SHREE VENKATESHWARA HI-TECH ENGINEERING COLLEGE, GOBI

DEPARTMENT OF MECHANICAL ENGINEERING

ME - MANUFACTURING ENGINEERING

MF7111 - COMPUTER AIDED DESIGN AND

COMPUTER AIDED MANUFACTURING LABORATORY

Year / Sem / Branch: I / II / MANUFACTURING ENGINEERING Batch: 2014-2016

LIST OF EXPERIMENTS

A. Study of Computer Aided Design (CAD).

1. 3D Modeling And Assembly Of Protected Type Flanged Coupling Using Pro/ E
2. 3D Modeling and Assembly of Universal Coupling Using Pro/E.
3. 3D Modeling and Assembly of Plummer Block Using Pro/ E.
4. Simple Sheet Metal Component Modeling Using Pro/E.
B. Study of Computer Aided Manufacturing (CAM).
5. Simple Facing and Turning Operation Using CNC Lathe.
6. Multiple Turning Cycles Operation Using CNC Lathe.
7. Multiple Facing Cycle Operation Using CNC lathe.
8. Canned Cycle Step Turning Operation Using CNC Lathe.
9. Simple Contour Milling Operation Using CNC Milling.
10. Mirroring Operation Using CNC Milling
C. Study of Sensors, Transducers and PLC.

LAB INCHARGE HOD/MECHANICAL

St Ex. No. A COMPUTER AIDED DESIGN (CAD)
Date :
AIM:
To study about Computer Aided Design using Pro/E.

DESIGN PROCESS AND ROLE OF CAD

The design process is an iterative procedure involving the following six phases:
1. Recognition of need 4. Analysis and optimization
2. Definition of problem 5. Evaluation
3. Synthesis 6. Presentation
Synthesis includes defining the design problem, design conceptualization, searching for
design information, modeling and simulation. Analysis and optimization may includes
parameter study, finite element analysis, etc. Although computers are being utilized more and
more in the design process, their use is still limited to the last, four steps in the design and they
are mainly used as a tool that helps the designer, rather than as a replacement for the designer.
Benefits of Using CAD:
1. Increasing productivity 3. Improving Communications
2. Improving quality of design 4. Creating database for manufacturing
The Design Process and Computer-Aided Design

Design Process
Recognition of Need

Problem Definition Computer Aided

Design

Synthesis Geometric Modeling

Analysis and Engineering Analysis

Evaluation Design Review and

Presentation Automatic Drafting

Computer Aided

Fig 1.1 Role of computers in design process

1. GEOMETRIC MODELING
The term geometric modeling (or representation) means a method of describing
commonly used curves and surfaces in terms of values of a few parameters.
Three Types of Geometric Models
Wireframe Model : Connect 3D vertex points, sometimes ambiguous.
Surface Model : Define surface to form an object.
Solid Model : Various representation schemes are used to describe a solid object
2. SOLID MODELING
A solid modeling system is usually an interactive computer graphics system that is
intended to create true three-dimensional components and assemblies. Recent advances in
CAD software, computers, and graphical displays have made it possible to use solid
representations of components being considered in the design process. These solid models can
be employed in numerous ways.
Advantages of Solid Modeling
A realistic visual display: By producing a shaded visible surface image of the solid, solid
modeling allows a designer to see exactly what has been created.
Easy to deal with different views: Once a part has been created, we have the ability to
rotate, shade, section, or produce almost any view required by a designer. Single associated
model database: The solid modeler provides the only database suitable for all CAD operations.
Almost all information needed for part generation is contained in the solid model. The
algorithm should be able to ensure that it represents physically possible shape that is complete
and unambiguous Applications e.g., automatic generation of a mesh for a finite element
analysis.
3. REQUIREMENTS FOR MODELING ASSEMBLING
1. Part modeling and analysis
The part analyses include the material type, mass and inertial properties, functional
properties of the faces, etc.
2. Hierarchical relationships
An assemble tree and assemble sequence must be given.
3. Mating conditions.
There are two methods for specifying mating conditions:
1. Specify the location and orientation of each part in the assembly, together with
the representation of the part itself, by providing a 4 x 4 homogeneous
transformation matrix. (i.e., transformation from MCS – Model Coordinate
System to WCS – Working Coordinate System)
2. Specify the spatial relationships between its individual parts as mating
conditions. For example, a mating condition can consist of planar faces butting
up against one another or requiring centerlines of individual parts to be collinear
(fits condition).
4. CADCAE/CAM DATA EXCHANGE
Computer databases are now replacing paper blueprints in defining product geometry
and non-geometry for all phases of product design, analysis, and manufacturing. It becomes
increasingly important to find effective procedures for transferring data among CAD/CAE/CAM
systems. The need to exchange modeling data is directly motivated by the need to integrate
and automate the design and manufacturing process to obtain the maximum benefits from
CAD/CAE/CAM systems.
Four Types of Modeling Data to be transferred:
1. Shape 3. Design
2. Non shape 4. Manufacturing
(1) Shape data consists of both geometrical and topological information as well
as part features. Entity attributes such as font, color, and layers as well as annotation
are considered part of the entity geometrical information. Topological information
applies only to products described via solid modeling. Features allow high-level concept
communication about parts. Examples are hole, flange, web, pocket, chamfer, etc.
(2) Non shape data includes graphics data such as shaded images, and model
global data as measuring units of the database and the resolution of storing the
database numerical values.
(3) Design data has to do with the information that designers generate from
geometric models for analysis purposes. e.g., mass property and finite element mesh
data.
(4) Manufacturing data consists of information such as tooling, NC tool paths,
tolerance, process planning, tool design, and bill of materials.
Commonly Used CAD Data Exchange Format
• IGES (Initial Graphics Exchange Specification)
• PDES (Product Data Exchange Using STEP)
IGES is focused on CAD-to-CAD exchange where primarily shape and nonshape data
were to be transferred from one system to another. PDES is previous called Product Data
Exchange Standard. It is for the exchange of complete product descriptions which covers the
four types of modeling data (i.e., shape, nonshape, design and manufacturing).Other data
exchange interfaces include: STL, Neutral, SET, ECAD, VDA, STEP, PDGS, CATIA, Render, CGM,
VRML, PATRAN, TIFF, etc.
5. PRO - E SOFTWARE OVERVIEW
Pro/ENGINEER wildfire is the leading product development solution for any
manufacturing industry. The software is developed and supported by the Parametric
Technology Corporation(PTC), based in United States. Pro/E wildfire is a unique software
developed for the manufacturing industry to meet the competing demand of engineering
productivity, faster time to markets, and improved product quality.Pro/ENGINEER wildfire is a
comprehensive product development Design Manufacturing
solution for concept and industrial design,
detailed design, simulation and analysis,
mold/tool/die design,and NC tool path Pro/E
CAD Analysis
creation. With the powerful tools of
ProE , you will be able to capture the
design intent of any complex model, by
Drawings Simulation
incorporating intelligence into design.

Fig 1.2: Pro/E Software Overview

Modules in ProE Wildfire
It is a complete product development solution. You can get the best in class tools
for product design, analysis, data management, and manufacturing in a single software. Some
of the important modules are as follows:
•ProE Foundation •ProE Cabling
•ProE Interactive Surface Design •ProE Intralink
Manufacturing Module
•ProE Machining •ProE tool design
•ProE NC SHEET METAL •ProE plastic advisor
Modules in ProE Foundation

Fig 1.3: Modules in Pro/E Foundation

Features of ProE Wildfire

ProE is a one-stop store for any manufacturing industry. It offers effective features,
incorporated for a wide varity of purpose. Some of the important features are as follows:
• Simple and powerful tools • Parent child relationship
• Parametric design • Associative and model centric
• Feature based approach
The Modeling Process
The following graphic illustrates the modeling process and the role design intent plays:

Fig 1.4: Parametric Modeling Process

SYSTEM REQUIREMENTS:
Operating System/ utilities: Hardware Requirements:
• Microsoft windows 2000/XP/7/8 • 2GB MB main memory
• Internet explorer 8.0 with SP1 or • 10 GB Disk space
later • 1.5GHz CPU speed
Constructive Solid Geometry (CSG)
In a CSG model, physical objects are created by combining basic elementary shapes
known as primitives like blocks, cylinders, cones, pyramids and spheres. The Boolean
operations like union, difference (–) and intersection ∩ are used to carry out this task. For
example, let us assume that we are using two primitives, a block and a cylinder which are
located in space as shown in Fig.1.5

Fig 1.5: Constructive Solid Geometry

A “union” operation (A U B) will combine the two to convert them into a new solid.(Fig.
1.5 (c)) The difference operation (A – B) will create a block with a hole (Fig. 1.5. (D)). An
intersection operation (A n B) will yield the portion common to the two primitives. (Fig.
1.5(E)).
Boundary Representation
Boundary representation is built on the concept that a physical object is enclosed by a
set of faces which themselves are closed and orientable surfaces. Fig. 1.6 shows a B-rep model
of an object. In this model, face is bounded by edges and each edge is bounded by vertices.
The entities which constitute a B-rep model are:
Geometric entities: Topological entities:
Point, Vertex,
Curve, Edge,
line, Face
Surface

Fig 1.6: B-REP Model

 A solid model is a 3-D representation of an object. It is an accurate geometric
description which includes not only the external surfaces of part, but also the part’s internal
structure. A solid model allows the designer to determine information like the object’s mass
properties, interferences, and internal cross sections. Solid models differ from wire frame and
surface models in the kind of geometric information they provide. Wire frame models only
show the edge geometry of an object. They say nothing about what is inside an object. Surface
models provide surface information, but they too lack information about an object’s internal
structure. Solid models provide complete geometric descriptions of objects. Engineers use solid
models in different ways at different stages of the design process. They can modify a design as
they develop it. Since computer-based solid models are a lot easier to change and manipulate
than the physical mock-ups or prototypes, more design iterations and modifications can be
easily carried out as a part of the design process. Using solid modeling techniques a design
engineer can modify a design several times while optimizing geometry. This means that
designers can produce more finished designs in less time than by using traditional design
methods or 2-D CAD drafting tools. Solid models can be used for quick and reliable design
analysis. Solid models apart from geometric information provide important data such as
volume, mass, mass properties and centre of gravity. The designer can also export models
created to other applications for finite element analysis (FEA), rapid prototyping and other
special engineering applications.
Finally designers can generate detailed production drawings directly from the solid
model. This capability increases design productivity considerably. Another important feature of
solid modeling is associativity. Detailed drawings are linked to solid model through the
associativity feature. This is a powerful function - as an engineer modifies a design, the
drawings get updated automatically. In bidirectional associativity, any modifications made to
geometry in the drawing are reflected in the model. In more advanced design and
manufacturing environments, solid models are used for rapid prototyping and automated
manufacturing applications. The salient features of the solid modeling approach to design are
discussed in the following sections.

CONCLUSION:
Thus, the Computer Aided Design using Pro/E ware studied successfully.
Ex. No: 1 3D MODELING AND ASSEMBLY OF POTECTED TYPE FLANGED
COUPLING USING Pro/ E
Date :

AIM:
1. To create 3D models of Protected type Flanged Coupling parts using Pro/E.
2. To Create the Assembly of Flanged Coupling using Pro/E.

SYSTEM REQUIREMENTS:
Software: Pro/E Creo Elements
Hardware: Processor: Intel Core i3
RAM: 2 GB
HDD: 500 GB
OS – Windows XP/7/8
PROCEDURE:
1. The drawings of Flanges, Shaft, Taper key, Hexagonal Bolt and Nut are studied.
2. 3D models of Flanges, Shaft, Taper key, Hexagonal Bolt and Nut are created using
Pro/E.
3. The Assembly of Flanged Coupling was created as per the drawing specification.

COMMANDS USED:

Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart Dimension, Relations, Show,
and View
Features Commands: Extrude (Pad) and Cut, Revolve (Shaft), Fillet/Round, Chamfer,
Hole - Simple, Pattern Fastening Features

Assembly Commands: Insert, Component, Existing Part/Assembly

Mating Commands: Coincident, Concentric, Distance

RESULT:

The 3D models of Protected type Flanged Coupling parts (Flanges, Shaft, Taper key,
Hexagonal Bolt and Nut) are created using Pro/E.
Ex. No: 2 3D MODELING AND ASSEMBLY OF UNIVERSAL COUPLING USING Pro/ E
Date :

AIM:
1. To create 3D models of Protected type Universal Coupling parts using Pro/E.
2. To Create the Assembly of Universal Coupling using Pro/E.

SYSTEM REQUIREMENTS:
Software: Pro/E Creo Elements
Hardware: Processor: Intel Core i3
RAM: 2 GB
HDD: 500 GB
OS – Windows XP/7/8
PROCEDURE:
1. The drawings of Flanges, Shaft, Taper key, Hexagonal Bolt and Nut are studied.
2. 3D models of Flanges, Shaft, Taper key, Hexagonal Bolt and Nut are created using
Pro/E.
3. The Assembly of Universal Coupling was created as per the drawing specification.

COMMANDS USED:

Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart Dimension, Relations, Show,
and View
Features Commands: Extrude (Pad) and Cut, Revolve (Shaft), Fillet/Round, Chamfer,
Hole - Simple, Pattern Fastening Features

Assembly Commands: Insert, Component, Existing Part/Assembly

Mating Commands: Coincident, Concentric, Distance

RESULT:

The 3D models of Protected type Universal Coupling parts (Yoke, Shaft, Flat key,
Hexagonal Bolt and Nut) are created using Pro/E.
Ex. No: 3 3D MODELING AND ASSEMBLY OF PLUMMER BLOCK USING Pro/E
Date :

AIM:
1. To create 3D models of Plummer Block parts using Pro/E.
2. To Create the Assembly of Plummer Block using Pro/E.

SYSTEM REQUIREMENTS:
Software: Pro/E Creo Elements
Hardware: Processor: Intel Core i3
RAM: 2 GB
HDD: 500 GB
OS – Windows XP/7/8

PROCEDURE:
1. The drawings of Body, Cap, Bearing top & Bottom half, Nuts and shaft are studied
2. 3D models of Body, Cap, Bearing top & Bottom half Nuts and shaft are created using
Auto CAD/CATIA.
3. The Assembly of Plummer block was created as per the drawing specification

Commands used:
Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart Dimension, Relations, and View

Features Commands: Extrude (pad) and Cut, Revolve (shaft), Fillet/Round, Chamfer, Hole -
Simple, Pattern, Fastening Features

Assembly Commands: Insert, Component, Existing Part/Assembly

Mating Commands: Coincident, Concentric, Distance

Result:
The 3D models of Plummer block parts (Body, Cap, Bearing top & Bottom half, Nuts
and shaft) are created using Pro/E.
Ex. No: 4 Simple Sheet Metal Component Modeling Using Pro/E

600
Ex. No: 4 Simple Sheet Metal Component Modeling Using Pro/E
Date :

AIM:
To create simple Sheet metal model parts using Pro/E.

SYSTEM REQUIREMENTS:
Software: Pro/E Creo Elements
Hardware: Processor: Intel Core i3
RAM: 2 GB
HDD: 500 GB
OS – Windows XP/7/8

PROCEDURE:
1. The drawings of Rectangular Funnel are studied
2. Completely and find out the front view of the given orthographic projection.
3. Create Sheet metal Blank Using Flat Wall icon with appropriate dimensions.
4. Mark the Reference line to perform Bending operation using sheet bend tool.
5. Mark the Hem edge to complete top portion of Rectangular Tray.
6. Similarly repeat the same to create Bottom of Funnel.
7. Finally the part drawing is converted into the drawing format.

Commands used:
Sketcher Commands: Line, Trim, Flat Wall, Edge Bent, Smart Dimension, Relations, and View

Features Commands:

Result:
The simple sheet metal component are created using Pro/E.
St Ex. No. B STUDY OF COMPUTER AIDED MANUFACTURING (CAM)
Date :

AIM:
To study about CNC Machines and Miscellaneous Codes, Part program in Computer
Aided Manufacturing.

CAM:
It has defined as the use of computer systems to plan, manage and control the
operations of a manufacturing plant through either direct or indirect computer interface with
the plant’s production resources.

APPLICATIONS OF CAM:
1. Computer aided monitoring and control
These are the direct applications in which the computer is connected directly to the
manufacturing process for the purpose of monitoring or controlling the process.
2. These are the indirect applications in which the computer is used in support of the
production operations in the plant, but there is no direct interface between the
computer and the manufacturing process.

BASIC COMPONENTS OF AN NC MACHINE:

An operational numerical control system consists of the following three basic
components.
i) Program of instructions iii) Machine tool
ii) Controller unit
The programs of instructions serve as the input to the controller unit, which in turn commands
the controller units, which commands the machine tool or other process to be controlled.

COMPUTER NUMERICAL CONTROL:

NC system utilizes a stored program computer to perform some or all-basic numerical
control functions.

PRINCIPLE FUNCTIONS OF CNC:

1. Machine tool control:
This involves conversion of the part program instructions into machine tool motions
through the computer interface and servo system.
2. In-process Compensation:
This involves the dynamic correction of the machine tool motions for changes or errors,
which occur during processing.
3. Improved Programming and Operating features
The flexibility of soft-wired control has permitted convenient programming and
operating feature like editing of part programs, graphic display of tool path, various
interpolations, manual data input, and storage capacity.
 4. Diagnostics
NC machine tools are complex and expensive systems. The complexity increases the risk
of component failures which load to system downtime. CNC’s are often equipped with a
diagnostic capability to consist in maintaining and repairing system.

CO-ORDINATE SYSTEM FOR A CNC LATHE:

Machining of a work piece by an NC program requires a coordinate system to be applied
to the machine tool. In programming the work piece is stationary and the tools move in the co-
ordinate system. There are three planes in which movement can take place.
i. Longitudinal
ii. Vertical
iii. Transverse
These three axes are identified by uppercase X,Y and Z and the direction movement
along each axis is specified as either plus or minus. When the tool traverses in the positive
direction, it moves away from the work piece. The z-axis is always parallel to the main spindle
of the machine. The x-axis is always parallel to the work holding surface and always at right
angles to the z-axis. The y-axis is at right angles to both z-axis and x-axis.
In turning machine the work piece is positioned within the coordinate system so that
the Z-axis coincided with the turning center line (axis of rotation) and the x and y coordinates
always have the same values. Therefore the y coordinate is not used in turning.

ZERO POINTS AND REFERENCE POINTS:

On CNC machines tool traverses are controlled by coordinating systems. Their accurate
position within the machine tool is established by Zero points.

MACHINE ZERO POINT (M):

It is specified by the manufacturer of the machine. This is the zero point for the
coordinate systems and reference points in the machine. On turning lathes, the machine zero
point is generally at the center of the spindle nose face. In milling machine, machine zero point
can be the centre of the table or a point along the edge of the traverse range, it varies
manufacturer to manufacturer.

REFERENCE POINT (R):

This point serves for calibrating and for controlling the measuring system of the slides
and tool traverses. It is determined by the trip dogs and limit switches. Therefore the reference
point coordinates always have the same, precisely known numerical value in relation the
machine zero point. After initiating the control system, the reference point must always be
approached from all axes to calibrate the traverse measuring system.

WORKPIECE ZERO POINT:

This point determines the work piece coordinate system in relation to the machine zero
point. The work piece zero point is chosen by the programmer and input into the CNC system
when setting up the machine. For turned parts, the work piece zero point should be placed
along the spindle axis. The work piece zero point is also called the Program Zero Point. For
milled parts, it is generally advisable to use an extreme corner point as the Work Piece Zero
Point in such a manner that the dimensions in the work piece drawing can be conveniently
converted into coordinate values.

TOOL REFERENCE POINT:

When machining a work piece, it is essential to control the tool cutting edges in precise
relationship to the work piece along the machining path. The tool dimensions are related to a
fixed tool setting point during pre-setting. This tool setting point is located at a certain point on
the tool holder as shown in fig. This setting point permits measuring of tool length, tool radius
are input into the tool data storage of the control system. The mate of the tool setting point is
the Socket point N on the tool carrier. When the tool or tool holder is inserted into the tool
carrier, the setting point and the tool socket point coincide.

DIMENSIONING SYSTEMS:
Dimensioning information in a work piece can be defined in two ways.

ABSOLUTE DIMENSINING SYSTEM:

Data in absolute dimension system always refer to a fixed reference point in the
drawing. This point has the function of a coordinate zero point. They are also called as
reference dimensions.
Advantages:
i. If the machine is stopped by interruptions before completing the work, the cutting tool
automatically returns to previous position and the machining proceeds from the same
block where it was interrupted.
ii. Whenever required the dimensional data can be changed easily.
iii. Absolute system is easier to check for errors.
INCREMENTAL DIMENSIONING SYSTEM:
In Incremental dimensioning system, every measurement refers to a previously
dimensioned position. It is the distance between adjacent points. They are also called as
Relative dimensions or Chain dimensions.
Advantages:
i. Mirror-image programming is facilitated with incremental systems.
ii. It is advantageous for certain individual partial contours in a work piece are repeated
several times and the associated program sections can be employed several times
without a coordinate shift.
ADVANTAGES OF CNC MACHINES:
1. The programs are entered into computer memory using some input devices, the editing
and modifying can be done in the computer itself.
2. Easy unit conversion from inches to SI units.
3. Greater flexibility in manufacturing.
4. Reduced non-productive time.
5. Immediate visual verification.
6. Improved quality control
7. They are easy to operate
8. Rapid fault elimination and program optimization.
CNC Part Programming:
The part programmer’s responsibility in computer assisted part programming consists of
two basic steps.
1. Defining the work piece geometry
2. Specifying the operation sequence and tool path.
The computer’s job:
1. Input Translation
2. Arithmetic Calculations
3. Cutter offset computation
4. Post processor
The part programmer enters the program written in the APT or other languages. The
input translation component converts the coded instructions contained in the program into
computer usable form, preparatory to further processing.
The arithmetic calculations unit of the system consists of a comprehensive set of
subroutines for solving the mathematics required to generate the part surface. These
subroutines are called by the various part programming language statements. The arithmetic
unit is really the fundamental element in the part programming package. This unit frees the
programmer from the time consuming geometry and trigonometry calculations, to concentrate
on the work part processing.
The preprocessor is a separate computer program that has been written.
The input to the postprocessor is a series of cutter locations and other instructions.

PROGRAM CODES:
Part programs are initially entered into a CNC system and are stored in computer
memory. The programs are fed into the system in the form of codes. It is then converted into
mechanical motion. The two types of codes generally used are
i. Preparatory codes (G – codes)
ii. Miscellaneous codes (M – codes)
Preparatory Codes: (G – Codes)
The codes are used for feed movement and operations. They are generally used to
specify dimensions, feed of tool, tool path etc.
Miscellaneous Codes: (M – Codes)
They are mainly sued to perform operations such as spindle ON/OFF, Coolant ON/OFF,
Chuck Close/Open, program stop etc.
CNC TURNING
G – CODES:
G00 Fast Traverse G42 Compensate Right G81 Drilling Cycle
G01 Linear G50 Clamp Spindle G90 Turning Cycle
G02 Clockwise Arc G50 Coordinate Setting G92 Threading Cycle
G03 Counter Clockwise Arc G70 Finishing Cycle G94 Facing cycle
G04 Dwell G71 Multiple Turning G96 Constant Surface
G20 Imperial G72 Multiple Facing G97 Variable Surface
G21 Metric G73 Pattern Facing G98 Feed Per Minute
G28 Go to Reference G74 Peck Drilling G99 Feed Per Revolution
G40 Cancel Compensation G75 Diameter Drilling
G41 Compensate Left G76 Multiple Thread
M CODES:
M00 Program Stop M09 Coolant Off M62 Output 1 On
M01 Optional Stop M10 Chuck Open M64 Output 1 Off
M02 Program End M11 Chuck Close M66 Wait Input 1 On
M03 Spindle Forward M25 Quill Extend M76 Wait Input 1 Off
M04 Spindle Reverse M26 Quill Retract M98 Subprogram Call
M05 Spindle Stop M30 Program End M99 Subprogram Exit
M06 Tool Change M38 Door Open
M08 Coolant On M39 Door Close
CNC MILLING
G – CODES:
G00 Fast Traverse G42 Right Tool Comp G87 Back Boring
G01 Linear Traverse G73 Fast Peck Drilling G89 Boring
G02 Clockwise Arc G74 Counter Tapping G90 Absolute
G03 Counter Clockwise Arc G76 Fine Boring G91 Incremental
G04 Dwell G80 Cancel Cycle G92 Set Datum
G20 Imperial Units G81 Spot Boring G94 Per Minute Feed
G21 Metric Units G82 Counter Boring G95 Per Revolution Feed
G28 Go to Reference G83 Peck Drilling G98 Initial Level Return
G40 Cancel Tool Comp G84 Tapping G99 R Point Return
G41 Left Tool Comp G85 Boring
MCODES:
M00 Program Stop M71 Y Mirror On
M02 End of Program M76 Wait Aux 1/2 low
M03 Spindle Forward M77 Wait Aux 1/2 low
M04 Spindle Reverse M80 X Mirror Off
M05 Spindle Stop M81 Y Mirror Off
M06 Tool Change M98 Subprogram Call
M08 Coolant On M99 Subprogram Exit
M09 Coolant Off
M10 Work Clamp
M11 Work Clamp
M13 Coolant, Spindle Fwd
M14 Coolant, Spindle Rev
M19 Orientate Spindle
M20 ATC Arm In/Out
M21 ATC Arm In/Out
M22 ATC Arm Down/Up
M23 ATC Arm Down/Up
M24 ATC Arm Clamping
M25 ATC Arm Clamping
M27 Reset Carousel
M32 ATC Clw/Cclw
M33 ATC Clw/Cclw
M62 Aux 1/2 On
M64 Aux 1/2 Off
M66 Wait Aux 1/2
M67 Wait Aux 1/2
M70 X Mirror On
PROVING PART PROGRAMS:
It is a safe practice to check the programmed path for any interference between the tool
and the work before using the part program for production. This process is known as proving
part program is done in several ways:
1. Visual Inspections:
It represents the method of checking visually the program present in the memory of the
CNC machine. In this, actual program is run and the programmed movements in all axes
are to be checked along with ensuring the tool offset and cutter compensation feature.
2. Single Step Execution:
Before auto-running the part program should be executed in a single step mode. During
this execution, spindle speed and feed rate override facilities are to be used so that the
axes movement can be easily monitored.
3. Dry run:
A dry run consists of running the part program in auto mode. The purpose of this run is
to verify the programmed path of the tool under continuous operation and to check
whether adequate clearance exists between the clamping arrangement and other
projections within the set up.
4. Graphical Simulation:
A graphical simulation package emulates the machine tool and using computer graphics,
plots out the machine movement on a VDU screen. Any deviations from the intended
tool path can be observed and any potential interference can be highlighted.

CONCLUSION:
Thus, the Study of CNC Machines and Miscellaneous Codes, Part program in Computer
Aided Manufacturing were studied.
Ex. No: 5 SIMPLE FACING AND TURNING OPERATION USING CNC LATHE.

22 mm
46 mm

Billet Size: φ 28 x 46mm

Ex. No: 5 SIMPLE FACING AND TURNING OPERATION USING CNC LATHE.
Date :

AIM: To write a program to facing operation on the given work piece and simulate the same
Using Cut Viewer CNC Lathe Simulator.

ALGORITHM:
1. Check the work piece for given dimensions.
2. Input in mm and feed rates are given.
3. Move the tool to feed rates are given.
4. Move the tool to home position.
5. Change the tool for the type of operation.
6. Spindle speed is given.
7. To make the facing and turning operation on the given work piece from X45 Z – 50 to
X18 Z -45 Return to the home position.
8. End the program.

PROGRAM:
M06 T03 Z-2 Z-45
M03 S1200 G00 X26 X26
G00 X26 Z1 G01 Z-4 Z1
G01 Z-1 X0 X24
X0 Z-3 G01 Z-45
Z0 G00 X26 X25
G00 X26 G01 Z-5 G00 Z1
G01 Z-2 X0 X23
X0 Z-4 G01 Z-45
Z-1 G00 X26 X24
G00 X26 G01 Z-3 G00 Z1
G01 Z-3 G00 X26 X22
X0 G01 X25 F35 G01 Z-45
X23 G01 Z-45 M05
G01 Z1 X22 M30
X21 G00 Z1

RESULT:
Thus the Facing, Turning program was written and the facing, turning operation virtual
simulation was performed using Cut Viewer CNC Lathe Simulator Software.
Ex.No: 6 MULTIPLE TURNING CYCLES OPERATION USING CNC LATHE.
Ex. No: 6 MULTIPLE TURNING CYCLES OPERATION USING CNC LATHE.
Date :

AIM: To write a program to perform multiple turning cycle operation on the work piece and
simulate the same using CNC Lathe Machine.
MATERIAL REQUIRED:
Material : ALUMINIUM ROUND BAR
Size : Length 100mm, DIA 25mm

ALGORITHM:
1. Check the work piece for given dimensions.
2. Input in mm and feed rates are given.
3. Move the tool to feed rates are given.
4. Move the tool to home position.
5. Change the tool for the type of operation.
6. Spindle speed is given.
7. To make the multiple turning cycles on the given work piece size X25, Z –100 Return to
the home position.
8. End the program.

PROGRAM:
(TOOL/STANDARD, 5, 80, 0, 4.5, 0) G01 Z0
M06 T02 G03 X10 Z-5 R5
(STOCK/100,20.001,0,0) G01 Z-15
M03 S1200 G01 X15 Z-20
G00 X22 Z1 G01 Z-28
G71 U1. R1. N20 G01 X20
G71 P10 Q20 U1 W1 F15 M05
N10 G01 X0 M30

RESULT:
Thus the program was written for performing the Multiple Turning cycle simulation
using Cut Viewer CNC Lathe Simulator and executed the same on work piece using CNC LATHE
Machine.
Ex.No: 7 MULTIPLE FACING CYCLE OPERATION USING CNC LATHE.
Ex. No: 7 MULTIPLE FACING CYCLE OPERATION USIN CNC LATHE.
Date :
AIM: To write a part program for performing Grooving operation and simulate the same using
Cut Viewer CNC Lathe Simulator

MATERIAL REQUIRED:
Material : ALUMINIUM ROUND BAR
Size : Length 100mm, DIA 25mm
ALGORITHM:
1. Check the work piece for given dimensions.
2. Input in mm and feed rates are given.
3. Move the tool to feed rates are given.
4. Move the tool to home position.
5. Change the tool for the type of operation.
6. Spindle speed is given.
7. To make the facing operation on the given work piece from X45 Z – 50 to X45 Z -45
Return to the home position.
8. End the program.

PROGRAM:
(TOOL/STANDARD,5,60,0,4.0,0) N08 G00 Z-29.0 S150 ;
(STOCK/90,30,0,0) N09 G01 X25.0 W5.0 F100;
N01 G00 G96 G98; N10 W8.;
N02 G28 U0 W0; N11 G02 X20.0 W3.0 R3.0;
N03 T0101; N12 G03 X17.0 W3.0 R3.0;
N04 M03 S100; N13 W5.;
N05 X30. Z2.; N14 X14. W5. ;
N06 G72 W1.0 R1.0; N15 G28 U0 W0 M5;
N07 G72 P08 Q14 U2.0 W1.0 F100 N16 M30;

RESULT:
Thus the program for Multiple Facing Cycle operation was written and simulated
successfully using Cut Viewer CNC Lathe Simulator.
Ex. No: 8 CANNED CYCLE STEP TURNING OPERATION USING CNC LATHE

φ 25 φ 18 φ 12

15
30
50

BILLET SIZE: φ 45 X 50
All dimensions are in MM
Ex. No: 8 CANNED CYCLE STEP TURNING OPERATION USING CNC LATHE
Date :
AIM:
To write a part program for the given work to perform Canned Cycle Step Turning
operation and Execute the same using FANUC CNC LATHE.
ALGORITHM:
1. Check the work piece for given dimensions.
2. Input in mm and feed rates are given.
3. Move the tool to feed rates are given.
4. Move the tool to home position.
5. Change the tool for the type of operation.
6. Spindle speed is given.
7. To make the facing operation on the given work piece from X45 Z – 50 to X45 Z -45
Return to the home position.
8. End the program.
PROGRAM:

MO3 S2000 X18

GOO X26 Z1 G90 X18 Z-15 F100
G90 X25 Z-30 F100 X17
X24 X16
X23 X15
X22 X14
X21 X13
X20 X12
X19 M30

RESULT:
Thus the program was written for performing canned Cycle Step Turning operation and
practiced using CNC LATHE.
Ex.No: 9 SIMPLE CONTOUR MILLING OPERATION USING CNC MILLING
Ex. No: 9 SIMPLE CONTOUR MILLING OPERATION USING CNC MILLING
Date :
AIM:
To write a program to perform simple contour milling operation on the work piece and
simulate the same using CNC Milling Machine.
ALGORITHM:
1. Start the program.
2. Define the work piece.
3. Set the datum for the work piece.
4. Define the tool with dia. of 5mm.
5. Set the unit in metric
6. Feed in mm/min
7. Move the tool in the position X = 22.5 and Y= 37.5
8. By using G03 command (Circular Interpolation in Anticlockwise) to do radius of 15mm.
9. Move the tool in the position of X 22.5 and Y-37.5
10. Return the tool to the original position
11. End of the program.
PROGRAM:
M03 S1000
M06 T1
G00 X60 Y60 Z5
G90 G00 X0 Y-37.5 Z5
G01 Z-2
G01 X-22.5 Y-37.5
G03 X-37.5 Y-22.5 R15
G01 X-37.5 Y22.5
G02 X-22.5 Y37.5 R15
G01 X22.5 Y37.5
G03 X37.5 Y22.5 R15
G01 X37.5 Y-22.5
G02 X22.5 Y-37.5 R15
G01 X0 Y-37.5
G01 Z5
G00 X60 Y60 Z5
M05
M30
RESULT:
Thus the program was written for performing the simple contour milling simulation
using Cut Viewer CNC Mill Simulator and executed the same on work piece using CNC Mill
Machine.
Ex.No: 10 MIRRORING OPERATION USING CNC MILLING

BILLET SIZE: 100 X 100 X 10

DEPTH OF CUT: 1 mm
TOOL DIAMETER: 5 mm
All dimensions are in mm
Ex. No: 10 MIRRORING OPERATION USING CNC MILLING
Date:

AIM:
To write a part program for the given design to perform Mirroring operation and
simulate the same using Cut Viewer CNC Mill Simulator
ALGORITHM:
1. Start the program
2. Define the work piece
3. Set the datum for the work piece
4. Define the tool with dia 5mm
5. Set the limit in metric
6. Feed in mm/min
7. By using G01 (linear interpolation) command to form the sub program
8. By using M98 command to mirror the operation with respect to x-axis
9. Return the tool to the home position
10. End the program

PROGRAM:
M03 S2500 O123
(STOCK/BLOCK,100,100,10,50,50,10) (TOOL/MILL,5,0,25,0)
M98 P123 (COLOR,255,255,255)
M21 G00 Z5
M98 P123 X5
M22 Y5
M98 P123 G01 Z-1 F40
M23 M22 X20
M98 P123 G01 X5 Y20
G00 Z5 G01 Y5
M30 G00 Z5
M99

RESULT:
Thus the program for mirroring operation was written and simulated successfully using
Cut Viewer CNC Mill Simulator.
St Ex. No. C STUDIES ABOUT MULTIAXIS CNC MACHINE EDM, EDM WIRE
CUT AND RAPID PROTOTYPING
Date:

AIM:
To study about Multiaxis CNC Machine, EDM, EDM Wire Cut and Rapid Prototyping.

MULTIAXIS CNC MACHINE

Multiaxis Machining is a manufacturing process, where computer numerically controlled
tools that move in 4 or more ways are used to manufacture parts out of metal or other
materials by milling away excess material, by water jet cutting or by laser cutting. Typical CNC
tools support translation in 3 axes; multiaxis machines also support rotation around one or
multiple axes.
There are now many CAM software systems
available to support multiaxis machining including
software that can automatically convert 3-axes tool
paths into 5-axes tool paths.
Multiaxis machines offer several improvements
over other CNC tools at the cost of increased complexity
and price of the machine:
• Amount of work is reduced, if the piece
would otherwise have to be turned
manually during the machining.
• Better surface finish can be obtained by
moving the tool tangentially about the
surface.
• More complex parts can be
manufactured, particularly parts with
curved holes.
Number of axes for Multiaxis machines varies from 4 to 9 Each axis of movement is
implemented either by moving the table (into which the work piece is attached), or by moving
the tool. The actual configuration of axes varies; therefore machines with the same number of
axes can differ in the movements that can be performed.
ELECTRICAL DISCHARGE MACHINING
1. Introduction
Electro Discharge Machining (EDM) is an electro-thermal non-traditional machining
process, where electrical energy is used to generate electrical spark and material removal
mainly occurs due to thermal energy of the spark. EDM is mainly used to machine difficult-to-
machine materials and high strength temperature resistant alloys. EDM can be used to machine
difficult geometries in small batches or even on job-shop basis. Work material to be machined
by EDM has to be electrically conductive.
2. Process

Schematic representation of the basic working principle of EDM process.

The material removal in EDM mainly occurs due to formation of shock waves as the
plasma channel collapse owing to discontinuation of applied potential difference. Generally
the work piece is made positive and the tool negative. Hence, the electrons strike the job
leading to crater formation due to high temperature and melting and material removal.
Similarly, the positive ions impinge on the tool leading to tool wear.
In EDM, the generator is used to apply voltage pulses between the tool and the job. A
constant voltage is not applied. Only sparking is desired in EDM rather than arcing. Arcing
leads to localized material removal at a particular point whereas sparks get distributed all
over the tool surface leading to uniformly distributed material removal under the tool.
4. Characteristics of EDM
(a) The process can be used to machine any work material if it is electrically conductive
(b) Material removal depends on mainly thermal properties of the work material rather
than its strength, hardness etc
(c) In EDM there is a physical tool and geometry of the tool is the positive impression of
the hole or geometric feature machined
(d) The tool has to be electrically conductive as well. The tool wear once again depends
on the thermal properties of the tool material
(e) Though the local temperature rise is rather high, still due to very small pulse on time,
there is not enough time for the heat to diffuse and thus almost no increase in bulk
temperature takes place. Thus the heat affected zone is limited to 2 – 4 μm of the
spark crater
5. Dielectric
In EDM, as has been discussed earlier, material removal mainly occurs due to thermal
evaporation and melting. As thermal processing is required to be carried out in absence of
oxygen so that the process can be controlled and oxidation avoided. Oxidation often leads to
poor surface conductivity (electrical) of the work piece hindering further machining. Hence,
dielectric fluid should provide an oxygen free machining environment. Further it should have
enough strong dielectric resistance so that it does not breakdown electrically too easily but at
the same time ionise when electrons collide with its molecule. Moreover, during sparking it
should be thermally resistant as well. Generally kerosene and deionizer water is used as
dielectric fluid in EDM. Tap water cannot be used as it ionizes too early and thus breakdown
due to presence of salts as impurities occur.
6. Electrode Material
Electrode material should be such that it would not undergo much tool wear when it is
impinged by positive ions. Thus the localized temperature rise has to be less by tailoring or
properly choosing its properties or even when temperature increases, there would be less
melting. Further, the tool should be easily workable as intricate shaped geometric features are
machined in EDM.
The followings are the different electrode materials which are used commonly in the
industry: •Graphite • Electrolytic oxygen free copper • Tellurium copper • Brass

WIRE CUT EDM

Wire EDM is an ultra-precise method to cut
virtually any electrically conductive material,
regardless of alloy or hardness.
A thin wire is rapidly charged to a voltage.
When the voltage reaches a certain level, a spark
jumps the gap to the part, and melts a tiny bit of
material. This "spark erosion" happens
continuously, and appears to the eye as being a
steady "burning away" of material. The entire
process typically happens while submerged in
very pure, deionizer, temperature-controlled
water.
This water is what continually flushes away
microscopic particles of removed material. There
is no physical contact between the wire and the
part being machined, so there are no cutting
forces as in other methods of machining. The wire
is "continuous", and constantly fed from a large spool. It passes through the work area (the
part) and is discarded out the back of the machine. The wire is not consumed or "burned up" as
it passes through the area where the "spark erosion" occurs, however wire is never re-used.
Wire diameters range from .0008"-.013" although .004" to .012" is the range most typically
used. Wire can be anything from plain brass to coated brass or copper, to molly, or even pure
tungsten.
The hardness of the work piece material has no adverse effect on the cutting speed, and
cutting parts after heat treating is quite common and often desirable. A modern Wire EDM
machine has 4 independent axes of movement. The position of the wire guides can be
independently and precisely controlled both above and below the part which allows "tipping"
of the wire in any direction. The 2 axes "below" the part are known as X/Y, and the 2 axes
"above" the part are known as U/V. The U and V axis are actually "differential" axis in that
moving X/Y moves the entire wire while keeping it vertical, while moving U and/or V moves the
top of the wire relative to X/Y. This allows the cutting of tapered parts, as well as other very
complex shapes. The only limitation is that the wire must be able to pass through or by the
work piece.
RAPID PROTOTYPING
DEFINITION:
The general definition of the prototype contains three aspects of interests
• The implementation of the prototype; from the entire product (or system) itself to
its sub-assemblies and components,
• The form of the prototype; from a virtual prototype to a physical prototype, and
• The degree of the approximation of the prototype; from a very rough
representation to an exact replication of the product.

TYPES OF RAPID PROTOTYPING

• Stereo lithography Apparatus(SLA) • Selective Laser Sintering (SLS)
• Fused Deposition Modeling (FDM) • Three Dimensional Printing (3DP)

ROLES OF THE PROTOTYPE:

• Experimentation and learning • Synthesis and integration
• Testing and proofing • Scheduling and markers
• Communication and interaction

STEREO LITHOGRAPHY PROCESS:

Stereo lithography Process

The process begins with a vat of photo curable resin. The part is sequentially built layer
by layer as it is incrementally lowered while setting on an elevator table. The laser is computer
driven by a CAD generated solid model converted to a still file representing cross-sectional
slices of the solid model. As each layer is photo cured by the moving laser, the elevator table
drops enough to cover the surface with a new layer of resin. A wiper is used to level the resin
between cycles and control the thickness and uniformity. The process continues until the part is
complete. To accelerate part generation, each layer is only partially cured during processing
and the final part post cured by exposure to higher dosage ultraviolet (UV) light or heat. A
number of variants of this general process exist. Key advantages of this process are its low cost
and high level of maturity.

CONCLUSION:
Thus, the Multiaxis CNC Machine, EDM, EDM Wire Cut and Rapid Prototyping ware
studied successfully.