COMPLEX ENGINEERING PROBLEM

Computer Aided Manufacturing (IM-402)

Submitted to: Dr. Maqsood Ahmed Khan

Prepared By:
Rouhan Ahmed Khan (IM-18075)
Syeda Hafza Jamil (IM-18046)
Usama Saif (IM-18066)
Syeda Zainab Haider (IM-18066)
Contents
Abstract ......................................................................................................................................................... 3
Project Scope ................................................................................................................................................ 4
Software and Workbench: ............................................................................................................................ 4
Tools .............................................................................................................................................................. 5
HSS Flat End Mills ...................................................................................................................................... 5
Limitations ................................................................................................................................................ 5
Drill Bits ..................................................................................................................................................... 5
CAD Modelling: ............................................................................................................................................. 6
Drawing of Given Part ............................................................................................................................... 6
Raw Material ............................................................................................................................................. 7
Step 1: ................................................................................................................................................... 8
Step 2: ................................................................................................................................................... 8
Step 3: ................................................................................................................................................... 9
Step 4: ................................................................................................................................................... 9
Step 5: ................................................................................................................................................. 10
Finished Part ....................................................................................................................................... 10
Part Machining ............................................................................................................................................ 11
Process Plan ............................................................................................................................................ 11
Part Operation 1 ..................................................................................................................................... 12
T1 End Mill D10 (Prismatic Roughing) ................................................................................................. 12
Step 1: ................................................................................................................................................. 12
Step 2: ................................................................................................................................................. 13
Step 3: ................................................................................................................................................. 15
G & M Codes: .......................................................................................................................................... 15
T3 Counter Bore Mill D20 (Counter Boring)............................................................................................ 17
Step 1 .................................................................................................................................................. 17
Step 2: ................................................................................................................................................. 18
G & M codes:........................................................................................................................................... 19
T2 End Mill D10 (Advanced Finishing) .................................................................................................... 19
Step 1: ................................................................................................................................................. 19
Step 2: ................................................................................................................................................ 21
G & M codes:........................................................................................................................................... 22
 T4 Drill D10 (Drilling 1) ............................................................................................................................ 23
Step 1: ................................................................................................................................................. 23
Step 2: ................................................................................................................................................. 25
G & M codes:........................................................................................................................................... 26
T4 Drill D10 (Drilling 2) ............................................................................................................................ 26
Step 1: ................................................................................................................................................. 26
Step 2: ................................................................................................................................................. 27
G & M codes:........................................................................................................................................... 28
Part Operation 2 ..................................................................................................................................... 28
Step 1: ................................................................................................................................................. 28
Step 2: ................................................................................................................................................. 29
G & M codes:........................................................................................................................................... 31
Difficulties Faced During the Project: ......................................................................................................... 32
Benefits of the Project ................................................................................................................................ 32
Alternate Methods ...................................................................................................................................... 32
 Abstract

This project is based on CEP (Complex Engineering Problem) and it aims to engage students in the
analysis of real-world problems that involve students in design, problem solving, decision-making, or
investigative activities. In this project, we integrated the CAD and CAM techniques in such manner that
we first design our part in CATIA software and then performed computer aided manufacturing by using
CATIA software. The tools were selected according to the suitable process of machining and the
parameters were set according to the standards of the workpiece material and simulations were run on
CATIA to visualize the process. NC codes were also created to understand the part programming system.
Project Scope
In this project, we performed CAD and CAM processes on the given part by using CATIA V5 software.

Work Piece Material Aluminum

Tool Used HSS Flat End Mill
HSS Drill
Cutting Parameters (Milling) Feed Rate (500mm/min)
Speed (5000 rpm)
Cutting Parameters (Drilling) Feed Rate (0.6mm/min)
Speed (4000 rpm)

Software and Workbench:

Workbench used for CAD model generation is Part Design.

Workbench used for tool path generation is Prismatic Machining.

Tools
HSS Flat End Mills
HSS Flat End Mills manufactured by RIGPL are in M2 (SKH51), M35 (SKH55) materials

Features

M42 material HSS Flat End Mills also manufactured on special request,

All HSS End Mills have 30* helical flutes and unmatched hardness to provide longer tool life,

Sharper cutting edges of HSS End Mills provide longer life,

These end mills comes with 4Flute & 6Flute (for bigger diameter)

All in-house heat treatment equipment enables RIGPL to provide better hardness & microstructure
control of these end mills.

Limitations
These end mills are not CNC manufactured, however they possess good quality to achieve suitable
productivity,

For Higher Productivity use our Carbide Flat End Mills [To start with you can go for C101 or C110 Series]

For Better Life & higher productivity you can always request for HSS M42 & Powder Metallurgy Grade
CNC manufactured HSS End Mills

Drill Bits
HSS bits are hardwearing and heat resistant. The large concentrations of chrome and nickel in stainless
steel ensure that HSS bits are super strong and durable. HSS drill bits are capable of safely drilling
through hardwood, some metals and plastic. They are safe to operate at high speeds (RPM) and provide
long-lasting performance – as long as they are maintained.

Over time, HSS drill bits can become blunt and need to be sharpened, which demands specialist tools
that are not always available. If you are using HSS drill bits for long periods or at high RPMs, you may
need to use cutting fluid to keep the bit cool.
CAD Modelling:
Drawing of Given Part
Raw Material
We used aluminum as the working raw material for the project as the tools and stock was readily
available for machining at CAD/CAM Lab.
Step 1: Create a sketch on x-y plane by drawing corner circles of D30mm and center circle of D50mm
and connecting them with tangent and pad up to 10mm

Step 2: Create a sketch on x-y plane by drawing center circle of D50mm and pad up to 28mm
Step 3: Create a sketch on x-y plane by drawing corner circle of D12mm and pocket down to 10mm

Step 4: Create a counter bore on x-y plane by drawing corner circle of D30mm, inner circle of D20mm
with a bore depth of 6mm
Step 5: Create a sketch on x-z plane by drawing circle of D6mm and pocket both sides 29mm

Finished Part
Part Machining
Process Plan

Step Description Process Tool Fixture Machine

1 Selection of Sizing 3-Axis Milling
Stock Machine
Size
100X60X38
2 Create the End Milling T1 End Mill Vice 3-Axis Milling
basic part D10 Machine
profile
3 Create the Counter T3 Counter Vice 3-Axis Milling
counter bore Boring bore Mill D20 Machine
hole in the
center
4 Finishing the Finished Cut T2 End Mill Vice 3-Axis Milling
base part D10 Machine
5 Create the Drilling T4 Drill D10 Vice 3-Axis Milling
side holes Machine
6 Drill through Drilling T2 Drill D10 Vice 3-Axis Milling
hole of D6mm Machine
on x-y plane
Part Operation 1

T1 End Mill D10 (Prismatic Roughing)

Step 1: Setting part operation features.

Step 2: Select Prismatic Roughing and setting its parameters.
Step 3: Simulation

G & M Codes:
%
O1000
(
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( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
* )
( * IMSPOST VERSION : 7.4R
* )
( * USER VERSION : 1
* )
(
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N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T1 END MILL D 1 )
N2 T0001 M6
N3 X36.769 Y-5.51 S5000 M3
N4 G43 Z15. H1
N5 G1 G94 Z5. F300.
N6 Z-5.
N7 Y0
N8 X0 F500.
N9 Y40.704
N10 X.593 Y39.607
N11 X.658 Y39.493
N12 X1.442 Y38.209
N13 X1.514 Y38.098
N14 X2.365 Y36.857
N15 X2.442 Y36.75
N16 X3.357 Y35.556
N17 X3.44 Y35.453
N18 X4.417 Y34.309
N19 X4.506 Y34.21
N20 X5.541 Y33.119
-

-
N2845 X3.596 Y71.134 Z-28.607
N2846 X3.484 Y70.76 Z-28.712
N2847 X3.676 Y70.634 Z-28.773
N2848 X3.771 Y70.786 Z-28.821
N2849 X3.908 Y70.98 Z-28.885
N2850 X4.008 Y71.134 Z-28.934
N2851 X3.845 Y71.265 Z-28.99
N2852 X3.681 Y71.396 F500.
N2853 X3.596 Y71.134
N2854 X3.484 Y70.76
N2855 X3.676 Y70.634
N2856 X3.771 Y70.786
N2857 X3.908 Y70.98
N2858 X4.008 Y71.134
N2859 X3.845 Y71.265
N2860 X3.758 Y71.31 Z-28.964
N2861 X3.661 Y71.318 Z-28.938
N2862 Z-18.938 F1000.
N2863 Z-8.938
N2864 G0 Z1.02
N2865 M30
%
T3 Counter Bore Mill D20 (Counter Boring)
Step 1: Select Counter Boring and setting its parameters.
Step 2: Simulation
G & M codes:
%
O1000
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( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
* )
( * IMSPOST VERSION : 7.4R
* )
( * USER VERSION : 1
* )
(
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N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T3 COUNTERBORE MILL D 2 )
N2 T0003 M6
N3 X27.5 Y55. S5000 M3
N4 G43 Z17. H3
N5 Z0
N6 M30
%

T2 End Mill D10 (Advanced Finishing)

Step 1: Select Advanced finishing and setting its parameters.
Step 2: Situation
G & M codes:
%
O1000
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( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
* )
( * IMSPOST VERSION : 7.4R
* )
( * USER VERSION : 1
* )
(
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N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T2 END MILL D 1 )
N2 T0002 M6
N3 X-1.358 Y49.421 S5000 M3
N4 G43 Z-.8 H2
N5 Z-4.8
N6 G1 G94 Z-6. F300.
N7 X.038 Y48.452
N8 X.265 Y48.516
N9 X.474 Y48.623
N10 X.659 Y48.769
N11 X.811 Y48.948
N12 X.926 Y49.154
N13 X.998 Y49.378
N14 X1.025 Y49.611
N15 X1.006 Y49.846
N16 X.833 Y50.803 F1.
N17 X.655 Y52.129
N18 X.551 Y53.382
N19 X.539 Y53.56
N20 X.502 Y54.89
-

-
N4590 X29.294 Y57.387
N4591 X29.674 Y57.044
N4592 X29.846 Y56.85
N4593 X29.999 Y56.634
N4594 X30.237 Y56.193
N4595 X30.398 Y55.711
N4596 X30.453 Y55.451
N4597 X30.48 Y55.198
N4598 X30.502 Y54.991 Z-22.978 F1000.
N4599 X30.523 Y54.791 Z-22.92
N4600 X30.543 Y54.604 Z-22.829
N4601 X30.562 Y54.436 Z-22.706
N4602 X30.577 Y54.292 Z-22.555
N4603 X30.589 Y54.175 Z-22.382
N4604 X30.598 Y54.091 Z-22.191
N4605 X30.604 Y54.04 Z-21.988
N4606 X30.605 Y54.026 Z-21.779
N4607 Z-20.579
N4608 Z-19.379
N4609 G0 Z2.
N4610 M30
%

T4 Drill D10 (Drilling 1)

Step 1: Select drilling and setting its parameters

.
Step 2: Simulation
G & M codes:
%
O1000
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)
( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
* )
( * IMSPOST VERSION : 7.4R
* )
( * USER VERSION : 1
* )
(
**********************************************************************
)
N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T4 DRILL D 1 )
N2 T0004 M6
N3 X27.5 Y90. S5000 M3
N4 G43 Z1. H4
N5 Z0
N6 M30
%

T4 Drill D10 (Drilling 2)

Step 1: Select drilling and setting its parameters.
Step 2: Simulation
G & M codes:
%
O1000
(
**********************************************************************
)
( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM
* )
( * IMSPOST VERSION : 7.4R
* )
( * USER VERSION : 1
* )
(
**********************************************************************
)
N1 G49 G64 G17 G80 G0 G90 G40 G99
( TOOL DATA : T4 DRILL D 1 )
N2 T0004 M6
N3 X27.5 Y20. S5000 M3
N4 G43 Z1. H4
N5 Z0
N6 M30
%

Part Operation 2
Step 1: Setting part operation features.
Step 2: Select Drilling and setting its parameters.
G & M codes:
%

O1000

( ********************************************************************** )

( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS-SOFTWARE.COM *)

( * IMSPOST VERSION : 7.4R *)

( * USER VERSION : 1 *)

( ********************************************************************** )

N1 G49 G64 G17 G80 G0 G90 G40 G99

( TOOL DATA : T1 DRILL D 1 )

N2 T0001 M6

N3 Y16. S70 M3

N4 G43 Z26. H1
N5 Z25.

N6 G94 F100.

N7 M30

Difficulties Faced During the Project:

 Face selection during the machining operation.

 Tool origin selection.

 Tool selection.

 Tool parameters

 Retract and approach of tool

 Axis of tools

 Selection of machining parameters

Benefits of the Project

 Solving complex engineering problems.

 Use of CATIA software and its prismatic workbench for CAM.

 Use of CATIA for generation of apt and g code.

 Tools and machine operations parameters.

 Tool path simulation.

 Features identification.

Alternate Methods
 Machine other than 3 axis can be used.

 Operation sequence can be changed. (drill will be before bore)

 Operations can be altered.

 Tool parameters can be changed.