cad/cam manual

DHIRAJLAL GANDHI COLLEGE OF TECHNOLOGY

(Approved by AICTE and Affiliated to Anna University)

LABORATORY MANUAL

DEPARTMENT OF MECHANICAL ENGINEERING

CAD /CAM LABORATORY

(VI Semester Mechanical Engineering)

Salem Bengaluru Salem-

1



LABORATORY MANUAL


ME 6611

CAD /CAM LABORATORY

(VI Semester Mechanical Engineering)

Salem Bengaluru Highway (NH7), Sikkanampatty, Opp. Airport,-636309, Tamilnadu. Phone: 04290 233333

mail Id : [email protected]




Highway (NH7), Sikkanampatty, Opp. Airport, 04290 233333

DHIRAJLAL GANDHI


Subject Name

Subject Code

Semester /Year

Department to conducting the Lab

University

Regulation

Publication

Prepared by

Prof .N.Panneerselvam

B.E.,ME., Asst

Professor/Mechanical/DGCT Prof

Salem Bangalore Highway (NH7), Sikkanampatty, Opp. Airport, Salem 636309,

Phone: 04290 233333 / mail

2



: CAD/CAM Laboratory

: ME 6611

: VI/III

Department to conducting the Lab : Mechanical Engineering

: Anna University

: 2013

: DGCT/ 2nd Edition [For private circulation only]

Reviewed by Approved by

Dr.A.Selvaraj

M.E.,Ph.D

Professor /Mechanical/DGCT

Dr. N.Sundaramoorthy

M.E.,Ph.D

Prof.& Head /Mechanical/DGCT

Highway (NH7), Sikkanampatty, Opp. Airport, Salem 636309, Tamilnadu.

04290 233333 / mail Id: [email protected]


Edition [For private circulation only]

Approved by

Dr. N.Sundaramoorthy

M.E.,Ph.D

Prof.& Head /Mechanical/DGCT

Highway (NH7), Sikkanampatty, Opp. Airport, Salem 636309,


(Approved by AICTE and

Department of Mechanical Engineering

Vision

• To improve the quality of human life through multiEngineering, architecture and management that are internationally

recognized and would economical and environmental development.

Mission

• To create a vibrant atmosphere that creates competent engineers, innovators, scientists, entrepreneurs, academicians and thinkers of

tomorrow. • To establish centers of excellence that provides sustainable solutions to

industry and society.

• To enhance capability through various value added programs so as to meet the challenges of dynamically changing global needs.

Vision:

To provide the highest state of the art research for innovation that will enable the students to excel in

their field. Mission:

- To achieve high ethical and professional standards through effective

teaching and learning process.- To provide infrastructure for research and development activities.

- To offer consultancy services for the industries.- To provide guidance to neighborhood and cultivate the spirit of

entrepreneurship.

Program Educational Objectives(PEOs)

PEO1

To prepare graduates who will create new ways to meet society's needs

with their updated knowledge of Mechanical Engineering.

PEO2

To develop the ability among students todata and technical concepts

PEO3 To provide opportunity for students to work as part of teams on

multidisciplinary projects.

PEO4

To provide students with a sound foundation in the mathematical,

scientific and engineering fundamentals necessary toand analyze engineering problemsstudies.

PEO5 To promote student's awareness of lifethem to professional ethics and codes of professional practice.

3




College

To improve the quality of human life through multi-disciplinary programs in Engineering, architecture and management that are internationally

recognized and would facilitate research work to incorporate social economical and environmental development.

To create a vibrant atmosphere that creates competent engineers, innovators, scientists, entrepreneurs, academicians and thinkers of

ters of excellence that provides sustainable solutions to industry and society.

To enhance capability through various value added programs so as to meet the challenges of dynamically changing global needs.

Department

To provide the highest quality in engineering education and establish the state of the art research for innovation that will enable the students to excel in

To achieve high ethical and professional standards through effective

teaching and learning process. To provide infrastructure for research and development activities.

To offer consultancy services for the industries. To provide guidance to neighborhood and cultivate the spirit of

Program Educational Objectives(PEOs)

graduates who will create new ways to meet society's needs

with their updated knowledge of Mechanical Engineering.

To develop the ability among students totechnical concepts for application to product design

opportunity for students to work as part of teams on

multidisciplinary projects.


scientific and engineering fundamentals necessary to formulate, solve, engineering problems and to prepare them for graduate

To promote student's awareness of life-long learning and to introduce them to professional ethics and codes of professional practice.

Affiliated to Anna University)

disciplinary programs in Engineering, architecture and management that are internationally

facilitate research work to incorporate social

To create a vibrant atmosphere that creates competent engineers, innovators, scientists, entrepreneurs, academicians and thinkers of

ters of excellence that provides sustainable solutions to

To enhance capability through various value added programs so as to meet

quality in engineering education and establish the state of the art research for innovation that will enable the students to excel in

To achieve high ethical and professional standards through effective

To provide infrastructure for research and development activities.

To provide guidance to neighborhood and cultivate the spirit of

graduates who will create new ways to meet society's needs

To develop the ability among students to synthesize product design.

opportunity for students to work as part of teams on


formulate, solve, and to prepare them for graduate

long learning and to introduce them to professional ethics and codes of professional practice.




PO1 a) Apply the knowledge of mathematics, science, engineering fundamentals to

the solution of complex problems in

PO2 b)

Identify, formulate, research literature, and

Engineering problems reaching substantiated conclusions using first

principles of mathematics, natural sciences, and engineering sciences.

PO3 c)

Design solutions for complex

system components or processes that meet t h e specified needs with

appropriate consideration for the public health and safety, and the cultural,

societal, and environmental considerations.

PO4 d)

Use research-based knowledge and research methods including design of

experiments, analysis and interpretation of data, and synthesis of the

information to provide valid conclusions related to

PO5 e)

Create, select, and apply appropriate techniques, resources, and modern

engineering and IT tools including prediction and

Mechanical engineering activities with an understanding of the limitations

PO6 f)

Apply reasoning informed by the

health, safety, legal

relevant to the professional engineering practice.

PO7 g)

Understand the impact of the professional engineering solutions in societal

and environmental contexts, and demonstrate the knowledge of, and need

for sustainable development.

PO8 h) Apply ethical principles and commit to professional ethics and responsibilities

and norms of the engineering practice.

PO9 i) Function effectively

teams, and in multidisciplinary settings.

PO10 j)

Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as, being able to

comprehend and write effective reports and design documentation, make

effective presentations, and give and receive clear instructions.

PO11 k)

Demonstrate knowledge and understanding of t h e engineering and

management principles and apply these to one’s own work,

and leader in a team, to manage projects and in multidisciplinary

environments.

PO12 l)

Recognize the need for, and have the preparation and ability to engage in

independent and life

change.

Program Specific Outcomes(PSOs)

PSO1 p) Ability of the graduates to perform in advanced machining by outrival of

schooling thro’u internship between institutes

PSO2 q) Graduates will demonstrate the ability to design a mechanical

complex modeling and analysis software thro’u continuing education.

PSO3 r) Graduates will be exposed to industrial practices and acquire the ability to

serve in core industry.

4



Department of Mechanical Engineering Program Outcomes(POs)

Apply the knowledge of mathematics, science, engineering fundamentals to

the solution of complex problems in Mechanical Engineering.

Identify, formulate, research literature, and analyze complex

problems reaching substantiated conclusions using first


Design solutions for complex Mechanical engineering problems and design



societal, and environmental considerations.

based knowledge and research methods including design of


information to provide valid conclusions related to Mechanical


engineering and IT tools including prediction and modeling

engineering activities with an understanding of the limitations

Apply reasoning informed by the contextual knowledge to assess societal,

legal and cultural issues and the consequent responsibilities

relevant to the professional engineering practice.


nd environmental contexts, and demonstrate the knowledge of, and need

for sustainable development.

Apply ethical principles and commit to professional ethics and responsibilities

and norms of the engineering practice.

Function effectively as an individual, and as a member or leader in diverse

teams, and in multidisciplinary settings.



and write effective reports and design documentation, make



management principles and apply these to one’s own work,



independent and life-long learning in the broadest context of technological

Program Specific Outcomes(PSOs)

Ability of the graduates to perform in advanced machining by outrival of

schooling thro’u internship between institutes – industry.

Graduates will demonstrate the ability to design a mechanical


Graduates will be exposed to industrial practices and acquire the ability to

serve in core industry.


Apply the knowledge of mathematics, science, engineering fundamentals to

complex Mechanical

problems reaching substantiated conclusions using first


engineering problems and design



based knowledge and research methods including design of


Mechanical Engineering.


modeling to complex

engineering activities with an understanding of the limitations

contextual knowledge to assess societal,

and cultural issues and the consequent responsibilities


nd environmental contexts, and demonstrate the knowledge of, and need

Apply ethical principles and commit to professional ethics and responsibilities

as an individual, and as a member or leader in diverse



and write effective reports and design documentation, make



management principles and apply these to one’s own work, as a member



long learning in the broadest context of technological

Ability of the graduates to perform in advanced machining by outrival of

Graduates will demonstrate the ability to design a mechanical system using


Graduates will be exposed to industrial practices and acquire the ability to




ME6611 CAD / CAM LABORATORY

1 To gain practical experience in handling 2D drafting and 3D modeling software

systems.

2 To study the features of CNC Machine Tool.

3 To expose students to modern control systems (Fanuc, Siemens etc.,)

4

To know the application of various CNC machines like CNC lathe, CNC Vertical

Machining centre, CNC EDM and CNC wireprototyping.

CO1 Apply the knowledge to

CO2 Expert in CNC part programming

CO3 Designing and Modeling of Various Mechanical components

CO4 Use of the modern concepts for Research and Development.

CO5 To do simulation and analysis

CO6 Ability to use software for reducing the error, work time, wastage, man power

and cost of work etc.,

5





Course Objectives

To gain practical experience in handling 2D drafting and 3D modeling software

To study the features of CNC Machine Tool.

To expose students to modern control systems (Fanuc, Siemens etc.,)


Machining centre, CNC EDM and CNC wire-cut and studying of Rapid

Course Outcomes(Cos)

knowledge to CNC control in modern manufacturing system.

CNC part programming for to perform automated

Designing and Modeling of Various Mechanical components

the modern concepts for Research and Development.

simulation and analysis of various Mechanical problems

Ability to use software for reducing the error, work time, wastage, man power

and cost of work etc.,


To gain practical experience in handling 2D drafting and 3D modeling software

To expose students to modern control systems (Fanuc, Siemens etc.,)


cut and studying of Rapid

CNC control in modern manufacturing system.

automated manufacturing.

the modern concepts for Research and Development.

of various Mechanical problems

Ability to use software for reducing the error, work time, wastage, man power

6

Mapping

Course Outcomes

(COs) a) b) c) d) e) f) g) h) i) j) k) l) p) q) r)

Apply the knowledge to

CNC control in modern

manufacturing system.

3 3 1 2 2 3 3 3 3 3 3 3 1 2 1

Expert in CNC

part programming for

to perform automated manufacturing.

3 3 1 2 2 3 3 3 3 3 3 3 1 2 1

Designing and Modeling of

Various Mechanical

components

3 2 1 2 2 2 3 3 3 3 3 3 2 2 2

Use of the

modern concepts for Research and Development.

2 2 2 1 2 2 3 3 3 3 3 3 2 2 2

Ability to use

software for

reducing the error,

work time,

wastage, man

power and cost of

work etc.,

3 2 2 2 1 1 2 2 3 3 3 3 3 2 3

To do simulation

and analysis of various

Mechanical problems

3 3 3 3 1 2 3 3 3 3 3 3 3 2 3

7

TIPS FOR A BETTER LAB SESSION

Some of the Best Practices to help the Lab run smoothly while

maximizing Student Learning.

1. Students should be familiar with the Lab exercises before coming to Lab.

2. Students should treat the Laboratory Exercises as original Research.

3. Students should make sure not to miss even a single Lab Class.

4. Students must apply the concepts learned in the class to New Situations.

5. Each student must try to do their Lab Exercises Individually.

6. The instructor will hold a pre-laboratory discussion on the lab exercises.

7. Each student should write the meaning of every command or statement in

the program by using pencil in the empty space. This will help them

understand the concepts more clearly at any point of time.

8. Each student should draw the model for the extra lab exercise questions

given in the manual before every Lab Session.

9. The students should come prepared for Viva based on the questions given

in the lab manual.

10.If the students come unprepared, he/she will not be allowed to do the Lab

exercise and will be marked absent.

11.The progress of every student will be monitored on a regular basis. Based

on the progress report Extra Credit Marks will be awarded for the students

in their Internals.

12.Every student must be able to explain the modeling concepts clearly at the

end of each Lab Session.

13.Labs are for you (students) and so consider it as your duty to use it

perfectly. It’s your responsibility to take care of the computer systems and

the other equipment.

8

I. EVALUATIONS:

� All students should go through the lab manual for the experiment to be

carried out for that day and come fully prepared to complete the experiment

within the prescribed periods. Student should complete the lab record work within

the prescribed periods.

� Students must be fully aware of the core competencies to be gained by

doing experiment/exercise/programs.

� Students should complete the lab record work within the prescribed

periods.

� The following aspects will be assessed during every exercise, in every lab

class and marks will be awarded accordingly:

� Preparedness, conducting experiment, observation, calculation, results,

record presentation, basic understanding and answering for viva questions.

� In case of repetition/redo, 25% of marks to be reduced for the respective

component.

a. Preparation means coming to the lab classes with neatly drawn

circuit diagram /experimental setup /written programs /flowchart, tabular

columns, formula, model graphs etc in the observation notebook and must

know the step by step procedure to conduct the experiment.

b. Conducting experiment means making connection, preparing the

experimental setup without any mistakes at the time of reporting to the

faculty.

c. Observation means taking correct readings in the proper order and

tabulating the readings in the tabular columns.

d. Calculation means calculating the required parameters using the

approximate formula and readings.

e. Result means correct value of the required parameters and getting

the correct shape of the characteristics at the time of reporting of the

faculty.

f. Viva voice means answering all the questions given in the manual

pertaining to the experiments.

g. Full marks will be awarded if the students perform well in each case

of the above component.

“ENJOY THE JOY OF COMPUTER AIDED DESIGNING AND MANUFACTURING

9

Syllabus


LIST OF EXPERIMENTS L T P C 0 0 3 2

1. 3D GEOMETRIC MODELLING 24

Introduction of 3D Modeling software

Creation of 3D assembly model of following machine elements

using 3D Modeling software

1 Flange Coupling 8 Crosshead

2 Plummer Block 9 safety Valves

3 Screw Jack 10 Non-return

valves

4 Universal Joint 11 Connecting rod

5 Lathe Tailstock 12 Piston

6 Machine Vice 13 Crankshaft

7 Stuffing box

* Students may also be trained in manual drawing of some of the above

components

2. Manual Part Programming. 21

(i) Part Programming - CNC Machining Centre

a) Linear Cutting.

b) Circular cutting.

c) Cutter Radius Compensation.

d) Canned Cycle Operations.

(ii) Part Programming - CNC Turning Centre

a) Straight, Taper and Radius Turning.

b) Thread Cutting.

c) Rough and Finish Turning Cycle.

d) Drilling and Tapping Cycle.

3. Computer Aided Part Programming

e) CL Data and Post process generation using CAM packages.

f) Application of CAPP in Machining and Turning Centre.

TOTAL: 45 PERIODS

11

CONTENT

S.N

o Date Experiment

Page

No Marks

Signature

of the staff

3D GEOMETRIC MODELLING

1 Introduction of 3D Modeling software 14

2 Flange Coupling 19

3 Plummer Block 23

4 Universal Coupling 27

5 Screw Jack 31

6 Machine Vice 35

7 Connecting Rod 39

8 Pipe Vice 43

COMPUTER AIDED PART PROGRAMMING

9 Study of CAM, CNC Turret Centre, CNC

Milling and these ‘G’ Codes And ‘M’ Codes 49

10

Manual Part Programming for Linear Interpolation in CNC Turret centre

(Facing, Step Turning and Taper Turning)

61

11

Manual Part Programming for Linear

Interpolation in CNC Turret centre (Chamfering, Drilling and Grooving)

65

12

Manual Part Programming for Circular Interpolation in CNC Turret centre

(Grooving, Counter sunk drilling and Fillet)

69

13 Manual Part Programming for Linear Interpolation in CNC Turret centre (Threading)

73

14 Manual Part Programming for Linear & Circular Interpolation in CNC Milling

77

15 Manual Part Programming for Linear &

Circular Interpolation in CNC Milling 81

Average Marks

13

3D GEOMETRIC MODELLING

15

Ex.No 01 STUDY OF 3D MODELING SOFTWARE

Date

Aim:

To study the 3D Modeling Software.

Introduction

The two dimensional orthographic views have been the conventional method of

representing a product shape. The two dimensional drawings have been very difficult to

understand. By creating three dimensional drawings of engineering components using

advanced software is known as 3D modeling.

Types of 3D Modeling

1. Wireframe modeling

2. Surface modeling

3. Solid modeling

Solid modeling

The difficulties in wire frame and surface modeling are overcome by solid modeling.

Solid modeling is classified in seven types

1. Primitive instancing

2. Generalized sweeping

3. Special occupancy enumeration

4. Cellular decomposition

5. Constructive Solid Geometry(CSG)

6. Boundary Representation (B-rep)

7. Hybrid System

Hybrid System

In the seven methods the hybrid system is an advanced solid modeling contains software

packages, the advantages, of CSG and B-rep are combined.

Software

1. I – DEAS

2. PRO / ENGINEER

3. UNIGRAPHICS

4. CATIA

5. SOLIDWORKS

The various commands used in 3D modeling as tabulated below.

S.No Command Description

1 Open Open the Existing Drawing file

2 New To Start new drawing

3 Part A 3D representation of a single design component

4 Drawing A 2D Engineering drawing, typically of a part or assembly

5 Assembly A 3D arrangements of parts or assemblies

6 Sketch To start new 2D sketch or 3D sketch

7 Smart dimension Create one or more dimensions of selected entities

8 Line Creates straight line segments

16

9 Rectangle To sketch a rectangle

10 Circle To sketch a circle

11 Arc Creates an arc

12 Polygon Sketch a polygon to different no of sides

13 Spline Sketch a spline

14 Fillet/Chamfer Bulge/Bevels the edges of object

15 Slot To create a elliptical hole

16 Ellipse To sketch a ellipse

17 Plane Inserts a plane in to 3D sketch

18 Text To create a text

19 Point To mark a point on entities

20 Trim/ Extend Trim/Extend the entities

21 Convert entities Convert selected model edges or sketch entities into sketch segments

22 Offset entities Adds sketch entities by offsetting faces

23 Move/Copy entities

Move/Copy the selected entities

24 Mirror entities Mirror selected entities about a center line

25 Linear/Circular

sketch pattern

Create copy entities along a curve /line about a

center for selected entities

26 Display/Delete

relations

Display/Delete the geometric relation between the

entities

27 Repair sketch Repair the sketch

28 Rapid sketch Allows 2D sketch in D sketch by dynamically

29 Quick snaps Quick snaps and filters

30 Zoom to fit Fit the sketch in to window

31 Zoom to area Zoom to the area in to selected boundary box

32 Previous view To see previous view

33 Section view Display a cutaways of part or assemble by one or more

no of planes

34 View orientation To view parts in to different views

35 Display style To view the parts in to different shade

36 Hide/Show items Appear/Disappear the parts

37 Edit appearance To change the color/transparency

38 Apply scene To change the background of the screen

39 View settings Toggles the sketch into real view, shadow or perspective

40 Features To draw the 3D drawing

41 Extrude Boss/Base To extrude the 2D into 3D parts

17

42 Revolved Boss/Base Create cylindrical parts about a center line

43 Swept Boss/Base Extrude the profile along specified path

44 Lofted Boss/Base Adds material between two or more sketches

45 Boundary Boss/Base Adds material between to or more sketches in to two

different directions

46 Extrude cut Cut the model using specified profile in to one or two

directions

47 Hole wizard Inserts a hole into a Predetermined cross sections

48 Revolved cut Cut the model using specified profile about a center line

49 Swept cut Cut the model using specified profile along a specified

path

50 Lofted cut Adds material between two or more sketches

51 Boundary cut Remove material l between two or more sketches in to

two different directions

52 3D fillet Bulge/Bevels the edges of extruded object

53 3D Linear/Circular

sketch pattern

Create copy entities along a curve /line about a center

for selected entities

54 Rib Add thin walled support to a solid body

55 Draft Tape the model on specified faces

56 Shell Remove the material from the solid body to create a

thin walled structure

57 Wrap Wraps the closed sketch contour on to a face

58 Dome Adds one or more domes on selected planer or non

planar faces

59 Mirror 3D Mirror selected 3D parts about a center line

60 Reference Geometry Create a reference plane/Line /Point/Coordinate system

61 Curves Draws helix/Spiral

RESULTS:

Thus the 3D modeling software was studied.

18

Parts Drawing

2D Drawing with Dimensions*

*The 2D drawing is to be drawn by manually with proper dimension in

Record note book by suitable scale.

19

Ex.No 02 FLANGE COUPLING

Date

Aim:

1. To create 3D models of Shaft Coupling parts using Solid works.

2. To Create the Assembly of Shaft Coupling using Solid works

Requirements:

Hardware

1. System : Windows 7 (32 Bit)

2. Processor : Intel Core I3

3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Flange1, Flange 2, Shaft, pin with nut, Feather key and Bush

are studied.

2. 3D models of Flange1, Flange 2, Shaft, pin with nut, Feather key and Bush

are created using Solid works

3. The Assembly of Shaft Coupling was created as per the drawing specification.

Commands used:

1. Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart

Dimension, Relations, Show, and View Features

2. Feature Commands: Extrude (pad) and Cut, Revolve (shaft),

Fillet/Round, Chamfer, Hole - Simple, Pattern, Fastening Features

3. Assembly Commands: Insert, Component, Existing Part/Assembly

4. Mating Commands: Coincident, Concentric, Distance

20

ASSEMBLY DRAWING OF FLANGE COUPLING *

* The assembly drawing image is to be saved in your folder which is

created in working directory and take color print out for to enclose in the

Record note book.

21

Viva voce questions:

1. What are the applications of coupling?

2. List out types of keys?

3. What are the types of bolts?

4. What are the various types of coupling?

5. What is coupling?

Result:

The 3D models of Flange Coupling parts are created and assembled using

Solid works.

22




23

Ex.No 03 PLUMMER BLOCK

Date

Aim:

1. To create 3D models of Plummer Block parts using Solid works.

2. To Create the Assembly of Plummer Block using Solid works

Requirements:

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. 1. The drawings of Base, Bearing Brass1, Bearing Brass 2, Cap, Bolt with

nuts are studied.

2. 2. 3D models of Base, Bearing Brass1, Bearing Brass 2, Cap, Bolt with

nuts are created using Solid Works

3. 3. The Assembly of Plummer Block was created as per the drawing

specification.

Commands used:

1. Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart Dimension,

Relations, Show, and View Features





24

ASSEMBLY DRAWING OF FLANGE COUPLING *



Record note book.

25

Viva voce questions:

1. What are the applications of Plummer Block?

2. Differentiate between Plummer Block and flange coupling

3. How the lubrication oil supplied in the Plummer Block?

4. Why check nut is used?

5. What are the material for base and bush?

Result:

The 3D models of Plummer Block parts are created and assembled using

Solid works.

26




27

Ex.No 04 UNIVERSAL COUPLING

Date

Aim:

1. To create 3D models of Universal Coupling parts using Solid works.

2. To Create the Assembly of Universal Coupling using Solid works

Requirements

Requirements:

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Shaft, Fork, Central block, Pin, Collar and Key are studied.

2. 3D models of Shaft, Fork, and Central block; Pin, Collar and Key are created

using Solid Works

3. The Assembly of Universal Joint was created as per the drawing specification.

Commands used:



2. Commands: Extrude (pad) and Cut, Revolve (shaft), Fillet/Round,

Chamfer, Hole - Simple, Pattern, Fastening Features



28

ASSEMBLY DRAWING OF UNIVERSAL COUPLING *



Record note book.

29

Viva voce questions:-

1. What are the applications of universal joint?

2. Differentiate between universal joint and flange coupling.

3. What are the material for fork and central block?

4. Where does the universal joint specifically used?

5. What is meant by collar? What is its material?

Result: The 3D models of Universal Coupling parts are created and assembled

using Solid Works.

30




31

Ex.No 05 SCREW JACK

Date

Aim:

1. To create 3D models of Screw Jack parts using Solidworks

2. To Create the Assembly of Screw Jack using Solidworks

Requirements

Requirements:

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Body, Nut, Screw Spindle, Cup, Washer Special, CSK Screw,

and Tommy Bar are studied.

2. 3D models of Body, Nut, Screw Spindle, Cup, Washer Special, CSK Screw, and

Tommy Bar are created using Solidworks

3. The Assembly of Screw Jack was created as per the drawing specification.

Commands used:



2. Feature Commands: Extrude and Cut, Revolve (shaft), Fillet/Round,




32

ASSEMBLY DRAWING OF SCREW JACK *



Record note book.

33


1. What are the applications of Screw jack?

2. What is the material for body of screw jack?

3. Where does the Plummer Screw jack specifically used?

4. Why square threads are preferred over V threads?

5. What is revolving command?

Result: The 3D models of Screw Jack parts are created and assembled using

Solid Works.

34




35

Ex.No 06 MACHINE VICE

Date

Aim:

1. To create 3D models of Machine Vice parts using Solidworks 2011.

2. To Create the Assembly of Machine Vice using Solidworks 2011.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Base, Screw, End Plate, Fixed jaw, Sliding Jaw, Block, Head

screw type1 and 2 are studied.

2. 3D models of Base, Screw, End Plate, Fixed jaw, Sliding Jaw, Block, Head screw

type1 and 2 are created using Solid Works

3. The Assembly of Machine Vice was created as per the drawing specification.

Commands used:






4. Mating Commands: Coincident, Concentric, Distance.

36

ASSEMBLY DRAWING OF MACHINE VICE *



Record note book.

37


1. What are the applications of Machine vice?

2. List out the various parts of Machine vice assembly.

3. Where does the Machine vice specifically used?

4. Why Machine vice is preferred over bench vice?

5. What are the types of vices?

Result: The 3D models of Machine Vice parts are created and assembled using

Solid Works.

38


The 2D drawing is to be drawn by manually with proper dimension in


39

Ex.No 07 CONNECTING ROD

Date

Aim:

1. To create 3D models of Connecting Rod parts using Solid works.

2. To Create the Assembly of Connecting Rod using Solid works.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Rod, cap, Bearing Brass, Bush, Bolt and Nut are studied.

2. 3D models of Rod, cap, Bearing Brass, Bush, Bolt and Nut are created using

Solid works

3. The Assembly of Connecting Rod was created as per the drawing

specification.

Commands used:







40

ASSEMBLY DRAWING OF CONNECTING ROD *



Record note book.

41


1. What are the applications of connecting rod?

2. List out the various parts of connecting rod assembly.

3. Where does the Connecting specifically used?

4. What is the material of connecting rod? Why it is preferred?

5. What is the material for bearing bush?

Result: The 3D models of Connecting Rod parts are created and assembled using Solidworks

43

Ex.No 08 PIPE VICE

Date

Aim:

1. To create 3D models of Pipe Vice parts using Solid works.

2. To Create the Assembly of Pipe Vice using Solid works.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Solid Works

Procedure:

1. The drawings of Rod, cap, Bearing Brass, Bush, Bolt and Nut are studied.

2. 3D models of Rod, cap, Bearing Brass, Bush, Bolt and Nut are created using

Solid works

3. The Assembly of Connecting Rod was created as per the drawing

specification.

Commands used:

1. Sketcher Commands: Line, Circle, Arc, Fillet, Trim, Smart

Dimension, Relations, Show, and View Features





44

ASSEMBLY DRAWING OF PIPE VICE

45

Viva-voce questions:

1. What is feature based modeling?

In advanced solid modeler software packages, the advantages, of Constructive Solid

Geometry (CSG) and Boundary representation (B-rep) approaches are combined. Using

modern software packages both CSG and B-rep methods can be simultaneously used to

increase productivity and to avoid complication in work. Using extrude, revolve, sweep

commands the modeling of objected can constructed easily. Such type modeling is

termed as feature based modeling.

2. What is software used for modern solid modeling?

I-DEAS, Pro-E, Unigraphics, and CATIA are the software used for solid modeling.

3. What are the commands involved during constructing the thread?

Sketch: Circle and Polygon

Feature: Springs and spiral and Swept cut

Result:

Thus the given solid modeling of a Pipe vice was constructed by feature based

modeling using Solid Work software.

47

COMPUTER AIDED PART PROGRAMMING

49

Ex.No 09 STUDY OF CAM, CNC TURRET CENTRE, CNC MILLING

AND IT’S ‘G’ CODES AND ‘M’ CODES Date

INTRODUCTION

Computer Aided Manufacturing is to Plan, Manage and Control the

operations of manufacturing plant through either direct or indirect computer

interface with the plant’s production resources. The inventor himself would not

have dream of the use of computers in various fields of life which is drastically

changing the entire scenario of the universe. It is now an integral part of our day

today life. There is lot of research going on with the help of computers in the field

of factory automation. The declining cost of computers coupled with the invention

of Multi task high speed micro processors, really made an industrial revolution and

there seems to be no end for this. A distinct trend can be observed in industries

which include an increase in the use of computer controlled machine tools, the

application of new manufacturing systems, such as laser beam machines and

appearance of new generation of industrial robots in the production line, the

manufacturing management through MRP.

Evolution of Automation

Automatically controlled factory is nothing more than the latest

development in the industrial revolution that began in Europe two centuries ago

and progressed through the following stages.

1. Mechanization started in 1870 at the beginning of industrial revolution

with simple production machines.

2. In 19th Century fixed automatic mechanism and transfer lines came into

existence for faster output and shorter production time.

3. Simple automatic control machines and copying machines were invented

in the later part of the 19th century. After 1950 the industrial

automation was started. In this second phase of the industrial

automation / revolution, workers, instead of physically performing all

the task, are placed in the control of the machines.

Progressive Change after 1950 is as follows

1. The introduction of Numerical Control (NC) in 1952 opened a new era in

automation.

2. The extension of NC was computerized control (CNC) machine tools in

which computer (Micro Processor) is included as an integral part of the

control system.

3. Commercial Industrial robot was manufactured in 1961 along with CNC

systems. The use of these robots, are well utilized only after 1970’s

4. The next logical extension is a fully automated factory which employs a

Flexible Manufacturing Systems (FMS) and Computer Aided Design /

Computer Aided Manufacturing (CAD / CAM) techniques.

51

5. The latest of the above is Computer Integrated Manufacturing (CIM)

which includes battery of CNC machines, with flexible modules, for

manufacturing tool head changers automatic material handling systems

like Automated Guided Vehicle (AGV) etc. with minimum number of

operating personals.

Computer Numerical Control

A dedicated micro processor or minicomputer on the machine control

makes the computer numerical control, very popular, coupled with lots of other

advantages.

Advantages

1. Accuracy and repeatability is very high

2. Reduced Scrap and Work

3. Reduced inspection time

4. Ease of inter changeability of machined parts

5. Reduced space

6. Reduced material handling

7. Less paper work

8. Less lead time

9. Less inventory

10.Easy editing of Programs

11.Complicated shapes and contours are easily manufactured with quality

assurance and better production management.

12.better utilization of machines

13.Reduced tooling

14.Reduced operator skill

15.No jigs and with minimum fixtures

16.Reduced floor space

17.Higher level of integration such as DNC, FMC, AC, CAD / CAM etc.,

Application of CNC

In automobile, aircraft and general Engineering industry, CNC machines are

essential to achieve competitive quality standards.

The following are the common CNC machine available in the industry

1. CNC lathe

2. CNC Milling / Drilling Machine

3. CNC Turning Centre

4. CNC Machining Centre, Multi machining centre

5. CNC Turn Mill Centre

6. CNC Tool and Cutter Grinding

7. CNC Grinding Machine, surface, Cylindrical etc.,

8. CNC boring and Jig boring machines etc.,

9. CNC EDM, Wire cut EDM etc.,

10.CNC Gear Hobbing, gear shaping, gear grinding etc.,

11.CNC Electron beam welding

53

12.CNC Laser / Plasma / arc welding machine etc.,

13.CNC Co – ordinate measuring machines (CMM)

14.CNC Nibbling press, press bruised, turret

COMMERCIAL CAM SOFTWARE

1. Master CAM

2. ESPRIT CAM

3. UG CAM

4. Edge CAM

5. DELCAM

6. Cimarron E

7. CADEM

8. Keller

SPECIFICATIONS:

MECHANICAL DETAILS

Swing Over Bed : 150 mm

Swing Over Cross Slide : 50 mm

Distance Between Centers : 300 mm

Travel ‘X’ Axis : 80 mm

Travel ‘Z’ Axis : 170 mm

Spindle speed (Step Less) : 0 – 3000 rpm

Spindle Bore : 21 mm

Spindle Taper : MT3

Tailstock Taper : MT2

X Axis Ball Screws : 12 mm x 2.5 mm Pitch

Z Axis Ball Screws : 16 mm x 5 mm Pitch

ELECTRICAL DETAILS

Main Supply Required : 50/60 Hz-Phase

: 220/240 Volts, 10 Amps

Spindle Power : 1 H.P

Axes Motor : Stepper Motor-200 Steps/rev

DIMENSIONS

Machine Length : 850 mm

Machine Depth : 584 mm

Machine Height : 548 mm

Machine Weight : 110 kg

54

GG--CCOODDEESS -- ((PPRREEPPAARRAATTOORRYY FFUUNNCCTTIIOONN))

TTUURRNNIINNGG PPRROOGGRRAAMMMMEE

S.No G –CODES FUNCTIONS

1 G00 Positioning (Rapid Traverse)

2 G01 Linear Interpolation (Feed)

3 G02 Circular Interpolation (CW)

4 G03 Circular Interpolation (CCW)

5 G04 Dwell

6 G20 Inch Data Input

7 G21 Metric Data Input

8 G28 Reference Point return (Home)

9 G32 Thread Cutting

10 G40 Tool nose radius compensation cancel

11 G41 Tool nose radius compensation left

12 G42 Tool nose radius compensation right

13 G50 Work co-ord. Change/Max.Spindle Speed setting

14 G70 Finishing cycle

15 G71 Stock removal in turning

16 G72 Stock removal in facing

17 G73 Pattern repeating

18 G74 Peck Drilling in Z axis

19 G75 Grooving in X axis

20 G76 Thread Cutting cycle

21 G90 Cutting cycle A (Turning)

22 G92 Thread Cutting cycle

23 G94 Cutting cycle B (Facing)

24 G96 Constant Surface speed control

25 G97 Constant Surface speed control cancel

26 G98 Feed per minute

27 G99 Feed per revolution

55

MM--CCOODDEESS -- ((MMIISSCCEELLLLAANNEEOOUUSS FFUUNNCCTTIIOONN))

S.No G –CODES FUNCTIONS

1 M00 Program Stop

2 M01 Optional Stop

3 M02 Program end

4 M03 Spindle Forward (CW)

5 M04 Spindle Forward (CCW)

6 M05 Spindle Stop

7 M06 Tool Change

8 M08 Coolant ON

9 M09 Coolant OFF

10 M10 Chuck Open

11 M11 Chuck Close

12 M30 Program Reset & rewind

13 M38 Door Open

14 M39 Door Close

15 M62 Output 1 On (Lathe)

16 M63 Output 2 On (Mill)

17 M64 Output 1Off(Lathe)

18 M65 Output 2 Off (Mill)

19 M66 Wait inpute1 On

20 M67 Wait inpute2 On

21 M76 Wait inpute1 Off

22 M77 Wait inpute2 Off

23 M98 Sub Program Call

24 M99 Sub Program Exit

56

CNC MILLING

57

SPECIFICATIONS:

MECHANICAL DETAILS

Table Size : 360x130 mm

Travel ‘X’ Axis : 170 mm

Travel ‘Y’ Axis : 90 mm

Travel ‘Z’ Axis : 115 mm

Spindle To Table : 190 mm

Spindle To Column : 110 mm

Spindle Taper : R8

Spindle Taper ATC : BT35

Z Axis Ball Screw : 16 mm Dia x 5mm Pitch

Y Axis Ball Screw : 16 mm Dia x 5mm Pitch

3 TEE Slots : 19 mm width

: 50 mm centers

ELECTRICAL DETAILS

Main Supply Required : 50/60 Hz-Phase

: 220/240 Volts, 8 Amps

Spindle Motor : 0.5 H.P

Axis Motor : Stepper Motor-200 Steps/Rev

DIMENSIONS

Machine Length : 550 mm

Machine Depth : 540 mm

Machine Height : 880 mm

Machine Weight : 113 kg

58

GG--CCOODDEESS –– ((PPRREEPPAARRAATTOORRYY FFUUNNCCTTIIOONN))

MMIILLLLIINNGG PPRROOGGRRAAMMMMEE

S.No G -CODES FUNCTIONS

1 G00 Positioning (Rapid Traverse)

2 G01 Linear Interpolation (Feed)

3 G02 Circular Interpolation (CW)

4 G03 Circular Interpolation (CCW)

5 G04 Dwell, Exact Stop

6 G17 XY Plane selection

7 G18 ZX Plane selection

8 G19 YZ Plane selection

9 G20 Inch Data Input

10 G21 Metric Data Input

11 G28 Reference Point return (Home)

12 G40 Cutter compensation cancel

13 G41 Cutter compensation left

14 G42 Cutter compensation right

15 G43 Tool length Compensation + direction

16 G44 Tool length Compensation -direction

17 G49 Tool length Compensation cancel

18 G73 High speed peck drilling cycle

19 G74 L.H Tapping cycle

20 G76 Fine boring

21 G80 Canned cycle cancel

22 G81 Continuous drilling cycle, spot boring

23 G82 Continuous drilling cycle, spot boring with dwell

24 G83 Peck drilling cycle

25 G84 R.H Tapping cycle

26 G90 Absolute Zero

27 G91 Incremental Command

28 G94 Feed per Minute

29 G170 & G171 Circular Pocketing

30 G172 & G173 Rectangular Pocketing

59

MM--CCOODDEESS –– ((MMIISSCCEELLLLAANNEEOOUUSS FFUUNNCCTTIIOONN))

MMIILLLLIINNGG PPRROOGGRRAAMMMMEE..

Result:

Thus the study of CAM, CNC turret centre, CNC milling and these G-codes

and M-codes are studied

S.No M-CODES FUNCTIONS

1 M00 Program Stop

2 M01 Optional Stop

3 M02 Program end

4 M03 Spindle Forward (CW)

5 M04 Spindle Reverse (CCW)

6 M05 Spindle Stop

7 M06 Tool Change

8 M08 Coolant ON

9 M09 Coolant OFF

10 M10 Vice Open

11 M11 Vice Close

12 M30 Program Reset & rewind

13 M38 Door Open

14 M39 Door Close

15 M62 Output 1 on (Lathe)

16 M63 Output 2 on (Mill)

17 M64 Output 1off (Lathe)

18 M65 Output 2 off (Mill)

19 M66 Wait inpute1 on

20 M67 Wait inpute2 on

21 M70 X-Mirror On

22 M71 Y-Mirror On

23 M76 Wait inpute1 off

24 M77 Wait inpute2 off

25 M80 X-Mirror Off

26 M81 Y-Mirror Off

27 M98 Sub Program Call

28 M99 Sub Program Exit

61

Ex.No 10 MANUAL PART PROGRAMMING FOR LINEAR INTERPOLATION (FACING, STEP TURNING AND

TAPER TURNING) Date

AIM:

To write the manual part program for linear interpolation (Step turning &

Chamfering) to the given dimensions and execute the program in CNC Lathe &

Edge CAM Simulation software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool

1. CNC Turret Centre

Procedure: (Edge CAM R14)

1. To enter NC program in simulation Editor.

2. To save the program file in proper location.

3. To open NC Verify and then open you’re saved file.

4. Then Go to NC job data and here enter Type –Turning, No of Axes-2.

5. Go to Tool Definition, Tool type- Turn ,Turning Tool Type-Diamond,

Nose Radius- 0.3, Click ok.

6. Please set FRONT VIEW for better visualization.

7. In model menu ,select the stock type – cylinder and use Bounding cylinder,

Click ok.

8. To simulate the program

Procedure: (CNC Turret centre)

1. The machine is switched on.

2. The single point cutting tool is set on the tool holder.

3. The given work piece is held between rigidly in the chuck.

63

4. The offsetting procedure is done on both axis of the machine.

5. Enter the program in Control panel display.

6. To check the program in the mode of Graph.

7. To close the door and Coolant & Spindle is on.

8. To execute the straight turning & taper turning and facing operation are done

in the required dimensions.

9. The machine is switched OFF.

10.The work piece is removed from the machine and checked for the given

dimensions.

11.Open the door and clean the chips.

Result:

Thus the manual part program for linear interpolation (FACING, STEP

TURNING AND TAPER TURNING) to the given dimensions and executed in CNC

Lathe & Simulation software.

65

Ex.No 11 MANUAL PART PROGRAMMING FOR LINEAR

INTERPOLATION IN CNC TURRET CENTRE

(GROOVING,DRILLING AND CHAMFERING) Date

AIM:

To write the manual part program for linear interpolation (Plain Turning,

Facing, Grooving, Drilling & Chamfering) to the given dimensions and execute the

program in CNC Lathe & Edge CAM Simulation software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool











Click ok.





67










dimensions.


Result:

Thus the manual part program for linear interpolation (GROOVING,

DRILLING AND CHAMFERING) to the given dimensions and executed in CNC


69

Ex.No 12 MANUAL PART PROGRAMMING FOR CIRCULAR


(GROOVING,COUNTER SHUNK DRILLING AND FILLET) Date

AIM:

To write the manual part programming for circular interpolation

(grooving, countersunk drilling and fillet) to the given dimensions and

execute the program in CNC Lathe & Edge CAM Simulation software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool











Click ok.





71










dimensions.


Result:

Thus the manual part program for circular interpolation (Grooving,

Countersunk drilling and Fillet) to the given dimensions and executed in CNC


73

Ex.No 12 MANUAL PART PROGRAMMING FOR LINEAR


(THREADING) USING CANNED CYCLE Date

AIM:

To write the manual part programming for circular interpolation

(grooving, countersunk drilling and fillet) to the given dimensions and

execute the program in CNC Lathe & Edge CAM Simulation software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool











Click ok.





75










dimensions.


Result:

Thus the manual part program for circular interpolation (Threading) using

canned cycle to the given dimensions and executed in CNC Lathe & Simulation

software.

77

Ex.No 14 MANUAL PART PROGRAMMING FOR LINEAR &

CIRCULAR INTERPOLATION IN CNC MILLING Date

AIM:

To write the manual part program for linear & Circular interpolation to

the given dimensions and execute the program in CNC Milling & Edge cam

software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool











Click ok.


Procedure: (CNC Milling)


2. The Milling cutter is set on the tool holder.

79

3. The given work piece is fixed on the working table using fixture.









dimensions.


Result:

Thus the manual part program for linear & Circular interpolation to the

given dimensions and executed in CNC Milling & Simulation software.

81

Ex.No 15 MANUAL PART PROGRAMMING FOR LINEAR &

CIRCULAR INTERPOLATION IN CNC MILLING Date

AIM:

To write the manual part program for linear & Circular interpolation to

the given dimensions and execute the program in CNC Milling & Edge cam

software.

Requirements

Hardware



3. Speed : 3.3GHz

4. Ram : 4 GB

5. HDD : 500 GB

Software

1. Edge CAM R14.

Machine tool











Click ok.


Procedure: (CNC Milling)


2. The Milling cutter is set on the tool holder.

83

3. The given work piece is fixed on the working table using fixture.









dimensions.


Result:

Thus the manual part program for linear & Circular interpolation to the

given dimensions and executed in CNC Milling & Simulation software.

cad/cam manual

Documents