CIM LAB Manual - 2021

CIM & AUTOMATION LABORATORY MANUAL
BANGALORE INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING
COMPUTER INTEGRATED MANUFACTURING LAB
1 Department of Mechanical Engineering, Bangalore Institute of Technology


Vision
To establish and develop the Institute as a centre of higher learning, ever
abreast with expanding horizon of knowledge in the field of engineering and
technology, with entrepreneurial thinking, leadership excellence for life-long
success and solve societal problem.
Mission
 Provide high quality education in the engineering disciplines from the
undergraduate through doctoral levels with creative academic and
professional programs.
 Develop the Institute as a leader in Science, Engineering, Technology and
management, Research and apply knowledge for the benefit of society.
 Establish mutual beneficial partnerships with industry, alumni, local, state
and central governments by public service assistance and collaborative
research.
 Inculcate personality development through sports, cultural and
extracurricular activities and engage in the social, economic and
professional challenges.
Long Term Goals
 To be among top 3 private engineering colleges in karnataka and top 20 in
India.
 To be the most preferred choice of students and faculty.
 To be the preferred partner of corporate.
 To provide knowledge through education and research in engineering.
 To develop in each student mastery of fundamentals, versatility of mind,
motivation for learning, intellectual discipline and self-reliance which
provide the best foundation for continuing professional achievement.
 To provide a liberal; as well as a professional education so that each student
acquires a respect for moral values, a sense of their duties as a citizen, a
feeling for taste and style, and a better human understanding.

DEPARTMENT OF MECHANICAL ENGINEERING

VISION STATEMENT
Transform Students to Broadly Educated, Talented and Competent Mechanical Engineers
MISSION
 Create an Environment as a Center of Learning.
 Train the Staff to Ensure the Student get an Excellent Education at par with Latest
Technology.
 Provide an Effective Means of Learning, Advance Knowledge and Facilitates
Personal Commitment to the Educational Success of Students
 Preparing the Students for a Productive Careers Globally.
 Inspire Hope and Contribute to Society by Providing the Best Practices.
 Prepares the Students for Research and Advanced Problem Solving Technique
Needed to Address Complex Mechanical Engineering Problems
 Educate Students to become Highly Successful Alumni who Contribute to the
Profession in the Global Society
PROGRAM EDUCATIONAL OBJECTIVIES (PEO’s)

By the End of Four Years, Majority of our Students would have Completed Under Graduate
Program, Advancing in Leadership Carrier in Industry, R & D Establishment,
Government/Public Sector, or Pursuing Higher Education or Entrepreneurial ventures.
Students of Bachelor of Engineering (B.E) in Mechanical Engineering at Bangalore Institute

of Technology has the following Program Educational Objectives (PEOs)
PROGRAM EDUCATIONAL OBJECTIVIES (PEO’s)

The Educational Objectives of UG Program in Mechanical Engineering are:
MEPEO1: To Prepare the Students for Successful Professional Careers with Strong
Fundamental Knowledge in Science, Mathematics, English, Engineering and Technology so
as to Enable them to Analyze the Mechanical Engineering Related Problems. (Preparation).
MEPEO2: To Develop Ability among the Students for Acquiring Technical Knowledge in
Specialized Areas of Mechanical Engineering such as Materials, Design, Manufacturing and
Thermal Engineering and Gaining the Technical Skills in Classical Software Packages (Core
Competence and Professionalism).
MEPEO3: To Provide Opportunities for the Students to Work with Multidiscipline Field of
Engineering so as to Enlarge the Ability Among the Students to Understand the Different
Industrial Environments (Breadth).
MEPEO4: To Promote the Students for Continuous Learning, Research and Development
with Strong Professional, Moral and Ethical Values and Zeal for Life-Long learning.
(Learning Environment)

PROGRAM OUTCOMES [PO`s]

Students after successful completion of the course Engineering Graduates will be able
to:
PO1. Engineering Knowledge: Apply basic knowledge of science, mathematics and
engineering fundamentals in the field of Mechanical Engineering to the solution of complex
engineering problems
PO2. Problem Analysis: Identify, formulate, review research literature and analyze complex
mechanical engineering problems by using basics principles of science, mathematics and
engineering for reaching substantiated conclusions.
PO3. Design/Development of Solutions: Design solution for complex mechanical
engineering problems and design system components or processes that meet specified needs
with appropriate consideration for the public health and safety, and the cultural, societal, and
environmental considerations.
PO4. Conduct Investigations of Complex Problems: Design and conduct experiments
using research-based knowledge and methods including design of experiments, analyze,
interpret the data, and synthesis of the information to provide the results with valid
conclusion.
PO5. Modern Tool Usage: Create, Select and apply appropriate techniques, resources, and
modern engineering and software tools including prediction and given profileling to complex
mechanical engineering activities with an understanding of the limitations.
PO6. The Engineer and Society: Apply reasoning informed by contextual knowledge to
assess societal, health, safety, legal and cultural issues and the consequent responsibilities
relevant to the professional mechanical engineering practice.
PO7. Environment and Sustainability: Understand the impact of the professional
engineering solutions in societal and environmental contexts, and demonstrate the knowledge
of, and need for sustainable development.
PO8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice.
PO9. Individual and Team Work: Function efficiently as an individual and as a member or
leader in diverse team, and in multidisciplinary settings.
PO10. Communication: Communicate effectively on complex mechanical engineering
activities with engineering community and with society at large, such as, being able to

comprehend and write effective reports and design documentation, make effective
presentation, and give and receive clear instruction.
PO11. Project Management and Finance: Demonstrate knowledge and understanding of
mechanical engineering and management principles and apply these to one’s own work, as a
member and leader in a team, to manage project and in multidisciplinary environments
PO12. Life-Long Learning: Recognize the need for, and have the preparation and ability to
engage in independent and life long learning in the broadest adapt to emerging field of
context of technological change.
PROGRAM SPECIFIC OUTCOMES (PSOs)

The Students Graduated in Mechanical Engineering Program will be able to:
 Advance themselves Professionally by Continuously Improving and Expanding their
Technical Skills through Formal Means or by Self-Study
 Will have Successful Careers in Engineering and can Occupy Responsible
Professional Positions
 Will act as a Responsible Citizenship by Undertaking Dynamic Roles, Locally,
Nationally and Globally.
 Adapt to the Changing Global Needs and Workforce Trends
METHODS AND STRATEGIES TO ACHIEVE PROGRAM

EDUCATIONAL OBJECTIVIES
 Enrich the Knowledge of Science and Mathematics applied to Engineering.
 An Understanding of Professional, Ethical Responsibility and to Communicate
Effectively.
 Provide a Solid Foundation and Understanding of the Fundamental of Mechanics,
Behavior of Materials (Solid, Liquid and Gas) and Manufacturing Process.
 Provide a Good Foundation and Understanding of the Fundamental Principles of
Thermal Fluids and Mechanical Systems Aspects of Mechanical Engineering.
 Instruct Students how to Design, Analysis, Simulations, Conduct Experiments and
Interpret the results in Thermal-Fluids and Mechanical Systems Engineering.
 Provide Students with an Opportunities to Design Mechanical Components,
Engineering Systems and Processes to meet the Specific Needs.

Do’s and Don’ts in the Lab

Do’s:
 Always save your progress

 Shut down the system when you are no longer using it.
 Read and understand how to carry out an activity thoroughly before coming to the
laboratory.
Don’ts:
 Do not eat or drink inside the laboratory
 Avoid stepping on electrical wires or any other computer cables
 Do not touch, connect or disconnect any plug or cable without permission
 Do not open any external memory drive or plug any other device
 Do not change the icons on the computer screen
 Do not install any other programs
 Do not attempt to repair, open, tamper or interfere with anything inside the lab
 Do not change any computer settings

Lab staff details:
1. LAB INCHARGE – Dr. SATISH N

Professor
2. FOREMAN - Mr. Mr. Ramachandra.G.B
3. INSTRUCTOR - 1) Mr. ManjeGowda

2) Mr. Renuka Prasad
4. MECHANIC - 1) Mr. Raghu S

2) Mr. Dileep B

Lab Equipment/Systems:
1) Denford Milling Machine – 1 no

2) Denford Turning Machine – 1 no
3) Digital Projector - 1no
4) Workstation – 1 no
MODEL – DELL, OS – WINDOWS-10, 2 QUAD CPU Q8400
@ 2.66 GHZ, 16GB RAM, 64-BIT OS
5) Systems – 17 nos
MODEL – DELL, OS -WINDOWS-7, INTEL ® CORE ™, 2 QUAD CPU
Q8400 , 2.66 GHZ, 4GB RAM, 32 – BIT OPERATING SYSTEM

CIM Lab Layout


Assessment Exam
Course Code Credits L-T-P
CIE SEE Duration
COMPUTER AIDED
MANUFACTURING 18MEL76 02 0-2-2 40 60 3Hrs
LAB
Part-A
Manual CNC part programming using ISO Format G/M codes for 2 turning and 2 milling
parts. Selection and assignment of tools, correction of syntax and logical errors, and
verification of tool path using CNC program verification software.
CNC part programming using CAM packages: Simulation of Turning, Drilling, Milling
operations. 3 typical simulations to be carried out using simulation packages like: Cadem,
CAM Lab-Pro, Master-CAM. Program generation using software. Optimize spindle power,
torque utilization, and cycle time. Generation and printing of shop documents like process
and cycle time sheets, tool list, and tool layouts. Cut the part in single block and auto mode
and measure the virtual part on screen. Post processing of CNC programs for standard CNC
control systems like FANUC, SINUMERIC and MISTUBISHI.
Part B
(Only for Demo/Viva voce)
FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval
system (ASRS) and linear shuttle conveyor Interfacing CNC lathe, milling with loading
unloading arm and ASRS to be carried out on simple components.
(Only for Demo/Viva voce)
Robot programming: Using Teach Pendent & Offline programming to perform pick and
place, stacking of objects (2 programs).
Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these
topics to be conducted.
Conduct of Practical Examination:
1. All laboratory experiments are to be included for practical examination.
2. Breakup of marks and the instructions printed on the cover page of answer script to be
strictly adhered by the examiners.
3. Students can pick one experiment from the questions lot prepared by the examiners.
Scheme of Examination:
One question from Part A: 40 marks
One question from Part B: 40 Marks
Viva voce: 20 Marks
Total: 100 Marks

COURSE OBJECTIVES
CO's The main Objectives of this laboratory course are : PO's
To introduce CNC manual part programming for
C476.1 simulation of various milling operations. PO1,PO2,PO4,PO6,
To train CNC manual part programming for simulation

C476.2 of various turning operations. PO1,PO2,PO4,PO6,
To generate tool path and G & M machining codes for

PO1,PO2,PO4,PO5,
C476.3 various complex milling components using CAM
PO10, PO12
software.
To educate the students on Flexible Manufacturing
PO1,PO2,PO4,PO5,
C476.4 System, Robot Programming,
PO10, PO12
To make students understand the importance of
PO1,PO2,PO4,PO5,
C476.5 automation in industries through exposure to hydraulics,
PO10, PO12
pneumatics and electro– pneumatic systems
COURSE OUTCOMES
Course Outcome : On completion of this Course students will be able to:
Develop fundamental skills to write manual part programming for various milling
C476.1
operations.
Develop knowledge to write manual part programming for various turning
C476.2
operations. Operations.
Evaluate the use of premium CAM software UG for generating tool path and G &
C476.3
M codes.
C476.4 Learn about Flexible Manufacturing System, Robot Programming in automation
C476.5 Analyze hydraulics software for the design and analysis of hydraulic circuits.
CO TO PO & PSO MAPPING
CO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2 PSO3
C478.1 3 3 3 2 3 3 2
C478.2 3 3 3 2 3 3 2
C478.3 3 3 3 3 3 2 3 3 3 3
C478.4 2 2 2 2 2 2 3 2 2 3
C478.5 2 2 2 2 2 2 3 2 2 2
AVG 2.6 2.6 2.6 1.4 2.2 1.2 1.8 2.6 2.6 2.4

Evaluation Procedure:
 Continuous Evaluation (CEE): In a class, 4 exercises to be completed –
to write the programs and execute. Each class will be evaluated for 15
marks; the division of marks is given in the table below.
Max. Marks.
Description
Marks Obtained
Program Write up 10
Execution 10
Presentation 10
TOTAL 30
Staff Signature with date
 Semester End Evaluation (SEE): Test and viva will be conducted with
weightage of 10 marks.

List of Programs/Exercises:
Sl.no/ No of
Details
Class programs
1. INTRODUCTION
MILLING
2. End Milling 4
3. End Milling/ Peck Drilling 4
4. Pocket Milling 4
5. Sub-Program/Mirroring 4
TURNING
Facing/Box Turning/Taper
6. 4
Turning/Grooving
7. Multiple Turning Cycle 4
8. Threading Cycle 4
9. Drilling/Boring 4
10. ROBOTICS (Demonstration & Write-up)

Hydraulics & Pneumatics (Demonstration &
11.
Write-up)

INTRODUCTION:
NC Machines
Numerical Control (NC) is a form of programmable automation in which the
processing equipment is controlled by means of numbers, letters, and other
symbols. The numbers, letters, and symbols are coded in an appropriate format
to define a program of instructions for a particular workpart or job.
Basic Components of NC
An NC system consists of three basic components:
The program of instructions is the detailed step y step commands that direct the
actions of the processing equipment. The program of instructions is called part
programs.
The machine control unit (MCU) consists or a microcomputer and related
control hardware that stores the program of instructions and executes it by
converting each command into mechanical actions of the processing equipment,
one command at a time.
The third basic component of an NC system is the processing equipment that
performs useful work. It accomplishes the processing steps to transform the
starting work piece into a completed part. Itsoperation is directed by the MCU,
which in turn is driven by instruction, contained in the part program.

Motion Control Systems

The NC system must possess a means of controlling the relative motion of the
tool with respect to the work. There are two types of motion control used in
numerical control:
 Point-to-pointsystems
 Contouring systems
Point-to-Point systems
Point-to-point positioning is used when it is necessary to accuratelylocate the
spindle, or the work piece mounted on the machinetable, at one or more specific
locations to perform suchoperations as drilling, reaming, boring, tapping, and
punching. Point-to-point positioning is the process of positioning from
onecoordinate (XY) position or location to another, performing themachining
operation, and continuing this pattern until all theoperations have been
completed at all programmed locations.
Continuous path(Contouring) systems

Contouring, or continuous path machining, involves work such asthat produced
on a lathe or milling machine, where the cutting toolis in contact with the work
piece as it travels from one programmedpoint to the next. Continuous path
positioning is the ability tocontrol motions on two or more machine axes
simultaneously tokeep a constant cutter-work piece relationship. The

programmedinformation in the CNC program must accurately position

thecutting tool from one point to the next and follow a predefinedaccurate path
at a programmed feed rate in order to produce theform or contour required.
NC Coordinate Systems
For flat and prismatic (block-like) parts:
• Milling and drilling operations
• Conventional Cartesian coordinate system
• Rotational axes about each linear axis

For rotational parts:

• Turning operations
• Only x- and z-axes
Fixed zero (M) or Machine Zero Point (M)

It is the zero point of the CNC machine tool fixed by the manufacturer. It is
always located the same position of the machine tool. For drilling, boring, and
milling machines it is at the lower left corner of the machine table and for
turning center it is on the spindle flange. This point was specified by the
manufacturer of the machine. The position of the machine zero point generally
varies from manufacturer to manufacturer. It is also called as home position.
Floating zero (W) or Work Piece Zero Point (W)
It is the zero point of the NC machine tool set by the operator at the any position
on the machine table / work piece. For turned parts, the work piece zero point
should be placed along the spindle axis in line into the right hand or left hand

end face of the finished contour. For milled parts its generally advisable to use
and extreme corner points of the work piece zero points.
NC Part Programming
NC part programming consists of planning and documenting the sequence of
processingsteps be performed on an NC machine. The part programmer must
have a knowledgeof machining (or other processing technology for which the
NC machine is designed) as well as geometry. The documentation portion of
part programming involvesthe input medium used to transmit the program of
instructions to the NC machine control unit (MCU).
The four types of part program methods are:
1. Manual data input
2. Manual Part-Programming
3. Computer-assisted part programming
4. Part programming using CAD/CAM
Manual Data Input
• Machine operator does part programming at machine
– Operator enters program by responding to prompts and questions
by system
– Monitor with graphics verifies tool path
– Usually for relatively simple parts
• Ideal for small shop that cannot afford a part programming staff
Computer-Assisted Part Programming
• Write machine instructions using natural language type statements
• Statements translated into machine code of the MCU
• APT (Automatically Programmed Tool) Language

Part programming using CAD/CAM

A CAD/CAM system is a computer interactive graphics system equipped with
software to accomplish certain tasks in design and manufacturing and to
integrate the design and manufacturing functions.
Manual Part Programming
Inmanual part programming, the programmer prepares the NC code using the
low-level machine language.The program is writtenusing G and M codes, the
details of which are explained below. In any case the part program is a block-
by-block listing of the machining instructions for the given job, formatted for
the particular machine tool to be used.
Manual part programming can be used for both point-to-point and contouring
jobs. It is most suited for point-to-point machining operations such as drilling. It
can also beused for simple contouring jobs, such as milling and turning when
only two axes are involved.

Programming Format
Word address is the most common programming format used forNC
programming systems. This format contains a large numberof different codes
(preparatory and miscellaneous) that transfersprogram information from the part
print to machine servos, relays,micro-switches, etc., to manufacture a part.
These codes, whichconform to EIA (Electronic Industries Association)
standards, arein a logical sequence called a block of information. Each
blockshould contain enough information to perform one machiningoperation.
Word Address
Every program for any part to be machined must be put in aformat that the
machine control unit can understand. The format used on any NC machine is
built in by the machine tool builderand is based on the type of control unit on
the machine. A variable-block format which uses words (letters) is most
commonlyused. Each instruction word consists of an address character,such as
X, Y, Z, G, M, or S. Numerical data follows this addresscharacter to identify a
specific function such as the distance, feedrate, or speed value.
Block of Information
Where,
N - sequence number prefix
G - preparatory words
– Example: G00 = PTP rapid traverse move
X, Y, Z - prefixes for x, y, and z-axes
F - feed rate prefix
S - spindle speed
T - tool selection
M - miscellaneous command
– Example: M07 = turn cutting fluid on

Sequence Number (N): A four digit sequence number can be specified (0001 -
9999) following the address code N, at the start of each block. The order of
these block numbers is arbitrary and need not be consecutive. Block numbers
can be specified for every program line, or just on program lines requiring them.
Preparatory functions (G): Preparatory functions, called G codes, are used to
determine the geometry of tool movements and operating state of the machine
controller; functions such as linear cutting movements, drilling operations and
specifying the units of measurement.They are normally programmed at the start
of a block. A G code is defined using the G address letter and a two digit
number as follows,
Feed function (F):The movement of the tool at a specified speed for cutting is
called the Feedrate. The feedrate is defined using the F address letter followed
by a numerical value.
Spindle speed function - cutting speed (S): The rotational speed of the tool,
with respect to the workpiece being cut, is called the spindle (or cutting) speed.
The spindle speed is defined using the S address letter, followed by a numerical
value, signifying the spindle RPM (revolutions per minute). The spindle speed
value specified must fall between the machine tool RPM range for the command
to be effective.
Tool function (T):Tool profiles can be changed during a program using the tool
function command. Each tool profile is assigned a number, which in the case of
an ATC (Automatic Tool Changer) will also coincide with one of the free bays
on its carousel magazine. The tool number is defined using the address letter T,
followed by a number assigned to the tool profile. To command a tool change,
the M06 code would precede the number of the "new" tool required.
Miscellaneous functions (M):Miscellaneous functions, called M codes, are
used by the CNC to command on/off signals to the machine functions. ie, M03 -
spindle forward (CW), M05 – spindle stop, etc.....

Preparatory functions (G- codes)

Preparatory functions (G-codes) are the codes which prepare machine to
perform particular functions like positioning, contouring, thread cutting and
canned cycling.
Preparatory function codes:
G00 - Rapid traverse.
G01 - Linear interpolation.
G02 - Circular interpolation (clockwise direction).
G03 - Circular interpolation (anti-clockwise direction).
G06 - Parabolic interpolation.
G20 - Inch data input.
G21 - Metric data input.
G28 - Return to machine zero.
G33 - Thread cutting.
G40 - Cutter radius compensation, cancel.
G41 - Cutter radius compensation, left.
G42 - Cutter radius compensation, right.
G90 - Absolute dimensioning.
G91 - Incremental dimensioning.
G94 - Specify feed rate in mm/min.
G95 - Specify feed rate in mm/rev.
G96 - Maintain constant surface speed.
G97 - Variable speed.
G98 - Feed / min.
G99 - Feed / rev.

Multi repetitive / canned cycles

Canned cycle is a term which has a preset sequence of events initiated by a
single NC command.In other words canned cycle or fixed cycle is an automatic
motion cycle which is held in buffer storage for the duration of the amount of
cycle repeats are programmed.By programming one cycle code number, as
many as distinct movement’s may occur. These movements would take blocks
of programme made without using Fixed or Canned cycles. The advantages of
writing a part programme with these structures are:
(a)Reduced lengths of part programme.
(b)Less time required developing the programme.
(c)Easy to locate the fault in the part programme.
(d)No need to write the same instructions again and again in the
programme.
(e)Less memory required in the control unit
Canned cycles G-codes:

G79 - Mill cycle.
G80 - Cancel fixed cycle.
G81 - Drill cycle.
G82 - Spot facing cycle.
G83 - Peck drilling cycle
G84 - Tap cycle.
G85 - Bore cycle.
G70 - Roughing cycle.
G71 - Finishing cycle.
G73 - Pattern repeating cycle.
G76 - Threading cycle.
G90 - Plane (or) step (or) taper turning.
G94 - Facing cycle.

Miscellaneous (or) auxiliary function (M-CODES)

These are the operations associated with the machine for functions other
than positioning or contouring.
MISCELLANEOUS FUNCTION:
M00 - Program stop.
M01 - Optional stop.
M02 - End program.
M03 - Spindle start (clockwise).
M04 - Spindle start (Anti-clockwise).
M05 - Spindle and coolant off.
M06 - Tool change.
M08 - Coolant ON.
M09 - Coolant OFF.
M10 - Clamp workpiece.
M11 - Release workpiece.
M30 - Stop program.
M17 - Return from sub-program.
M-CODES (MIRROR OPERATION):
M70 - Mirror on X-Plane.

M71 - Mirror on Y-Plane.
M80 - Cancel mirror on X-Plane.
M81 - Cancel mirror on Y-Plane.
M98 - Calling Sub-Program.
M99 - Exiting Sub-program and entering new program.

G00 – Rapid Traverse (Positioning)

Each axes moves as much as commanded data in rapid feedrate.This is to
command the cutter to move from the existing point to the target point at the
fastest speed of the machine.

G01 – Linear Interpolation

This is to command the cutter to move from the existing point to the target point
along a straight line at the speed designated by the F-address.

G02 – Circular Interpolation – clockwise direction

This is to command the cutter to move from the existing point to the target point
along acircular arc in clockwise direction or counter clockwise direction.

G02 – Circular Interpolation – counter-clockwise direction


1. Write a part program to obtain the given profile.
[BILLET SIZE X-120 Y-100 Z-10]

G91 G28 X0 Y0 Z0;
M06 T01;
M03 S1500;
G90;
G00 X0 Y0 Z5;
G01 Z-2 F60;
X70 Y0;
X70 Y20;
X100 Y20;
X100 Y50;
X70 Y50;
X70 Y80;
X50 Y80;
X35 Y65;
X35 Y50;
X0 Y50;
X0 Y0;
G00 Z5;
G28 X0 Y0 Z5;
M05;
M30;

[BILLET SIZE X 150 Y 100 Z 10]
G91 G28 X0 Y0 Z0;

M06 T01;
M3 S1200;
G90 G00 X0 Y0 Z5;
G01 X0 Y0 Z-1;
G01 X20 Y0;
G02 X56 Y0 R18;
G01 X76 Y0;
G01 X91 Y10;
G01 X91 Y30;
G03X81 Y40 R10;
G01 X41 Y40;
G03 X0 Y15 R38;
G01 X0 Y0;
G00 X0 Y0 Z5;
G28 X0 Y0 Z0;
M05 M30;

G91 G28 X0 Y0 Z0;

M06 T01;
M3 S1200;
G90 G00 X0 Y0 Z5;
G01 X0 Y0 Z-1;
X30;
G03 X54 Y0 R12;
G01 X82 Y0;
G02 X108 Y0 R13;
G01 X123 Y0;
G01 X80 Y45;
G01 X40 Y45;
G01 X40 Y75;
G03 X35 Y80 R5;
G01 X20 Y80;
G03 X0 Y80 R10;
G01 X0 Y0;
G00 X0 Y0 Z5;
G28 X0 Y0 Z0;
M05;
M30;

G91 G28 X0 Y0 Z0;

M06 T01;
M3 S1200;
G90 G00 X0 Y0 Z5;
G01 X0 Y0 Z-1;
G01 X40 Y0;
G03 X50 Y5 R20;
G01 X50 Y45;
G03 X45 Y50 R5;
G01 X30 Y50;
G03 X20 Y40 R10;
G01 X20 Y30;
G01 X10 Y30;
G03 X0 Y20 R10;
G01 X0 Y0;
G00 X0 Y0 Z5;
G28 X0 Y0 Z0;
M05 M30;

G91 G28 X0 Y0 Z0;

M06 T01;
M3 S1200;
G90 G00 X0 Y0 Z5;.
G01 X0 Y0 Z-1;
G01 X10 Y0;
G02 X40 Y0 R15;
G01 X100 Y0;
G01 X100 Y50;
G01 X90 Y42;
G01 X80 Y50;
G01 X80 Y20;
G01 X55 Y20;
G01 X40 Y50;
G03 X10 Y50 R15;
G01 X10 Y20;
G01 X0 Y20;
G01 X0 Y0;
G00 X0 Y0 Z5;
G28 X0 Y0 Z0;
M05 M30;


G91 G28 X0 Y0 Z0;
M06 T01;
M03 S1600;
G90;
G00 X0 Y0 Z5;
G01 Z-2;
X80 Y0;
X80 Y80;
X0 Y80;
X0 Y0;
G00 Z5;
G28 X0 Y0 Z0;
M06 T02;
M03 S1200
G00 X20 Y20 Z5;
G83 X20 Y20 Q2 R2Z-10 F100;
X40 Y40;
X60 Y60;
G00 Z5;
G28 X0 Y0 Z0;
M05;
M30;


G91 G28 X0 Y0 Z0;
M06 T01;
M03 S1000;
G90;
G00 X0 Y0 Z5;
G01 Z-5 F40;
G01 X60 Y0;
X60 Y60;
X0 Y60;
X0 Y0;
G00 Z5;
G00 X10 Y10 Z5;
G83 X10 Y10 Z-20 Q2 R2 F40;
X30 Y10;
X50 Y10;
X30 Y30;
X10 Y50;
X30 Y50;
X50 Y50;
G00 Z5;
G28 X0 Y0 Z0;
M05;
M30;

POCKET MILLING CODES
P-0 - Roughing cycle.

P-1 - Finishing cycle.
R-0 - Position of the tool to start.
Q - Peck increment (each time taken for a depth of2mm).
X0 Y0 - Centre of pocket.
Z-10 - Depth of cut.
I0 - Side finishing allowance.
J0 - Base finishing allowance.
K - Radius of pocket.
P - Percentage overlap or cut width percentage.
S - Spindle speed.
R - Feed in z direction.
F - Roughing feed in xy plane.
B and J - Finishing spindle speed and finishing speed.

POCKET MILLING
The following canned cycles, will machine either a circular pocket to any diameter and
depth, or a rectangular pocket to any side length and depth.
Both canned cycles require two blocks of information each, with each block having its
own G code:
G170 and G171 - Circular pocket milling codes.

G172 and G173 - Rectangular/square pocket milling codes.
For G170 block,
R defines the position of the tool to start cycle ie. 0 (surface of job).
P defines when P is zero(0) the cycle is a roughing cycle.
Q defines the peck increment, 5 pecks each of 2mm.
X defines the pocket centre in X axis (0).
Y defines the pocket centre in Y axis (0).
Z defines the pocket base (-10mm) from job surface.
I defines the side finish allowance (0 as this is a roughing cycle only).
J defines the base finish allowance (0 as this is a roughing cycle only).
K defines the radius of pocket (-25) negative value - cut in CCW direction).
For G171 block,

P defines the cut width percentage.
S defines the roughing spindle speed (S2000).
R defines the roughing Feed in Z (50).
F defines the roughing feed XY (100).
B defines the finishing spindle speed (1500, not applicable as roughing only).
J defines the finishing feed (150, not applicable as roughing only).
The direction of the cutter path is controlled by K, a negative (K-25) value for K means
the cutter path is in a CCW direction and if the K value is positive (K+25) the cutterpath
is in a CW direction.
When the tool has finished cutting the tool retracts 1mm in the Z axis, moves to the
centre of the circular pocket at rapid traverse, retracts again in the Z axis .

For G172 block,

I defines the pocket X length (-70).
J defines the pocket Y length (-50)
K defines the radius of corner roundness (K=0)
P defines that 0 = roughing cycle.
Q defines the peck increment, 5 pecks each of 2mm
R defines the position of the tool to start cycle ie. 0 (surface of job).
X defines the pocket corner X (Absolute position relative to the X datum
position (X-35)).
Y defines the pocket corner Y (Absolute position relative to the Y datum
position(Y-25)).
Z defines the absolute Z base of pocket (-10, ie, a depthof 10mm).
For G173 block,
I defines the pocket side finish (0 as this is aroughing cycle).
K defines the pocket base finish (0 as this is a roughingcycle).
P defines the cut width percentage (75% of tool dia.).
S defines the spindle speed for roughing (2000rpm).
R defines the roughing feed for Z (50).
F defines the roughing feed X and Y (150).
B defines the finishing spindle speed (1500 rpm).
J defines the finishing feed (150).
Z defines the safety Z (5mm above 'R' point).
For G172 block:
- The I and J are signed according to the direction oftravel +/positive being CW
and -/negative beingCCW.
- K must be programmed as 0 (zero),the corner radius is the cutter radius.
- X and Y relate to an absolute zero on theworkpiece, ie, the centre of the
workpiece. Inprogram the zero is set in thecentre of the workpiece so the
distance to thebottom LH corner is Y -25 and X -35.


G21;
G91 G28 X0. Y0. Z0.;
M06 T01;
M03 S2000 F50.;
G90;
G00 X0. Y0. Z5.;
G01 Z-2.;
G01 X0.Y0.;
X100. Y0.;
X100. Y100.;
X0. Y100.;
X0. Y0.;
G00 Z5.;
G28 X0. Y0. Z0.;
M06 T02;
M03 S1200
G90 G00 X50. Y50. Z0.;
G170 P0 R0 Q-2 X50. Y50. Z-10. I0. J0. K25.;
G171 P75 S1000 R75 F100 B1500 J150;
G01 Z5.;
G91 G28 X0. Y0. Z0.;
M05;
M30;


G21;
G91 G28 X0 Y0 Z0;
M06 T01;
M03 S2000 F50;
G90;
G00 X0 Y0 Z5;
G01 Z-2;
G01 X100 Y;
X100 Y100;
X0 Y100;
X0 Y0;
G00 Z5;
G28 X0 Y0 Z0;
M06 T02;
M03 S1200;
G00 X0 Y0 Z5;
G172 P0 R0 Q-2 X15 Y25 Z-10 I70 J50 K0;
G173 P75 S1000 R75 F100 I0 K0 B1500 J150;
G01 Z5;
G91 G28 X0 Y0 Z0;
M05;
M30;



G21;
G91 G28 X0 Y0 Z0;
M06 T01;
M03 S2000 F50;
G90;
G00 X0 Y0 Z5;
G01 Z-2;
G01 X100 Y;
X100 Y100;
X0 Y100;
X0 Y0;
G00 Z5;
G28 X0 Y0 Z0;
M06 T02;
M03 S800;
G90 G0 X15 Y12.5 Z5;
G83 X15 Y12.5 Z-20 Q2 R2 F50;
X50 Y12.5;
X85 Y12.5;
X15 Y87.5;
X50 Y87.5;
X85 Y87.5;
G00 Z5
G28 X0 Y0 Z0;
M06 T03;
M03 S1200;
G00 X50 Y50 Z5;
G170 P0 R0 Q-2 X50 Y50 Z-10 I0 J0 K25;
G171 P75 S1000 R75 F100 I0 K0 B1500 J150;
G01 Z5;
G91 G28 X0 Y0 Z0;
M05 M30;



G21;
G91 G28 X0 Y0 Z0;
M06 T01;
M03 S2000 F50;
G90;
G00 X0 Y0 Z5;
G01 Z-2;
G01 X100 Y;
X100 Y100;
X0 Y100;
X0 Y0;
G00 Z5;
G28 X0 Y0 Z0;
M06 T02;
M03 S800;
G90 G0 X15 Y12.5 Z5;
G83 X15 Y12.5 Z-20 Q2 R2 F50;
X50 Y12.5;
X85 Y12.5;
X15 Y87.5;
X50 Y87.5;
X85 Y87.5;
G00 Z5
G28 X0 Y0 Z0;
M06 T03;
M03 S1200;
G00 X50 Y50 Z5;
G170 P0 R0 Q-2 X50 Y50 Z-10 I0 J0 K25;
G171 P75 S1000 R75 F100 I0 K0 B1500 J150;
G01 Z5;
G91 G28 X0 Y0 Z0;
M05 M30;

SUB – PROGRAM
The sub program can be called into operation when the machine is set to run in Auto
Mode. Sub programs can also call other sub programs into operation. When the main
program calls one sub program into operation, the process is called a one-loop sub
program call. It is possible to program a maximum fourloop sub program call within the
main program
To call a sub program the M98 code is used followed by P0000 (the number of the sub
program required – the number can be from 0000-9999).
For example,
M98 P2000
This command is read call program number 2000.
A sub program call command (M98 P0000) can be specified along with a move
command in the same block.
For example,
G01 X42.5 M98 P1000;
At the end of a sub program, the M99 code is entered. This returns control to the main
program.
The M99 code will return control to the next block after the M98 sub program call block
in the main program.
If the code M99 P0000 is entered, control will pass to the main program at a block with
the N number equal to that of the P number stated after the M99 code.
For example,
M99 P0160
This command is read return to the main program at block number N0160.
M98 - Calling sub program.

M99 - Exit sub program and entering main program.
“P ’’ value specifies the program number and number of time to execute the program.

G91 G28 X0 Y0 Z0;

M06 S2000;
M03 S1500;
G90;
G00 X10 Y0 Z5;
G01 Z-0.5;
M98 P01 1234;
G01 Z-1.0;
M98 P01 1234;
G01 Z-1.5;
M98 P01 1234;
G01 Z-2;
M98 P01 1234;
G01 Z-2.5;
M98 P01 1234;
G01 Z-3;
G00 Z5;
G91 G28 X0 Y0 Z0;
M05;
M30;

SUB PROGRAM [; 1234]

:1234 ;
G01 X10 Y0;
G01 X60 Y0;
G03 X60 Y20 R10;
G01 X45 Y20;
G02 X35 Y30 R10;
G01 X35 Y60 ;
G01X10 Y60;
G03 X0 Y50 R10;
G01 X0 Y10 ;
G03 X10 Y0 R10;
G00 Z5;
M99 P50;


Sub program.
G91 G28 X0 Y0 Z0;
M06 S2000;
M03 S1500;
G90;
G00 X0 Y-40 Z5;
G01 Z-0.5;
M98 P01 1234;
G01 Z-1.0;
M98 P01 1234;
G01 Z-1.5;
M98 P01 1234;
G01 Z-2;
M98 P01 1234;
G01 Z-2.5;
M98 P01 1234;
G01 Z-3;
G00 Z5;
G91 G28 X0 Y0 Z0;
M05;
M30;

SUB PROGRAM [; 1234]

:1234;
G01 X-40 Y0;
G03 X0 Y40 R40;
G01 X40 Y0;
G03 X0 Y-40 R40;
G00 Z5;
M99 P50;

MIRRORING OPERATION
14 . Write a part program to obtain the given profile.

MIRRORING OPERATION
G91 G28 X0 Y0 Z0;
M06 T01;
M03 S1500;
G90;
G00 X0 Y0 Z5;
G01 Z-2;
M98 P01 5555;
M70;
M98 P01 5555;
M80;
M70;
M71;
M98 P01 5555;
M80;
M81;
M71;
M98 P01 5555;
G00 Z5;
M05 M30;

SUB PROGRAM
: 5555;
G01 X0 Y0 Z-2;
G01 X20 Y0;
G01 X20 Y20;
G01 X0 Y20;
G01 X0 Y0;
G00 Z5;
M99;
MIRRORING OPERATION
M70 - Mirror axis on x-plane.
M71 - Mirror axis on y-plane.
M80 - CancelMirror axis on x-plane.
M81 - CancelMirror axis on y-plane.


G91 G28 X0 Y0 Z0;

M06 T01;
M03 S1500;
G90;
G00 X20 Y10 Z5;
G01 Z-2;
M98 P01 5555;
M70;
M98 P01 5555;
M80;
M70;
M71;
M98 P01 5555;
M80;
M81;
M71;
M98 P01 5555;
G00 Z5;
M05 M30;

SUB PROGRAM
:5555;
G01 X20 Y10 Z-2;
G01 X50 Y10;
G03 X60 Y20 R10;
G01 X60 Y50;
G03 X50 Y60 R10;
G01 X30 Y60;
G02 X10 Y30 R20;
G01 X10 Y20;
G03 X10 Y10 R10;
G00 Z5;
M99

ADDITIONAL EXCERISES:
 Write programs for the following milling profiles:
Write a mirror program for the components shown below:


FACING OPERATION

[BILLET SIZE X-35 Z-60]
G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X37 Z2;
G94 X0 Z-1 F60;
Z-2;
Z-3;
Z-4;
Z-5;
Z-6;
G91 G28 U0 W0;
M05;
M30;


G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X32 Z2;
G90 G94 X10 Z-1 F60;
Z-4;
Z-6;
Z-8;
Z-10;
G91 G28 U0 W0;
M05;
M30;
G90 – BOX TURNING CYCLE


3. Write a part program to obtain the given profile, using box turning
cycle.

G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X37 Z2;
G90 X35 Z-45 F60;
X33;
X31;
X29;
X27;
X25;
G91 G28 U0 W0;
M05;
M30;

[BILLET SIZE X-100 Y-100 Z-20 ]
G98 G40
G91 G28 U0 W0
M06 T01
M03 S2000
G00 X42 Z2
G90 X15 Z-10 F60
X10
X25 Z-20
X20
X35 Z-30
X30
G91 G28 U0 W0
M05
M30

TAPER TURNING
G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X42 Z2;
G90 X40 Z-30 R-1 F60;
R-2;
R-3;
R-4;
R-5;
G90 X40 Z-50;
G28 U0 W0;
M05;
M30;

GROOVING

20
30
18
8
30
35
60
G21 G98;
G91 G28 U0 W0;
M06 T01;
M03 S1500;
G00 X32 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1 F80;
TURNING OPERATION
N10 G01 X18 Z0;
G01 X20 Z-1;
Z-35;
X30;
Z-60;
N20 G00 X32;
M03 S2000;
G70 P10 Q20 F20;
G28 U0 W0;
M05;

GROOVING OPERATION
M06 T02;
M03 S1000;
G00 X22 Z-30;
G75 R1;
G75 X8 Z-35 P2000 Q2000 R0 F0.1;
G00 X22;
G28 U0 W0;
M05;

G70 & G71 – Multiple Turning Cycle


Format for Multiple Turning Cycle

G71 - Multiple turning cycle or stock removal cycle.
G70 - Finishing cycle.
U 0.5 - Depth of cut is 0.5mm.
R1 - Tool retraction distance after 1 cut.
G71 P10 Q20 - Multiple turning between block N10 and N20.
U0.1 W0.1 - Finishing allowance for x and z axis.

G21 G40 G98; G28 U0 W0;
G91 G28 U0 W0; M05;
M06 T01; M30;
M03 S1500;
G00 X32 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1;
N10 G01 X0 F50;
Z0;
G03 X10 Z-5 R5;
G01 Z-15;
G01 X20 Z-25;
Z-35;
G02 X30 Z-40 R5;
N20 G01 Z-45;
M03 S2000;
G70 P10 Q20 F20;


G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X22 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1;
N10 G01 X0 F50;
Z0;
G03 X2.5 Z-2.5 R2.5;
G01 Z-12.5;
G02 X10 Z-17.5 R5;
G01 Z-27.5;
G02 X15 Z-32.5 R5;
G01 X20 Z-37.5;
G01 Z-52.5;
N20 G01 Z-52.5;
M03 S2000;
G70 P10 Q20 F20;
G28 U0 W0;
M05;
M30;


G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X22 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1;
N10 G01 X0 F50;
Z0;
G01 X5 Z-5;
Z-10;
G02 X10 Z-15 R5;
G01 Z-25;
G03 X15 Z-30 R5;
G01 X20 Z-30;
Z-50;
N20 G01 Z-50;
M03 S2000;
G70 P10 Q20 F20;
G28 U0 W0;
M05 M30;


G98 G40;
G91 G28 U0 W0;
M06 T01;
M03 S2000;
G00 X22 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1;
N10 G01 X0 F50;
Z0;
G00 X0 Z0;
G01 X8 Z0;
G01 X14 Z-8;
X14 Z-18;
G03 X26 Z-24 R5;
G01 X28 Z-24;
G01 X28 Z-44;
X32 Z-52;
G01 X32 Z-62;
N20 X34 Z-62;
G70 P10 Q20 F20;
G28 U0 W0;
M05;
M30;

THREADING OPERATION
Various codes used
TO1 - Rough turning tool.
T02 - Grooving tool.
G76 - Thread cutting operation
P02 - Number of finishing passes
P15 - Pull out angle of tool.
60 - Angle of thread
Q100 - Minimum cutting depth
R0.1 - Finishing allowance
X16.9328 - Core diameter of thread
Z-30 - Length of thread
P1533 - Height of thread
Q100 - Depth of cut for first pass
F2.5 - Pitch of thread

G21 G98;
G91 G28 U0 W0;
M06 T01;
M03 S1500;
G00 X37 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1 F80;

TURNING OPERATION
N10 G01 X18;
Z0;
X20 Z-1;
Z-35;
X30;
N20 Z-60;
M03 S2000;
G70 P10 Q20 F20;
G28 U0 W0;
M05;
GROOVING OPERATION
M06 T02;
M03 S1000;
G00 X22 Z-30;
G75 R1;
G75 X8 Z-35 P2000 Q2000 R0 F0.1;
G00 X22;
G28 U0 W0;
M05;
THREAD CUTTING OPERATION
M06 T03;
M03 S500;
G00 X22 Z2;
G76 P02 1560Q100 R0.1
G76 X16.9328 Z-30 P1533 Q100 F2.5;
G91 G28 U0 W0;
M05;
M30;


G21 G98;
G91 G28 U0 W0;
M06 T01;
M03 S1500;
G00 X37 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1 F80;
TURNING OPERATION
N10 G01 X10Z0;
G01 X12 Z-1;
X12 Z-20;
G02 X16 Z-30 R25;
G01 X16 Z-40;
G03 X22 Z-50 R16;
G01 X22 Z-55;
N20 G00 X24;
M03 S2000;
G70 P10 Q20 F20;
G28 U0 W0;
M05;
GROOVING OPERATION
M06 T02;
M03 S1200;
G00 X14 Z-17;
G75 R1

G75 X9 Z-20 P1000 Q1000 R0 F0.1;

G00 X14;
G28 U0 W0;
M5;
THREAD CUTTING OPERATION

M06 T03;
M03 S500;
G00 X12 Z0;
G76 P02 1560 Q100 R0.1;
G76 X9.83 Z-18 P1060 Q100 F1;
G91 G28 U0 W0;
M05 M30;


G74 cycle - PECK DRILLING

G21 G40 G98;
G91 G28 U0 W0;
M06 T01;
M04 S1500;
G00 X37 Z2;
G90 X35 Z-60 F100;
G91 G28 U0 W0;
M06 T02;
M03 S1200;
G00 X0 Z2;
G74 R2;
G74 Z-50 Q500 F2;
G91 G28 U0 W0;
M05;
M30;


TAPER BORING [G90 G71 G74 cycles]

G21 G40 G98;
G91 G28 U0 W0;
M06 T01;
M03 S1500;
G00 X37 Z2;
G90 X35 Z-60 F60;
G91 G28 U0 W0;
M06 T02;
G00 X0 Z2;
G74 R1;
G74 Z-50 Q1500 F40;
G91 G28 U0 W0;
M06 T03;
M04 S750;
G00 X20 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1;
N10 G01 X20 Z0;
G01 X20 Z-20;
N20 G01 X12 Z-40;
G91 G28 U0 W0;
M05;
M30;

BILLET SIZE [X32 Z70]

G21 G40 G98;
G91 G28 U0 W0;
M06 T01;
M03 S1500;
G00 X32 Z2;
G90 X30 Z-70 F60;
G00 X32
G91 G28 U0 W0;
M06 T02;
M03 S1200
G00 X0 Z2;
G74 R2;
G74 Z-35 Q1500 F35;
G91 G28 U0 W0;
M06 T03;
M04 S750;
G00 X12 Z2;
G71 U0.5 R1;
G71 P10 Q20 U0.1 W0.1 F20;
N10 G01 X30 Z0;
G02 X25 Z-8 R16;
G01 X25 Z-16;
G03 X20 Z-21 R16;
G01 X16 Z-25;
N20 G01 X12 Z-25;
G70 P10 Q20 F50;
G91 G28 U0 W0;
M05 M30;


STEP or COUNTER BORING - G90 cycle.
BILLET SIZE [X37 Z70]
G21 G40 G98;
G91 G28 U0 W0;
M06 T01 (rough tool)
M03 S1200;
G00 X37 Z2;
G90 X35 Z-60 F35;
G91 G28 U0 W0;
M06 T02 (drill tool of 12mm dia)
M04 S1000;
G00 X0 Z2;
G74 R2;
G74 Z-50 Q1500 F10;
G91 G28 U0 W0;
M06 T03 (internal groove tool)
M03 S1200;
G00 X12 Z2;
G90 X12 Z-40 F20;
X13;
X16;
X19 Z-30;
X20;
X21 Z-10;
X22;
X24;
G91 G28 U0 W0;
M05 M30;

ADDITIONAL EXCERISES:
 Write programs to obtain the following profiles:
Ex-1 Ex-2
Ex-3 Ex-4

UNI GRAPHICS
To Design:
New – file name – ok.
Start – given profiling.
Sketch –select XC – yc plane – ok
Rectangle - create rectangle.
Inferred dimensions- select line and give dimensions
Constraints- select sketch line and axis line- collinear- finish sketch
Extrude- select sketch- Give dimension- select Boolean function- ok

To Obtain NC Program:
Start- Manufacturing- Cam general- Mill Planar- initialize
Create Operation- Select Planar mill
Program- program
User geometry- workpiece
Use tool – none
Use method- mill finish
Name- SRS- OK
Floor- Select – Filter - Face – select bottom face of inner rectangle- ok
Groups- start new- Select mill planner tool- OK
Give diameter- 5
Display tool- ok
Main- cut depth – user defined- max – 5 – ok
Feed rates – Reset from table – ok
Tool path – display option – 2D- Pause after display- ok
Verify- Rectangle speed – play –ok
Post Processing – Mill 3 axis – ok
Copy and paste the program in CNC trainer – run it.

ROBOTICS
Robot Programming
There are various methods which robots can be programmed to perform a given work
cycle. Programming methods can be divided into four categories.
1. Manual method
2. Walkthrough method
3. Lead through method
4. Off-line programming
Manual method:
This method is not really programming in the conventional sense of the world. It is
more like setting up a machine rather than programming. It is the procedure used for the
simpler robots and involves setting mechanical stops, cams, switches or relays in the robots
control unit. For these low technology robots used for short work cycles (e.g., pick and place
operations), the manual programming method is adequate.
Walkthrough method:
In this method the programmer manually moves the robots arm and hand through the
motion sequence of the work cycle. Each movement is recorded into memory for subsequent
playback during production. The speed with which the movements are performed can usually
be controlled independently so that the programmer does not have to worry about the cycle
time during the walk through. The main concern is getting the position sequence correct. The
walk through method would be appropriate for spray painting and arc welding.
Lead through method:

The lead through method makes use of a teach pendant to power drive the robot
through its motion sequence. The teach pendant is usually a small hand held device with
switches and dials to control the robots physical movements. Each motion is recorded into
memory for future playback during work cycle. The lead through method is very popular
among robot programming methods because of its ease and convenience.

On-Line/Lead -Through programming

Advantage:
 Easy
 No special programming skills or training
Disadvantages:
 not practical for large or heavy robots
 High accuracy and straight-line movements are difficult to achieve, as are
any other kind of geometrically defined trajectory, such as circular arcs,
etc.
 difficult to edit out unwanted operator moves
 difficult to incorporate external sensor data
 Synchronization with other machines or equipment in the work cell is
difficult
 A large amount of memory is required
Off- line programming:

This method involves the preparation of the robot program off-line, in a manner
similar to NC part programming. Off-line robot programming is typically accomplished on a
computer terminal. After the program has been prepared, it is entered in to the robot memory
for use during the work cycle. The advantaged of off-line robot programming is that the
production time of the robot is not lost to delay in teaching the robot a new task.
Programming off-line can be done while the robot is still in production on the preceding job.
This means higher utilization of the robot and the equipment with which it operates.
Another benefit associated with off-line programming is the prospect of integrating
the robot into the factory CAD/CAM data base and information system.
Advantages of off-line programming:
 Textural programming languages

 Enhanced sensor capabilities
 Improved output capabilities to control external equipment
 Program logic
 Computations and data processing
 Communications with supervisory computers
Robot Programming Languages

 Large number of robot languages available
 AML, VAL, AL, RAIL, RobotStudio, etc. (200+)
 Each robot manufacturer has their own robot programming language
 No standards exist
 Portability of programs virtually non-existent

HYDRAULICS & PNEUMATICS
1. Define Fluid Power. Give classification of fluid systems.

Fluid Power is defined as the technology that deals with the generation, control and
transmission of power using pressurized fluids.
Types of Fluid Systems:
a. Fluid Transport systems: The objective of the fluid transport systems is to transport
fluids from one place to another place to achieve some useful purpose.
b. Fluid Power systems: The Fluid power system is primarily designed to perform
work. That is these systems use pressurized fluids to produce some useful mechanical
movements to accomplish the desired work.
Method of transmitting power:

1. Electrical power transmission
2. Mechanical power transmission
3. Fluid power transmission
4. Hydraulic power transmission
5. Pneumatic power transmission
2. Mention advantages and limitations of fluid power.

Advantages of Fluid Power are:
1. Easy and Accuracy to Control With the use of simple levels and push buttons, the
fluid power system can facilitate easy starting, stopping, speeding up or slowing down
and positioning forces that provide any desired power
2. Multiplication of small forces to achieve greater forces for performing work
3. It easily provides infinite and step less variable speed control which is difficult to
obtain from other drives
4. Accuracy in controlling small or large forces with instant reversal is possible with
hydraulic systems
5. Constant force is possible in fluid power system regardless of special motion
requirements. Whether the work output moves a few millimeters or several meters per
minute.
6. As the medium of power transmission is fluid, it is not subjected to any breakage of
parts as in mechanical transmission.

7. The parts of hydraulic system are lubricated with the hydraulic liquid itself.
8. Overloads can easily controlled by using relief valves than is possible with
overload devices on the other systems. Air equipments reduces the danger of fire and
explosion hazard in industries such as painting and mining.
9. Because of the simplicity and compactness the cost is relatively low for the power
transmitted.
10. No need of lubrication
Disadvantages of Fluid Power are

1. Leakage of oil or compressed air
2. Busting of oil lines, air tanks
3. More noise in operation
3. List out the Applications of Fluid Power?

1. Agriculture: Tractors and farm equipments like ploughs, mowers, chemical
sprayers, fertilizer spreaders, haybalers
2. Automation: Automated transfer machines
3. Aviation: Fluid power equipments like landing wheels on aeroplane and helicopter,
aircraft trolleys, aircraft engine test beds.
4. Building Industry: For metering and mixing of concrete ingredients from hopper.
5. Construction Equipment: Earthmoving equipments like excavators, bucket
loaders, dozers, crawlers, post hole diggers and road graders.
6. Defense: Missile-launch systems and Navigation controls
7. Entertainment: Amusement park entertainment rides like roller coasters
8. Fabrication Industry: Hand tools like pneumatic drills, grinders, bores, riveting
machines, nut runners
9. Food and Beverage: All types of food processing equipment, wrapping, bottling
10. Foundry: Full and semi automatic molding machines, tilting of furnaces, die
casting machines
11. Glass Industry: Vacuum suction cups for handling
12. Material Handling: Jacks, Hoists, Cranes, Forklift, Conveyor system

4. Define Pascal’s law. Mention practical application which works on Pascal’s law.
Pascal’s law states that the pressure exerted on a confined fluid is transmitted
undiminished in all directions and acts with equal force on equal areas and at right angles to
the containing surfaces.
Fig. Principle of Pascal’s law

Practical applications of Pascal’s law:
• Hydraulic Lift
• Hydraulic Jack
• Air-to-Hydraulic Pressure Booster
• Hydraulic Brakes
• Hydraulic Pumps
• Aircraft Hydraulic System
5. What is Pneumatic system in automation?

In machine automation a pneumatic system provides a simple and cost-effective
means to move, clamp, rotate, grind and screw. A pneumatic system is a collection of
interconnected components using compressed air to do work for automated equipment.
Examples can be found in industrial manufacturing, a home garage or a dentist office.
This work is produced in the form of linear or rotary motion. The compressed air or
pressurized gas is usually filtered and dried to protect the cylinders, actuators, tools and
bladders performing the work. Some applications require a lubrication device that adds an
oil mist to the closed pressurized system.

6. Mention all the components of hydraulic and pneumatic system.

Hydraulic system: Oil Reservoir, oil filter, Hydraulic Pump, Motor, Valves (PCV, DCV,
FCV), Actuator.
Fig. Components of Hydraulic system

Pneumatic system: Air compressor, Air filter, Air cooler, Motor, storage tank, Valves
(PCV, DCV, FCV), Actuator.
Fig. Components of Pneumatic system

7. Compare Hydraulics and pneumatics.
Hydraulic System Pneumatic System

It employs a pressurized liquid as a fluid. It employs a compressed gas, usually air, as a
fluid.
An oil hydraulic system operates at pressures A pneumatic system usually operates at 5–10
up to 700 bar. bar.
Generally designed as closed system. Usually designed as open system.
The system slows down when leakage Leakage does not affect the system much.
occurs.
Valve operations are difficult. Valve operations are easy.
Heavier in weight. Lighter in weight.
Pumps are used to provide pressurized Compressors are used to provide compressed
liquids. gases.
The system is unsafe to fire hazards. The system is free from fire hazards.
8. Mention advantages and disadvantages of hydraulic system.
Advantages of hydraulic system:

 Multiplication and variation of force
• Linear or rotary force can be multiplied from a fraction of an ounce to
several hundred tons of output.
 Easy, accurate control
• You can start, stop, accelerate, decelerate, reverse or position large
forces with great accuracy.
 Multi-function control
• A single hydraulic pump or air compressor can provide power and
control for numerous machines or functions when combined with fluid
power manifolds and valves.
 High horsepower/low weight ratio
• Pneumatic components are compact and lightweight. You can hold a 5
horsepower hydraulic motor in the palm of your hand.
 Variable Speed
• Actuators can be driven from a high to low speed using a flow control
valve.
 Reversible
• Hydraulic actuators can be instantly reversed in direction of motion.
 Overload Protection
• A pressure relief valve protects a hydraulic circuit from overload.
Disadvantages of hydraulic system:

 Poor resistance to working fluid pollution

 Sensitive to temperature changes;

 Hidden danger of leakage;
 Difficult manufacturing and high cost;
 It is not suitable for long-distance transmission and requires hydraulic energy.

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CIM & AUTOMATION LABORATORY MANUAL

BANGALORE INSTITUTE OF TECHNOLOGY

COMPUTER INTEGRATED MANUFACTURING LAB

1 Department of Mechanical Engineering, Bangalore Institute of Technology

BANGALORE INSTITUTE OF TECHNOLOGY

2 Department of Mechanical Engineering, Bangalore Institute of Technology

DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVIES (PEO’s)

3 Department of Mechanical Engineering, Bangalore Institute of Technology

Students of Bachelor of Engineering (B.E) in Mechanical Engineering at Bangalore Institute

PROGRAM EDUCATIONAL OBJECTIVIES (PEO’s)

4 Department of Mechanical Engineering, Bangalore Institute of Technology

PROGRAM OUTCOMES [PO`s]

5 Department of Mechanical Engineering, Bangalore Institute of Technology

PROGRAM SPECIFIC OUTCOMES (PSOs)

METHODS AND STRATEGIES TO ACHIEVE PROGRAM

6 Department of Mechanical Engineering, Bangalore Institute of Technology

COMPUTER INTEGRATED MANUFACTURING LAB

Do’s and Don’ts in the Lab

 Always save your progress

7 Department of Mechanical Engineering, Bangalore Institute of Technology

Lab staff details:

1. LAB INCHARGE – Dr. SATISH N

2. FOREMAN - Mr. Mr. Ramachandra.G.B

3. INSTRUCTOR - 1) Mr. ManjeGowda

4. MECHANIC - 1) Mr. Raghu S

8 Department of Mechanical Engineering, Bangalore Institute of Technology

1) Denford Milling Machine – 1 no

9 Department of Mechanical Engineering, Bangalore Institute of Technology

CIM Lab Layout

10 Department of Mechanical Engineering, Bangalore Institute of Technology

COMPUTER INTEGRATED MANUFACTURING LAB

11 Department of Mechanical Engineering, Bangalore Institute of Technology

To train CNC manual part programming for simulation

To generate tool path and G & M machining codes for

C476.4 Learn about Flexible Manufacturing System, Robot Programming in automation

CO TO PO & PSO MAPPING

12 Department of Mechanical Engineering, Bangalore Institute of Technology

Staff Signature with date

13 Department of Mechanical Engineering, Bangalore Institute of Technology

3. End Milling/ Peck Drilling 4

10. ROBOTICS (Demonstration & Write-up)

14 Department of Mechanical Engineering, Bangalore Institute of Technology

15 Department of Mechanical Engineering, Bangalore Institute of Technology

Motion Control Systems

Continuous path(Contouring) systems

16 Department of Mechanical Engineering, Bangalore Institute of Technology

programmedinformation in the CNC program must accurately position

17 Department of Mechanical Engineering, Bangalore Institute of Technology

For rotational parts:

Fixed zero (M) or Machine Zero Point (M)

Floating zero (W) or Work Piece Zero Point (W)

18 Department of Mechanical Engineering, Bangalore Institute of Technology

19 Department of Mechanical Engineering, Bangalore Institute of Technology

Part programming using CAD/CAM

20 Department of Mechanical Engineering, Bangalore Institute of Technology

21 Department of Mechanical Engineering, Bangalore Institute of Technology

22 Department of Mechanical Engineering, Bangalore Institute of Technology

Preparatory functions (G- codes)

23 Department of Mechanical Engineering, Bangalore Institute of Technology

Multi repetitive / canned cycles

Canned cycles G-codes:

24 Department of Mechanical Engineering, Bangalore Institute of Technology