CNC and Casting Simulation LAB Subject Title Subject Code Periods/Week Periods/Semester : : : 06 96 : CNC and

Casting Simulation lab

S. No.

TOPIC ANALYSIS Name of Experiment Part-A Study of CNC lathe, milling Setting Machine zero – Tool zero, Job zero, dry run, jog mode Study of international standards ISO/EIA/ANSI Programming – Turning simulator – Milling simulator, Exercise practice CNC Lathe Develop a part program for step turning and simulate Develop a part program for taper turning and simulate Develop a part program for circular interpolation and simulate Develop a part program for multiple turning operation and simulate Develop a part program for thread cutting, grooving and simulate Develop a part program for internal drills, boring and simulate Exercise practice CNC Milling Develop a part program for grooving and simulate Develop a part program for drilling (canned cycle) and simulate Develop a part program for mirroring with subroutines and simulate Develop a part program for rectangular and circular pocketing and simulate Part-B Casting Simulation Exercises

No of Hours allotted

1 2 3 4 5 6 7 8 9 10 11 12 13

06 06 06 03 03 06 06 03 03 06 06 06 06

14

18

5. To Develop a part program for mirroring with subroutines and simulate 13 To Develop a part program for rectangular and circular pocketing and simulate 14 To learn the use of CASTING simulation softwares COURSE CONTENTS 1. 10. 3. 2. 7.15 Industry innovations and environmental concerns Tests and Revisions Total 06 06 96 On Completion of the Course. grooving and simulate To Develop a part program for internal drills. 3. 6. the student should be able to: 1. Appreciate the importance of CNC lathe and CNC Milling machines Understand the codes (G-code and M-Code) used in CNC machines for programming To Develop Programming skills To develop a part program for step turning and simulate To Develop a part program for taper turning and simulate To Develop a part program for circular interpolation and simulate To Develop a part program for multiple turning operation and simulate To Develop a part program for thread cutting. 4. 10. To Develop a part program for drilling (canned cycle) and simulate 12. Develop a part program for drilling (canned cycle) and simulate . 2. 7. To Develop a part program for grooving and simulate on CNC Milling 11. boring and simulate 8. grooving and simulate Develop a part program for internal drills. 9. 5. 9. boring and simulate 8. 4. Study the importance of CNC lathe and CNC Milling machines Write the codes (G-code and M-Code) used in CNC machines for programming Develop Programming skills by using G codes and M-codes Develop a part program for step turning and simulate Develop a part program for taper turning and simulate Develop a part program for circular interpolation and simulate Develop a part program for multiple turning operation and simulate Develop a part program for thread cutting. 6. Develop a part program for grooving and simulate on CNC Milling 11.

analyze its thickness and shape complexity. complete and uniform filling of the mold cavity. . Lab Exercise 2: Core print design The objective of this exercise is to design the core prints to support the core in mold. model and verify the gating channel design for the given casting. compute its geometric properties. to achieve smooth. quality and cost.12. Develop a part program for mirroring with subroutines and simulate 13 Develop a part program for rectangular and circular pocketing and simulate PART-B Casting Design and Simulation Lab Exercises using any CASTING simulation softwares (One lab exercise from this part for 20 marks in the final exam) A. The following steps are involved: Lab Exercise 3: Mold cavity layout The objective of this exercise is to determine the correct combination of mold box and number of cavities to achieve the desired ratio of cast metal to mold material. whereas a high ratio leads to poor quality Lab Exercise 4: Feeder design and solidification simulation The objective of this exercise is to design. to obtain a casting free of solidification shrinkage defects along with the highest possible yield. model and verify the feeding system design for the given casting. Lab Exercise 5: Gating design and mold filling simulation The objective of this exercise is to design. manufacture. Specific objectives Lab Exercise 1: Part modeling and geometry analysis The objective of this exercise is to create a 3D CAD model of a given part. All these affect tooling design. General objectives Lab Exercise 1: Part modeling and geometry analysis Lab Exercise 2: Core print design Lab Exercise 3: Mold cavity layout Lab Exercise 4: Feeder design and solidification simulation Lab Exercise 5: Gating design and mold filling simulation Lab Exercise 6: Casting cost estimation B. A low ratio leads to poor utilization of production resources.

Lab Exercise 6: Casting cost estimation .

c .The objective of this exercise is to estimate the cost of a casting. and to study the effect of various factors on total cost.

Six lab turns can be planned: part modeling. It is usually included in first or second making and sand mould preparation. core d gating design and cost estimation. width. There is experiment to support the theory courses. inner diameter.C astingDesig and S ulation L Exercises usingAutoCA n im ab Foundry practice is an essential and integral part of Me diploma courses. inner hole lengt . length. fi Cruciform: height. Thus students never get a practical experience also exposed to metal casting theory. inner hole length Hollow cylinder: height. outer diameter. Casting simulation lab exercises can be introduced in the s allow the students to study the effect of various design p yield. usually as a part of their third year. The AutoCAST software all the modules needed for conducting the above exerc submit hand calculations as well as the simulation resu Each student can be given a unique part in terms of shap can also be varied (ex. Most institutes do n reluctant to allow students to melt and pour molten me concerns. arm length. steel or aluminum). arm width. or as a full elective course. The shapes and Rectangular block: height.

2. Prepare a report comparing the hand calculations and computed results. weight. 4.Lab Exercise 1: Part modeling and geometry analysis The objective of this exercise is to create a 3D CAD model of a given part. All these affect tooling design. Create a 3D CAD model of the part. quality and cost. and compute its volume and weight. Viva Questions: a. Compute the shape complexity in terms of various ratios. Compute the minimum and maximum thickness and identify their locations. Draw the three orthographic views of the part. What are the geometric differences between machined and as-cast part? e. analyze its thickness and shape complexity. What is the difference between IGES and STL format? c. 6. b. Are large fillets always desirable in a casting? Lab Exercise 2: Core print design . The steps include the following: 1. Compute its volume and weight. Import the part model into AutoCAST. 5. 3. and measure wall thickness. minimum and maximum wall thickness. manufacture. Why is there a difference in volume calculation from IGES and STL file? d. Name a few CAD file formats. compute its geometric properties. Calculate its volume.

Viva Questions: a. 2. Calculate the buoyancy force on the core. What is the direction of the net force acting on a core? Is it always up or down? d. Generate a methods report with the image of the core prints. Is there any difference in buoyancy force for a vertical and horizontal core with the same dimensions? c. Open the previous casting project in AutoCAST. 4. The following steps are involved: 1. Prepare a report comparing the hand calculations with the methods report generated by the program. and the buoyancy forces. 5. What are the different purposes of core prints? b. Select the cored hole for print design. What will happen if buoyancy force is too large for a vertical core? What is the remedy? .The objective of this exercise is to design the core prints to support the core in mold. Identify the cored holes. 6. Calculate the diameter and length of core prints for the given part considering weight balance. Compute the volume and weight of each core along with its print. Change the diameter and length of each core print if needed. 3. What happens if a thin core is placed in a thick section of a casting? e.

What will happen if cavity to mold wall gap is too small? c. Select the mold box option. 4.Lab Exercise 3: Mold cavity layout The objective of this exercise is to determine the correct combination of mold box and number of cavities to achieve the desired ratio of cast metal to mold material. A low ratio leads to poor utilization of production resources. Generate a methods report with the image of the best mold cavity layout. Decide the cavity-cavity and cavity-mold wall gap. What is the ideal ratio of cast metal to mold material for steel? For aluminum? e. Compute the values of cast metal to mold material ratio for each option (mold box and number of cavities). 6. to be equal to maximum thickness of part. Open the previous casting project in AutoCAST. Decide the maximum number of cavities that can be accommodated in different sizes of mold box. What will happen if cavity-cavity gap is too small? Too large? b. Select the option with the highest ratio. Calculate the ratio of cast metal to mold material for each case. Prepare a report comparing the hand calculations with the methods report generated by the program. Viva Questions: a. 2. Why does the ideal cavity-cavity gap depend on part wall thickness? d. design and model the maximum number of cavities for the mold box. 5. 3. whereas a high ratio leads to poor quality. What is the typical strength of green sand and resin-bonded molds? . The following steps are involved: 1.

What are relative advantages of side and top feeders? c. Estimate the solidification time of the casting. What is the ideal shape of a feeder? Explain why? b. Verify the design by simulation again. and apply feed aids like insulating sleeves and chills. to obtain a casting free of solidification shrinkage defects along with the highest possible yield. Design feeder(s) for the given casting based on modulus principle. Note down the solidification time. Generate a methods report for the best feeder design (best quality and yield). specify the feeder type and position. 2. How can you measure the efficiency of a feeder? e. change the feeder shape and dimensions.Lab Exercise 4: Feeder design and solidification simulation The objective of this exercise is to design. 5. Open the previous casting project in AutoCAST. Can you replace all feeders for a casting with chills? d. The following steps are involved: 1. find the hot spots. If needed. Prepare a report comparing the hand calculations with the methods report. 3. model and verify the feeding system design for the given casting. Verify the feeder design by solidification simulation: shrinkage porosity should shift to the feeder(s). design and model the feeder(s). What is feeder yield? Why is yield higher for cast iron than for steel? . 6. Viva Questions: a. 4.

What will happen if filling time is too long or too short? d. runner and gates in mold filling? c. complete and uniform filling of the mold cavity. Also check the effect of gating on casting solidification. What are the different casting defects arising out of improper filling of mold cavity? Lab Exercise 6: Casting cost estimation . model and verify the gating channel design for the given casting. Decide the locations of sprue. Generate a methods report for the final gating design. to achieve smooth.Lab Exercise 5: Gating design and mold filling simulation The objective of this exercise is to design. Viva Questions: a. Verify the gating design by mold filling simulation: check the impact velocity of molten metal on the mold walls. What is gating ratio? Compare converging and diverging gating ratios. 3. What are the roles of sprue. Open the previous casting project in AutoCAST. complete the gating layout. 2. and compute the dimensions of the gating channels. 6. b. Decide the ideal filling time of the casting and design the choke. Prepare a report comparing the hand calculations with the methods report. runner(s) and gate(s) and calculate their dimensions. vertical velocity in the top portions. Why sprue should be tapered down (bottom dia smaller than top dia)? e. 5. 4. and the total filling time. Modify the gating design if needed. The following steps are involved: 1. and verify by simulation again.

and compute the above costs using the program. What are the different ways to reduce the total cost of a casting? SCHEME OF VALUATION . 4. 2. other). energy. considering recycling). and change their values. and to study the effect of various factors on total cost. etc. furnace efficiency).The objective of this exercise is to estimate the cost of a casting. The following steps are involved: 1. Check the effect of casting rejection and yield on the total cost. 1000). Prepare a report comparing the hand calculations with the methods report. If the number of cavities per mold is changed. labour. d.) and various factors (ex. Calculate the cost of tooling. 6. 3. What are the fixed and variable costs in a casting? e. What is the approximate cost of melting energy per kg of casting? b. energy (melting. Generate a methods report including the cost data. Check the difference in costs when mold and core recycling is either zero or 100%. and amortize it over a given order quantity (ex. Open the previous casting project in AutoCAST. 5. which costs will be affected? c. Viva Questions: a. and labour. if needed. Calculate the cost of direct metal (part weight). Check the values of various cost rates (metal. indirect material (mold and core material weight.

4 Any one Casting simulation software (AutoCAST/ ProCAST/MagmaCAST) 4.5 KvA 3. LCD projector-2 Nos. UPS-minimum 7.2 nos.Serial no Description Writing one programme on CNC Marks 1 (Two questions should be given and the student is required to write any one programme and same should be simulated) Simulation 20 2 a)CNC b)CASTING SIMULATION(only one exercise) 40 20 3 Viva Total 20 100 Facilities required for imparting training: 1. Laser jet printer for getting hard copies of student work System Requirements 1. 4. Computers with latest configurations-CPU-3.0GHz-RAM-2Gb/hdd-250Gb/dedicated graphics card1Gb 2. CNC Lathe and Milling simulation softwares 3. . MS Windows OS (Version 2000 or above) 2. Printers-Laser.