M3 N6 Z20. N7 Z10.001 N8 G1 Z.001 F300. N9 X6.612 Y28.983
Z-.002 N10 X6.531 Y28.92 Z-.029 N11 X6.456 Y28.855 Z-.056 N12 X6.386 Y28.787
Z-.082
N13 X6.321 Y28.715 Z-.108 N14 X6.26 Y28.639 Z-.134 N15 X6.205 Y28.56 Z-.16
All the codes written above have their own different description. For example,
STARTFIFO indicate the beginning of the G-code and must be written to make sure that the
machine can understand as starting language and run. Moreover, N1, N2, N3 and others
indicate the block number. Next, code G is the preparatory function such as G000 is the rapid
positioning, code M is the machine function such as M6 is tool change, code S is the spindle
speed such as S1000 where is 1000 indicate the spindle speed in rev/min, code T is the tool
selection such as T01 is tool selection, code F is the feed rate such as F10 is feed at rate of
10" per revolution and code R is the radius of the curvature.
In conclusion, the objectives of this experiment have been successfully achieved as a
product had been made by using a basic NC program design on the CNC milling machine. By
using NC program in CNC milling machine ease the process due to NC program have
flexibility with accuracy, easy machine adjustments and high production rates with good
quality product produced. Lastly, despite having possible errors occurs during the lab session
the student managed to achieve the objectives and gain more knowledge throughout the lab
session.

7.0 RECOMMENDATION

There are few recommendation that can be consider for further investigation.
Machining tolerance, also known as dimensional precision, is the rate of acceptable
component dimension variance. Parts are considered beyond tolerance if their dimension falls
between these limits. CNC machine tolerance is the degree of dimensional precision that a
machine can achieve when machining a component. CNC machines are very precise.
However, different CNC machine tolerances vary, and are typically specified by the
manufacturer. As a recommendation, we can use smaller machining tolerance to obtain most
accurate product.
Choosing the incorrect cutting instrument will result in a poor material finishes. This
can be seen as raw edges, cutter marks on the top, raised marks, or burn marks on the edges
or corners of the object. Extensive tool wear may result from this error. Poor material finishes
might also be either by bluntness of the instrument used or to an improper feed rate ratio. It
can also be influenced by inappropriate measurements of the tool for the task at hand in terms
of its size, consistency or matching of the material. As a recommendation, it is necessary to
choose the right tool and set it for the job and the material.
Modern machines with certain continuously moving mechanical parts require daily
cleaning and maintenance to keep them working optimally. Failure to remove dust, material,
and other debris could result in a build-up that could result in machining inaccuracies or even
machine failures over time. As a recommendation, comprehensive maintenance scheme
should be done for the machine tools in operation such as periodically check coolant or
airflow to ensure that the operation can be run smoothly.
 As highly advanced CNC computer-controlled machines, issue that occur in CNC
machining is also programmed. These may result from a lack of understanding of the
numerous G and M codes used for controller, incorrect set-up, or inputting incorrect data
variables into CNC controller. As a recommendation, the student need to have better
understanding in the various ways CNC machines can be programmed.

8.0 REFERENCES

1. Sinha, N. (n.d.), Introduction to Non-Traditional Machining.

Retrieved from http://home.iitk.ac.in/~nsinha/Non-traditional-machining.pdf

2. Editor of Lincoln Tech News (2016), What is CNC Machining and Why is it

Important? Retrieved from https://www.lincolntech.edu/news/skilled-trades/cnc-

machining-and-manufacturing/what-is-a-cnc-machining-and-manufacturing/what-is-

a-cnc-machine#:~:text=People%20from%20all%20different%20pursuits,more

%20efficient%20and%20safer%2C%20t

3. Laith, A., & Mohammed. (n.d.), Lab Sheet for CNC Laboratory Department of

Production Engineering and Metallurgy. Retrieved from

https://www.uotechnology.edu.iq/depproduction/labe_cnc_files/CNCLabsheet.pdf

4. Editor of Staff Writer (2020), Understanding CNC Machining.

Retrieved from https://www.thomasnet.com/articles/custom-manufacturing-

fabricating/understanding-cnc-machining/

5. Editor of Design Tech (2015), Introduction to CAD, Background, Uses and Types of

CAD Software.

Retrieved from https://www.designtechcadacademy.com/knowledgebase/introduction

cad#:~:text=CAD%20(Computer%20Aided%20Design)%20is,component%20in

%20a%20graphical%20form.

6. Editor of Xometry Europe (2019), Tolerances in CNC machining, tolerancing tips |

Blog | Xometry Europe.

Retrieved from https://xometry.de/en/tolerances-in-cnc-machining/

 7. ‌Editor of Azura Website (2020), Automatic Rough Stock. Retrieved from

http://catiadoc.free.fr/online/cfyugtpe_C2/cfyugtpegautoroughstock.htm

8. Editor of American Micro (2019), The Differences between G codes and M codes.

Retrieved from https://www.americanmicroinc.com/difference-g-code-m-code.html

9. ‌Editor of Fusion 360 Blog (2018), What is Computer Aided Manufacturing (CAM)?

Retrieved https://www.autodesk.com/products/fusion-360/blog/computer-aided-

manufacturing-beginners/

10. Editor of American Micro Industries (2020), Machining Tolerances

Retrieved from https://www.americanmicroinc.com/machining-tolerances.

9.0 APPENDIX

Figure 9.1: CNC Milling machine

Figure STARTFIFO
9.2: Rectangular block with Student ID created using CATIA software
N1 G54 G64 G40 G90 G17 G94 G49 G80
N2 M8
N3 G53
N4 T1 M6
N5 G0 X6.62 Y28.988 S1000 M3
N6 Z20.
N7 Z10.001
N8 G1 Z.001 F300.
N9 X6.612 Y28.983 Z-.002
N10 X6.531 Y28.92 Z-.029
N11 X6.456 Y28.855 Z-.056
N12 X6.386 Y28.787 Z-.082
N13 X6.321 Y28.715 Z-.108
N14 X6.26 Y28.639 Z-.134
N15 X6.205 Y28.56 Z-.16
-----------------------------------------------------------------------------------
N7195 X90.611 Y23.842
N7196 X90.566 Y23.855
N7197 X90.509 Y23.879
N7198 X90.457 Y23.909
N7199 X90.409 Y23.945
N7200 X90.364 Y23.988
N7201 X90.327 Y24.034
N7202 X90.299 Y24.061 Z-.989
N7203 X90.267 Y24.083 Z-.979
N7204 X90.23 Y24.098 Z-.968
N7206 X90.153 Z-.947
N7207 X90.114 Y24.098 Z-.937
N7208 X90.078 Y24.083 Z-.926
N7209 X90.045 Y24.062 Z-.916
N7210 Z9.084
N7211 G0 Z20.
N7212 M5
N7213 M30
N7214 M2
N7215 M30

Figure 9.3: List of G-code generated