ME2309 CAD CAM Lab Manual

ME2309 CAD / CAM Lab
Ex. No.
Date of the
Experiment
Mechanical Engineering
Name of the Experiment
2013-2014
Date of
Submission
Staff
Sign.
CAD LAB
CAM LAB
St.Josephs College of Engineering/St.Josephs Institute of Technology 1
ISO9001:2008
ME2309
2013-2014
CAD/CAM LAB
TPC 0032
3D GEOMETRIC MODELING
Creation of 3D Models - Wire Frame, Surface, Solid modeling Techniques Using CAD
Packages CSG, B-Rep Approaches in Solid Modeling - Feature Based Modeling
Technique Assembly Detailing - Exposure to Industrial Components Application of
GD&T
STL FILE GENERATION REVERSE ENGINEERING
Manual CNC Part Programming
Manual CNC Part Programming Using Standard G and M Codes - Tool Path Simulation
Exposure to Various Standard Control Systems- Machining simple components by
Using CNC machines.
COMPUTER AIDED PART PROGRAMMING
CL Data Generation by Using CAM Software Post Process Generation for Different
Control System Machining of Computer Generated Part Program by Using Machining
Center and Turning Center.
STUDY OF EXPERIMENTS
Multi-axial Machining in CNC Machining Center EDM EDM Wire Cut - Rapid
Prototyping
TOTAL: 45 PERIODS
CONTENTS
Sl.No
1
2
3
4
5
6
7
8
9
10
11
12
Name of the Experiment

Introduction to CAD
3D Modeling of Screw Jack
3D Modeling of Plummer Block
3D Modeling of Flanged Coupling
3D Modeling of Universal Coupling
Introduction to CAM
Taper Turning
Multiple Turning
Turning and Drilling
Multiple Threading
Linear & Circular Interpolation
Viva Questions
Page No.
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Expt .No:
Date:
INTRODUCTION TO CAD
Computer-aided design is essentially based on a versatile and powerful technique called
computer graphics, which basically means the criterion and manipulation of pictures on a display
device with the aid of a computer. Computer graphics originated at the Massachusetts institute of
technology (MIT) in 1950when the first computer-driven display, linked to a Whirlwind 1 computer,
and was used to generate some pictures. The first important step forward in computer graphics came
in 1963 when a system called SKETCHPAD was demonstrated at the Lincoln Laboratory of MIT.
This system consists of a cathode ray tube (CRT) driven by TX2 computer. The CRT had a keyboard
and a light pen. Pictures could be drawn on the screen and then manipulated interactively by the user
via the light pen.
Computer Aided Design is the process of developing and using computer assisted design
tools in the design process. The advent of computers has contributed to significant advance in
calculation, data handling and utilization applications. The ability to use the computers in these
application areas enhances the capability of the design team significantly. Drafting and geometric
modeling play significant roles in CAD. The module therefore concentrates on the general design
process with specific consideration to drafting and geometric modeling. Three different CAD systems
are referred to in the module. The syllabus includes: historical development, the design process,
traditional drawing practice and the development of the CAD industry, system hardware, computers
micros to mainframes, output devices, storage, workstations, networked systems, examples of CAD
systems; simple entity descriptions: points, lines, arcs, made-edge lists, free-form curves, free-form
surfaces; transformations: pan, rotate and scale, 3D transformations, observer angles, perspective,
depth cueing; geometric modeling: wire frame modelers, surface modelers, solid modelers (CSG and
B- rep), hidden line removal and mass properties; user interface: input devices, menus, graphics
interface language, parametric.
ROLE OF COMPUTERS IN DESIGN
As manual design process has several risk factors including human fatigue and the evaluation
of design based on his previous experience. With the advent of computer and the development in the
field of computer graphics, various design & manufacturing process takes place new faster rate with
minimum or optimum error. The below figure shown the implementation of computer in design:
Implementation of computer in the design stage becomes the subset of design process. Once the
conceptual design materializes in the designer mind the geometric model starts by the appropriate
CAD software. The choice of geometric model to CAD is analogous to the choice. The various design
related tasks which are performed by a modern computer-aided design system can be grouped into
four functional areas:
1. Geometric Modelling
2. Engineering Anlaysis
3. Design review and evaluation
4. Automated drafting.
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INTRODUCTION TO CATIA V5
ISO9001:2008
2013-2014
Result:
Viva Questions:
1. What do you meant by CAD?
2. States some of the commonly used CAD softwares?
3. How CAD softwares are classified?
4. What are the advantages of CAD softwares?
5. What do you meant by GUI?
ISO9001:2008
Expt .No:
2013-2014
Date:
ISO9001:2008
2013-2014
SCREW JACK
Aim:
To create a 3D view of the Screw Jack model using a computer package.
Software Used:
CATIA V5.
Plotter:
HP design Jet 10PS.
Commands Used:
Line, Circle, Trim, Symmetry, Pad, Pocket, Shaft, Groove, Hole, Rib, Slot, Loft,
Dimension, Print, etc.
Description:
Screw jack is a manually operated device. It is used to lift automobile vehicles and any heavy
objects through a small height by applying small effort. The effort is given by a tummy bar. One type
of screw jack is shown in the figure. It consists of a cast iron body, with a circular base which
provides a larger bearing area. A gun metal nut tight fitted at the top of the body.
A mild steel, square threaded screw spindle is screwed through the GM Nut. The head of the
screw spindle has holes to insert the tummy bar. A load bearing cup is mounted at the top of the screw
spindle.
The cup is loosely held in position by a washer and CSK screw so that when the spindle is
rotated cup moves only up and down but will not rotate.
Procedure:
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Result:
Inference:
Viva Questions:
1.
2.
3.
4.
5.
6.
7.
Differentiate First angle & third angle Projection?

What is meant by Assembly Drawing?
Differentiate orthographic and isometric projections?
What is expansion of CATIA?
What is parametric modeling?
In CATIA V5, you can a hexagon using Rectangle tool. (T/F)
To scale the sketched elements, select them and then choose the Translate Tool from the
Transformation toolbar. (T/F)
Expt .No:
Date:
ISO9001:2008
2013-2014
PLUMMER BLOCK (PEDESTAL BEARING)

Aim:
To create a 3D view of the Plummer Block model using a computer package.
Software Used:
CATIA V5.
Plotter:
HP design Jet 10PS.
Commands Used:
Description:
It is a split type of journal bearing to support horizontal shafts. It is used for supporting shafts
which run at high speed. It consists of a cast iron block, brasses and a cast iron cup. The brasses
(bush) are provided in between the block and cup and fastened by using two square headed bolts and
lock nuts.
The block has hole. The bottom brass has a snug. It seats on the snug hole provided in the
block. This arrangement is to prevent the rotation of the bush. Collars provided at the both end of the
brasses prevent axial movement of the brasses.
Procedure:
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Result:
Inference:
Viva Questions:
1. How many Modules are in CATIA?
2. What are the types of Assembly design in CATIA?
3. What are the types of drafting techniques in CATIA?
4. What is work bench in CATIA?
5. What are the features in the Part Design workbench in CATIA?
6. You can also draw an arc, while working with the Profile tool. (T/F)
7. You can, draw the key profile in the Sketcher workbench of CATIA V5. (T/F)
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ISO9001:2008
Expt .No:
2013-2014
Date:
FLANGED COUPLING
Aim:
To create a 3D view of the Flanged Coupling model using a computer package.
Software Used:
CATIA V5.
Plotter:
HP design Jet 10PS.
Commands Used:
Description:
Shaft couplings are used for transmitting rotary motion directly from one shaft to another.
They may be classified as (1) Rigid coupling (2) Loose coupling and (3) Flexible coupling. Flanged
coupling is a rigid coupling. This is a standard form of coupling and is extensively used.
It consist of two cast iron flanges, keyed to the ends of two shafts and fastened together by
means of a number of tight fitting bolts. Sunk taper keys of rectangular or square cross section are
commonly used for the purpose. For ensuring correct alignment one of the shafts is extended so that
its end partly enters the flange keyed to the other shaft. Now the axis of the two shafts will be in
straight live.
Procedure:
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Result:
Inference:
Viva Questions:
1. What are the tools in the Sketcher Based Feature Tool bar?
2. What are the tools in the Dress-Up Feature Tool bar?
3. What are the tools in the Transformation Feature Tool bar?
4. How you can modify the setting in CATIA?
5. What are types of Constrains?
6. You can invoke the Pad tool first and then draw the sketch. (T/F)
7. You can also Pan the view of the model using CATIA Compass. (T/F)
8. You can also Rotate the view of the model using CATIA Compass. (T/F)
Expt .No:
Date:
ISO9001:2008
2013-2014
UNIVERSAL COUPLING
Aim:
To create a 3D view of the Universal Coupling model using a computer package.
Software Used:
CATIA V5.
Plotter:
HP design Jet 10PS.
Command Used:
Description:
When two shafts are at some inclination to one another, universal coupling is used to connect
these shafts. The angle between the two shafts is usually less than 30. The angle between the two
shafts may be varied even when they are in motion. It is used in automobile propeller shaft,
differential, and milling machine etc.
In this coupling, there are two forks keyed to the shafts. The forks are connected to a central
cross piece by using pins. The axis of pins will be at right angle to each other.
Procedure:
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Expt .No:
Date:
Assembled View of Universal Coupling
Details
Item No.
1
2
3
4
5
6
7
Description
Fork
Centre
Shaft
Parallel Key
Pin
Collar
Taper pin
Quantity
2
1
2
2
2
2
2
Result:
Inference:
Viva Questions:
1. What are tools in the Geometric Constrains Toolbar?
2. What are tools in the Assembly Constrains Toolbar?
3. What is use of OFFSET command?
4. What is use of ARRAY command?
5. What is the difference between TRIM and BREAK command?
6. What is the difference between FILLET and CHAMFER command?
ISO9001:2008
Expt .No:
2013-2014
Date:
INTRODUCTION TO CAM
Aim:
To study the different operations in CAM.
Part programming fundamentals
NC procedure
The following are the basic steps in NC procedure
Process planning
Part programming
Part program entry
Proving the part programs
Production
In detail,
Process planning
The part programmer will often carryout the task of process planning. Process planning is the
procedure of deciding what operations are to be done on the component, in what order, and with what
tooling and work holding facilities.
Procedure
Receive the part drawing .from the part drawing information, check suitability of part to be
machined against the machine capacity.
Determine a method of driving the component (chuck type, chuck size, type of jaw, collet
size, face driver etc.,) and the method of machining.
Determine the tooling required to suit the method of machining and utilize as much as
possible the tools which are permanently in the turret set upon the machine.
Determine the order of machining and the tooling stations.
Determine planned stops (cycle interrupt procedure, incorporating block delete codes) for
checking dimensional sizes where required by operator.
Determine the cutting speeds based on
Component material, method of driving, rigidity of component.
The tooling selected for roughing and finishing.
Determine the depth of cut and feeds for roughing operations based on horsepower available
for cutting and rigidity of the part.
Determine the surface finish requirements the cutter nose radius most suited for finishing
operations and determine feed rates.
Allocate tool offsets as required.
Complete planning sheet.
Part programming
After completing the planning sheet, draw the component showing the cutter paths (a simple
sketch sufficient for simple components).
Select a component datum and carryout the necessary calculations at slopes and arcs.
Prepare tooling layout sheet showing tools to be used in the program and indicate the station
number for each tool.
Indicate the ordering code for each tool and the grade and type of inserts to be used.
Write the part program according to the sequence of operations.
Manual programming
In this method the necessary program information is taken directly from the work piece
drawing and set down in the form of program blocks which are then input into the control system
(possibly by punched tape). We speak of manual programming, for example, if programming is
carried out in the programming language of the CNC system (i.e., a control plane followed
ISO9001:2008
2013-2014
established standards) regardless of whether such programming is carried out in the workshop or in
the planning department. Manual programming is suitable only to develop part programs for 2D and
2-1/1 D surface machining.
NC program BUILD UP
In a NC program, the machining steps for producing a part on the machine tool are laid down
in a form that the control system can understand. A program is composed of several blocks. A block is
a collection of NC words .A NC word is a collection of address letter and a sequence of numbers.
Address characters as per DIN 66025
Character
Meaning
A
Rotation about X-axis
B
Rotation about Y-axis
Rotation about Z-axis
D&E
F
G
H
I
J
K
L
M
N
O
P,Q,R
S
T
U,V,W
X
Y
Z
Rotation about additional axes

Feed
Preparatory function, identifying the action to be executed
Unassigned
Interpolation parameter , thread pitch parallel to
X-axis
Thread pitch parallel to Y-axis
Thread pitch parallel to Z-axis
Unassigned
Auxiliary function
Block number
Not used
Thread movement parallel to X, Y, Z axes respectively. P & Q are also used as
parameters in cycles.
Spindle speed
Tool
Second movement parallel to Z,Y,Z axes respectively
Movement in X-axis
Movement in Y-axis
Movement in Z-axis
All the NC words may not be used on every CNC machine. Using these words as an example, the
composition of a block is assembled as follows
N
G
X
Z
F
S
T
M
;
In the programming language of a CNC control system, the manufacturer specifies
What instructions can be programmed
What supplementary functions are possible in conjunction with the individual instruction
Of what letters and number sequences the instruction and supplementary functions are
formed.
ISO9001:2008
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PART PROGRAM FORMATS
The order in which these words appear in a block of instructions is called the format. Basically there
are two types of format:
Fixed block format
-Fixed Sequential format (fixed block)
-Tab sequential Format (Fixed Block)
Word address format(Variable block)
1) Fixed block format
a) Fixed Sequential Format
Every instruction contains all the words in the same sequence irrespective of the words
being the same as in the previous blocks. Hence the identifying address letter need not be
provided. For example, if some coordinate values (ie...X, Y, Z coordinates) remain constant from
one block to next block these values have to be specified in the next block also. the data must be
input in a specified sequence and characters within each word must be of the same length.
Example: N010 G00 X10 Z0 F60 S800 EOB
N020 G01 X20 Z0 F60 S800 EOB
b) Tab Sequential Format
The words in each instruction/block are always provided in the same sequence but
each word is preceded by the TAB Character. If instructions remain unchanged in the succeeding
blocks, the instructions need not be repeated but the TAB character must be punched. Here also
the identifying letter address need not be employed.
Example: N010 G00 X10 TAB Z0 TAB F60 TAB S800 EOB
N020 G01 X20 EOB
2. Word access format
Each word is precedes and identified by its letter address. This format enables
instructions which remain unchanged from the preceding block, to be omitted from succeeding
blocks. This system speeds programming, and the tape lengths are considerably reduced. This is
the format adopted by most CNC machine control units. Detailed format classification is
provided by the control system manufacturer.
Miscellaneous Codes and Preparatory Codes for CNC Lathe
a) Miscellaneous Functions (M codes)
M Codes are instructions describing Miscellaneous Functions like calling of tool,
spindle rotation, coolant on, etc.
M Codes
M00
Program Stop
M02
Optional Stop
M03
Spindle Forward (CW)
M04
Spindle Reverse (CCW)
M05
Spindle Stop
M06
Tool Change
M08
Coolant On
M09
Coolant Off
M10
Vice Open
M11
Vice Close
M62
Output 1 On
M63
Output 2 On
M64
Output 1 Off
M67
Wait Input 1 On
M76
Wait Input 1 Off
M77
Wait Input 2 Off
ISO9001:2008

M98
M99
2013-2014
Sub Program Call

Sub Program Exit
b) Preparatory Functions (G Codes)

A 2-Digit Number following address G determines the meaning of the command of the
block concerned. The G codes are divided into the following two types:
Types
Meaning
One Short G
The G Code is effective only at the block in which it is specified
Codes
Model G Codes
The G Code is effective until another G Codes in the same group is
commanded
NOTES ON G CODES
Maximum spindle speed setting (50) is valid when the constant surface speed control (option) is
provided.
The G codes are marked * are set when the power is turned on.
The G codes in groups 00 are not modal. They are effective only in block in which they are
specified.
A number of G codes can be specified in a block even if they do not belong to the same group.
When a number of G codes of the same group are specified, the G code specified last is effective.
All the G codes may not apply to each machine.
ISO9001:2008
2013-2014
G Codes
G Codes
Group
Function
G00
G01
G02
G03
1
1
1
1
Positioning (Rapid Traverse)

Linear interpolation(Feed)
Circular Interpolation(CW)
Circular Interpolation(CCW)
G04
Dwell
G20
G21
6
6
Inch Data Input

Metric Data Input
G28
Reference Point return
G32
Thread Cutting
G40
G41
G42
7
7
7
Tool Nose Radius Compensation cancel

Tool Nose Radius Compensation left
Tool Nose Radius Compensation right
G50
Work Co-ord. Change/Max.Spindle speed setting
G70
G71
4
4
Finishing cycle
Stock removal in turning
G72
G73
G74
G75
G76
0
0
0
0
0
Stock removal in Facing

Pattern repeating
Peck drilling in Z axis
Grooving in X axis
Thread cutting cycle
G90
G92
G94
1
1
1
Cutting cycle A
Thread cutting cycle
Cutting cycle B
G96
G97
G98
G99
2
2
11
11
Constant surface speed control

Constant surface speed control cancel
Feed per minute
Feed per revolution
Result:
Viva Questions:
1.Define CAM.
2.Define NC program.
3.How do the composition of a block is assembled?
4. What is a format?
5.What are the types of part program format?
Expt .No:
Date:
TAPER TURNING
ISO9001:2008
2013-2014
Aim:
To write manual part programming using G & M codes, simulate & machining the given
component as shown in the figure in a CNC lathe trainer.
Materials Required:
Aluminium billet 32mm diameter and 70mm length.
Tools Used:
Single point cutting tool of radius 2mm, Allen key, chuck key.
Machine Details:
CNC Machine : XL TURN;
CONTROLLER
: FANUC;
Tool Setting Procedure:
In order to guide the tool to exactly where the workpiece, is present we need to do a toll
setting procedure.
In tool setting, we control the movement of tool by the 4 axis movement present in the
controller pad of the CNC machine.
Tool can made to move by also operating the 4 way movement cursor if axis movement is not
desired.
Program:
[BILLET X32 Z70;
G21 G98;
G28 U0 W0;
M06 T01;
M03 S1500;
G00 X33 Z1;
G90 X32 Z-60 F50;
X31;
X30;
G00 X31 Z1;
G90 X30 Z-6 F50;
X29;
X28;
X27;
X26;
X25;
X24;
X23;
X22;
X21;
X20;
G00 X31 Z-5;
G90 X30 Z-21 R0 F30;
X30 R-0.5;
X30 R-1;
X30 R-1.5;
Expt .No:
Date:
TAPER TURNING
ISO9001:2008
2013-2014
X30 R-2;
X30 R-2.5;
X30 R-3;
ISO9001:2008
2013-2014
X30 R-3.5;
X30 R-4;
X30 R-4.5;
X30 R-5;
G00 X31 Z1;
G01 X30;
G01 Z-39;
G90 X30 Z-54 R0 F30;
X29 R0.5;
X28 R1;
X27 R1.5;
X26 R2;
X25 R2.5;
X24 R3;
X23 R3.5;
X22 R4;
X21 R4.5;
X20 R5;
G00 X31 Z-54;
G90 X30 Z-60 F50;
X27;
X26;
X25;
X24;
X23;
X22;
X21;
X20;
G28 U0 W0;
M05;
M30;
Result:
Inference:
Viva Questions:
1.What is a fixed sequential format?
2.what is Tab sequential format?
3.What are M codes?
4.What is word access format?
5.What does CNC stand for?
Expt .No:
Date:
MULTIPLE TURNING
ISO9001:2008
Expt .No:
2013-2014
Date:
MULTIPLE TURNING
Aim:
ISO9001:2008
2013-2014
Materials Required:
Tools Used:
Machine Details:
CONTROLLER
: FANUC;
setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in
the controller pad of the CNC machine. Tool can made to move by also operating the 4 way
movement cursor if axis movement is not desired.
Program:
[BILLET X32 Z70;
G21 G98;
M06 T07;
G28U0 W0;
M03 S1500;
G00 X33 Z1;
G71 U0 R1;
G71 P1 Q2 U0.1 W0.1 F50;
N1 G01 X20;
G01 Z0;
G01 X22 Z-2;
G01 X22 Z-15;
G02 X27 Z-22 R10;
G01 X27 Z-32;
G03 X32 Z-39 R10;
N2 G01 X32 Z-39;
G28 U0 W0;
M06 T15;
M03 S1500;
G00 X33 Z0;
G70 P1 Q2 F30;
G28 U0 W0;
M05; M30;
Result:
Inference:
Viva Questions:
1.What does M00 specify?
2.what does M02 specify?
Expt .No:
Date:
ISO9001:2008
2013-2014
TURNING & DRILLING
Expt .No:
Date:
TURNING & DRILLING
Aim:
ISO9001:2008
2013-2014
Materials Required:
Tools Used:
Machine Details:
CONTROLLER
: FANUC;
setting procedure.
desired.
Program:
[BILLET X32 Z70;
G21 G98;
G28 U0 W0;
M06 T01;
M03 S1500;
G00 X33 Z1;
G94 X0 Z-.5 F50;
Z-1;
G90 X32 Z-50 F50;
X31;
X30;
X29;
X28;
X27;
X26;
X25;
G90 X24 Z-25;
X23;
X22;
X21;
X20;
G28 U0 W0;
M06 T04;
M03 S1000;
G00 X0 Z1;
G74 R1;
G74 X0 Z-20 Q1000 F30;
G28 U0 W0;
M05;
ISO9001:2008
2013-2014
M09;
M30;
Result:
Inference:
Viva Questions:
1. What are preparatory functions?
2.What isone short G codes?
3.What are Model G codes?
4.What does G00 specify?
Expt .No:
Date:
MULTIPLE THREADING
Aim:
ISO9001:2008
2013-2014
Materials Required:
Tools Used:
Machine Details:
CONTROLLER
: FANUC;
setting procedure.
desired.
Program:
[BILLET X32 Z70;
G21 G98;
G28 U0 W0;
M06 T01;
M03 S1500;
G00 X33 Z1;
G90 X33 Z-40 F50;
X32;
X31;
X30;
X29;
X28;
X27;
X26;
X25;
G90 X25 Z-20 F50;
X24;
X23;
X22;
X21;
X20;
X19;
X18;
X17;
X16;
X15;
X14;
X13;
X12;
G01 X11 Z0;
G01 X12 Z-1;
Expt .No:
Date:
MULTIPLE THREADING
ISO9001:2008
2013-2014
G28 U0 W0;
M06 T08;
M03 S1500;
ISO9001:2008
2013-2014
G01 X13 Z1;

G76 P031560 Q200 R0.15;
G76 X9.853 Z-15 P1075 Q250 F1.75;
G28 U0 W0;
M05;
M30;
Result:
Inference:
Viva Questions:
1.what is the G code for thread cutting cycle?
2.What is the G code for feed per minute?
3. what does G50 specify?
5.What is the G code for Grooving in x axis?
Expt .No:
Date:
ISO9001:2008
2013-2014
LINEAR & CIRCULAR INTERPOLATION
Expt .No:
Date:
LINEAR & CIRCULAR INTERPOLATION
Aim:
component as shown in figure in the CNC milling trainer.
ISO9001:2008
2013-2014
Materials Required:
Aluminium billet 10010010mm.
Tools Used:
Milling cutter 6mm diameter.
Machine Details:
CNC Machine : XL MILL;
CONTROLLER
: FANUC;
setting procedure.
desired.
Program:
[BILLET X100 Y100 Z10;
[TOOL DEF T01 D06;
[EDGE MOVE X-50 Y-50;
G21 G94;
G91 G28 Z0;
G28 X0 Y0;
M06 T01;
M03 S1500;
G90 G00 X-22.5 Y-37.5 Z5;
G01 Z-1 F50;
G01 X22.5 Y-37.5;
G02 X37.5 Y-22.5 R15;
G01 X37.5 Y22.5;
G03 X22.5 Y37.5 R15 ;
G01 X-22.5 Y37.5 ;
G02 X-37.5 Y22.5 R15 ;
G01 X-37.5 Y-22.5 ;
G02 X-22.5 Y-37.5 R15 ;
G00 Z5 ;
G91 G28 Z0 ;
M05 ;
M30 ;
Result:
Inference:
Viva Questions:
1.What is linear interpolation?
2.what is circular interpolation?
ISO9001:2008

ME2309 CAD CAM Lab Manual

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ME2309 CAD CAM Lab Manual

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ME2309 CAD / CAM Lab

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St.Josephs College of Engineering/St.Josephs Institute of Technology 1