LABORATORY MANUAL

MEC 469
NON TRADITIONAL AND COMPUTER
AIDED MANUFACTURING
LABORATORY

Table of contents
S. No NAME OF THE EXPERIMENT

Page No

Part Programming of Taper and radius turning

Part Programming for grooves and reliefs

Part Programming for threading of single and multi start threads

11

Generation of CNC program from CAM software for a given model

15

Introduction to NX CAM

19

Introduction to various commands, interface of NX CAM

22

Introduction to tool definition and cutting parameters.

25

Cavity mill For roughing cycle and finishing cycle

28

Cavity mill For contour area Milling using NX CAM

32

Cutting of simple cavity on EDM Machine and estimating MRR for

different Parameters

36

10

Experiment 1: Part Programming of Taper and radius turning.

Machines/Equipments/tools to be used: CNC Turning Machine, Carbide
Cutting tools, Micrometers, vernier calipers, radius gauge, bevel protector.

Material required: Aluminium bars.

Learning objectives: To learn CNC program generation and execution on
the Turning machine.

Outlines of the Procedure:

1. Write the program as per the drawing.
2. Set the tool offset.
3. Simulate on the machine controller.
4. Execute the actual cutting.
5. Check for the dimensions as per the sketch
6. Analyze the surface finish.
Cautions:
1.

Dont operate the machine without the presence of faculty member

or lab instructor.

2.

Make sure the simulation does not show any gauging off tool.

3.

Wear apron, shoes and tight fitted clothes.

4.

Be careful and attentive while working on this job.

5.

Use proper tools for each operation.

3

6.
7.

Dont keep any sharp tool in your pocket.

Tools being used should be well sharpened.

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

Experiment 2: Part Programming for grooves and reliefs.

Machines/Equipments/tools to be used: CNC Turning Machine,
Carbide Cutting tools, Micrometers, vernier calipers.
Material required: Aluminium bars.
Learning objectives: To learn CNC program generation and execution on
the machine to create grooves and reliefs.

Outlines of the Procedure:

1. Write the program as per the drawing.
2. Set the tool offset.
3. Simulate on the machine controller.
4. Execute the actual cutting.
5. Check for the dimensions as per the sketch
6. Analyze the surface finish.
Cautions:
1.

Dont operate the machine without the presence of faculty member

or lab instructor.

2.

Make sure the simulation does not show any gauging off tool.

3.

Wear apron, shoes and tight fitted clothes.

4.

Be careful and attentive while working on this job.

7

5.

Use proper tools for each operation.

6.

Dont keep any sharp tool in your pocket.

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

10

Experiment 3: Part Programming for threading of single and multi

start threads.
Machines/Equipments/tools to be used: CNC Turning Machine,
Carbide Cutting tools, Micrometers, vernier calipers, thread gauges.
Material required: Aluminium bars.
Learning objectives: The objective is to learn CNC program generation
and execution on the machine.

Outlines of the Procedure:

1. Write the program as per the drawing.
2. Set the tool offset.
3. Simulate on the machine controller.
4. Execute the actual cutting.
5. Check for the dimensions as per the sketch
6. Analyze the surface finish.
Cautions:
1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
11

4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.

12

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

13

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

14

Experiment 4: Generation of CNC program from CAM software for a given

model.
Machines/Equipments/tools to be used: CNC Milling Machine, Carbide
Cutting tool, Micrometer, vernier caliper, thread gauge.
Material required: Aluminium.
Learning objectives: To learn procedures for CNC program generation
and execution on the machine for milling operation.

Outlines of the Procedure:

1. Write the program as per the drawing.
2. Set the tool offset.
3. Simulate on the machine controller.
4. Execute the actual cutting.
5. Check for the dimensions as per the sketch
6. Analyze the surface finish.
Cautions:
1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
15

4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.
7. Tools being used should be well sharpened.

16

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

17

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
1
Understanding of the student about the
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

18

Experiment 5: Introduction to NX CAM software.

Machines/Equipments/tools to be used: Computer with NX CAM
software.
Material required: none.
Learning objectives: To practice CAM program generation and simulation
on machine.
Outlines of the Procedure:
1. Make the CAD Model.
2. Make CAM Program.
3. Simulate the CAM program.
Required results: Check for Gauging of the tools in simulation.
Cautions:
1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
4. Be careful and attentive while working on this job.

19

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

20

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
1
Understanding of the student about the
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

21

Experiment 6: Introduction to various commands, interface of NX CAM.

Machines/Equipments/tools to be used: Computer with NX CAM
software.
Material required: none.
Learning objectives: to write and CAM program generation and simulation
it on 3 axis machine.
Outlines of the Procedure:
1. Make the CAD Model.
2. Make CAM Program.
3. Simulate the CAM program.
Required results: Check for Gauging of the tools in simulation.
Cautions:
1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
4. Be careful and attentive while working on this job.

22

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

23

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
1
Understanding of the student about the
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

24

Experiment 7: Introduction to tool definition and cutting parameters.

Machines/Equipments/tools to be used: Computer with NX CAM
software.
Material required: none.
Learning objectives: To learn steps required for CAM program generation
and simulation on machine.
Outlines of the Procedure:
1. Make the CAD Model.
2. Make CAM Program.
3. Simulate the CAM program.
Required results: Check for Gauging of the tools in simulation.
Cautions:
1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
4. Be careful and attentive while working on this job.

25

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

26

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

27

Experiment 8: Cavity mill for roughing cycle and finishing cycle.

Machines/Equipments/tools to be used: Computer with NX CAM
software.
Material required: none.
Learning objectives: To learn steps required for CAM program generation
and simulation on machine.

28

Outlines of the Procedure:

1. Make the CAD Model.
2. Make CAM Program.
3. Simulate the CAM program.
Required results: Check for Gauging of the tools in simulation.
Cautions:
1. Dont operate the machine without the presence of faculty member or
lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
4. Be careful and attentive while working on this job.

29

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

30

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

31

Experiment 9: Cavity mill For contour area Milling using NX CAM

Machines/Equipments/tools to be used: Computer with NX CAM
software.
Material required: none.
Learning objectives: To learn steps required for CAM program generation
and simulation on machine.

32

Outlines of the Procedure:

1. Make the CAD Model.
2. Make CAM Program.
3. Simulate the CAM program.
Required results: Check for Gauging of the tools in simulation.
Cautions:
1. Dont operate the machine without the presence of faculty member or
lab instructor.
2. Make sure the simulation does not show any gauging off tool.
3. Wear apron, shoes and tight fitted clothes.
4. Be careful and attentive while working on this job.

33

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

34

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
Understanding of the student about the
1
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

35

Experiment 10: Cutting of simple cavity on EDM Machine and estimating

MRR for different Parameters.
Equipment required: EDM, Vernier caliper, Tool holder, Copper
Electrode, Micrometer etc.
Material Required: Workpiece and EDM oil.

Learning object: To study Non- Conventional machining equipment and the

metal removal process and better understand the relationship between
time for which the current is supplied and metal removed.
Outline of procedure:
1. Take a work piece and submerge it into EDM oil before
switching on the power supply to EDM.
2. Switch on the machine in the presence of operator and Set the
proper current value. Set the proper voltage value. See the
depth of material removed as indicated on the m/c)
3. Switch off the power supply to the machine when the
desired depth of material is removed.

36

Material removal rate Vw versus the surface current density

Result Scope: Notice the time taken for the material removed with
different current settings.
Cautions:
1. Keep in mind that machinery capable of cutting metal is
inherently dangerous.
2. Operator should be present at the time of operation of the machine.
3. Make sure the work piece is adequately clamped .
4. Make sure the tool holder and electrode is adequately clamped for the
job being performed.
5. Always wear safety glasses when around the machine.
6. Loose clothing, rings or watches should not be worn when
operating machine.
7. Use extreme caution while operating the machine as high current is used.

37

Process Sheet
Workshop Name:

Date:

Name of Student:

Section:

Roll No.:

Registration No.:

Job:
Drawing:

S.
No.

Job
Operations
Specification
/ Dimension

Tools Used

Equipment/Machine Remark
Used

38

Learning Outcome:

To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10
Marks
excellent)
obtained
1
Understanding of the student about the
procedure/apparatus. (process sheet)
2
3

Dimensional Accuracy, Finishing and Learning

Outcome.

20

20
10

Completion of experiment/job, Discipline and

Cleanliness
Signature of Faculty

Max. Marks

Total marks
obtained

39