THE KAVERY ENGINEERING COLLEGE, MECHERI DEPARTMENT OF MECHANICAL ENGINEERING

A Observation Manual On

Computer Aided Manufacturing Lab

VI SEMESTER R 2008 SYLLABUS

PREPARED BY E.JAMUNA AP/MECH

DEPARTMENT OF MECHANICAL ENGINEERING

SYLLABUS
COMPUTER AIDED MANUFACTURING (CAM) LABORATORY LIST OF EXPERIMENTS

1 Manual part programming (Using G and M Codes) in CNC lathe i. ii. Part programming for Linear and Circular interpolation, Chamfering and Grooving Part programming using standard canned cycles for Turning, Facing, Taper turning and Thread cutting. 2 Manual part programming (using G and M codes) in CNC milling 2.1 Part programming for Linear and Circular interpolation and Contour motions. 2.2 Part programming involving canned cycles for Drilling, Peck drilling, and Boring. 3 Exposure to Component Modeling and CL data generation using CAD/CAM Software like Unigraphics, Pro/E, Edge CAM etc., NC code generation using CAD/CAM software-Post processing for standard CNC control like FANUC, SINUMERIC etc.,

EXPT. NO: 1 DATE AIM: :

STUDY OF CNC MACHINES

To study the basic components and details of CNC machine. BASIC COMPONENTS: An operational CNC machine consist of i) Program of instruction ii) Machine control unit iii) Machine tool. PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched t ape. MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit. CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control information such as the new required position of each axis, its direction of motion and velocity and auxiliary control signals to relays. MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in the operation.

MACHINE TYPES Lathe The engine lathe, one of the most productive machine tools, has always been an efficient means of producing round parts. Most lathes are programmed on two axes. The X axis controls the cross motion of the cutting tool.Negative X (X-) moves the tool towards the spindle centerline; positive X moves the tool away from the spindle centerline. The Z axis controls the carriage travel toward or away from the headstock.

Fig. 1.The main axes of a lathe or turning center.

Milling Machine The milling machine has always been one of the most versatile machine tools used in industry (Fig. 2). Operations such asmilling, contouring, gear cutting, drilling, boring, and reaming areonly a few of the many operations which can be performed on a milling machine. The milling machine can be programmed on Three axes:

 The X axis controls the table movement left or right. The Y axis controls the table movement toward or away from the column. The Z axis controls the vertical (up or down) movement ofthe knee or spindle. .

Fig. 2 The main axes of a vertical machining center

RESULT: Thus the basic components of CNC machine have been studied

EXPT. NO: 2 DATE AIM: :

PART PROGRAMMING FUNDAMENTALS

To know about part programming fundamentals for CNC turning. 1. CO-ORDINATE SYSTEM FOR A CNC LATHE: Machining of the work piece by an NC programming requires a coordinate system to be applied to the machine tool. As all machine tool have more than one slide, it is important that each slide is identified individually. There are three planes in which movements can take place: (1.) Longitudinal (2.) Transverse (3.) Vertical. Each plane is assigned a letter and is referred t o an axis (i.e.) (1.) Axis-x (2.) Axis-y (3.) Axis-z The three axis are identified by the upper case x, y and z and the direction of movement along each axis specified as either (+) or (-). The three axes are always at right angles and parallel to work holding surface. The zaxis is at right angles to both x and y axis. 2. MACHINE ZERO POINT: The manufacturers of the machine specify machine zero point. This is zero point for the co-ordinate system and reference point in the machine on turning the lathe. The machine zero point is generally at the center of the spindle nose face. The main spindle axis represents the z-axis, and the face determines x-axis.

3. WORK PIECE ZERO POINT: The point determines the work piece co-ordinate system in relation to the machine zero point. The work piece zero point is chosen by the programmer and the input to the system. 4. NC PROGRAM BUILT UP: In an NC program, the machining system operations 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 block s. A block is a collection of NC works. An NC word is collection of address, letter and sequence of number. BASIC COMPONENTS: An operational CNC machine consists of (i) Program of instruction (ii) Machine control unit (iii) Machine tool. PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched t ape. MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit. CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control information such as the new required position of each axis, its direction of motion and velocity and auxiliary control signals to relays. MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in

the operation. CNC Systems: Point-to-point control is the positioning of the tool from one y point to another within a coordinate system. Most often used for positioning to a point where a manual machining operation such as drilling or boring would occur. Straight-cut control has the ability move a tool, while engaged, y straight in all axes of the machine and has the ability to do angles of 45 degrees. Contouring control systems generate a continuously controlled y tool path by interpolating intermediate points or coordinates. Interpolating means the ability to generate the points that make up a path.

Fig.3 point-to-point positionin andContouring, or continuous path machining,

Cutting Data and Formulae: Here are some of the most common terms used for expressing cutting data: Spindle speed - Spindle speed is the rotational speed of the spindle and tooling. This value is usually expressed in RPM. (Revolutions per Minute). Feed rate value - The feed rate value is the numerical value at which a tool will traverse a work piece. It is usually expressed in either IPM (Inches per Minute) or IPR (Inches per Revolution). Cutting speed - Cutting speed is the rotational speed of the cutting tool or work piece. It can be stated as either RPM or SFM. (Surface Fee Per Minute). Depth of Cut - Depth of cut is the distance the tool tip is engaged into the wor piece. It is incorporated into the X, Y, and Z values in a CNC program. Separate from the program, it can be expressed in inches or mm Tooling Requirements: Tooling requirements and selection are based on part restrictions and industry manufacturing practices. Most of these ideas are common sense thoughts. Good CNC programmers and operators should be aware of them. Know the material to be machined and its characteristics. Use industry standard catalog tooling to cut costs. Make use of technical services offered by tooling manufacturers. Quality of the fixture should be based on the number of pieces that will eventually be produced. Always use the right tool for the right machining operation.

 Keep spares or backups of tooling in the event resharpening is needed or tool breakage occurs. Keep an assortment of tooling in case one type does not perform the job as desired. Use high speed steel tools on easily machined materials. Use carbide tools on difficult to cut materials. Use cobalt or oxide coated tools for exotic alloys. Use inserts type tooling where possible t o cut costs. Consider using reamers, instead of boring bars, on lathe applications where chatter and chip control may be a problem Be aware of the flexing that occurs with long length tools. Extra passes may be required to eliminate tapering and chattering. Unit Systems and Input Modes: Unit Systems are the units of measurement to be used for the CNC program. All machines understand both English and Metric standards. When programming in English units you are using inches. And in metric its the millimeter (mm.). The CNC machine needs to be told which units are being used. Some machines are automatically set-up at the factory for inches or mm. Normally at the beginning of a CNC program you will see either; G70 to specify inches or G71 to specify mm.. Input modes refer to the type of coordinate information that is input into the program for the CNC machine. There are two types. Absolute input , designated by the G90 c ode, specifies distances from the origin or program zero point. Absolute is the most common mode. Incremental input , designated by the G91 code, specifies distances and directions based on the previous point as an origin. Incremental input is sometime called point-to-point. All CNC systems can be switched from absolute to incremental mode and back unlimited times within a program.

Other input modes such as Helical also exist

PREPARATORY FUNCTIONS (G codes)

The G-codes are the codes that position the tool and do the actual work, as opposed to M-codes, that manages the machine; T for tool-related codes. S and F are tool-Speed and tool-Feed, and finally D-codes for tool compensation. The programming language of Numerical Control (NC) is sometimes informally called G-code. But in actuality, G-codes are only a part of the NC-programming language that controls NC and CNC machine tools. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. G00 - Rapid move (not cutting) G01 - Linear move G02 - Clockwise circular motion G03 - Counterclockwise circular motion G04 - Dwell G05 - Pause (for operator intervention) G08 - Acceleration G09 - Deceleration G17 - x-y plane for circular interpolation G18 - z-x plane for circular interpolation G19 - y-z plane for circular interpolation G20 - turning cycle or inch data specification G21 - thread cutting cycle or metric data specification G24 - face turning cycle G25 - wait for input #1 to go low (Prolight Mill) G26 - wait for input #1 to go high (Prolight Mill) G28 - return to reference point G29 - return from reference point G31 - Stop on input (INROB1 is high) (Prolight Mill) G33-35 - thread cutting functions (Emco Lathe)

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49.

G35 - wait for input #2 to go low (Prolight Mill) G36 - wait for input #2 to go high (Prolight Mill) G40 - cutter compensation cancel G41 - cutter compensation to the left G42 - cutter compensation to the right G43 - tool length compensation, positive G44 - tool length compensation, negative G50 - Preset position G70 - set inch based units or finishing cycle G71 - set metric units or stock removal G72 - indicate finishing cycle (EMCO Lathe) G72 - 3D circular interpolation clockwise (Prolight Mill) G73 - turning cycle contour (EMCO Lathe) G73 - 3D circular interpolation counter clockwise (Prolight Mill) G74 - facing cycle contour (Emco Lathe) G74.1 - disable 360 deg arcs (Prolight Mill) G75 - pattern repeating (Emco Lathe) G75.1 - enable 360 degree arcs (Prolight Mill) G76 - deep hole drilling, cut cycle in z-axis G77 - cut-in cycle in x-axis G78 - multiple threading cycle G80 - fixed cycle cancel G81-89 - fixed cycles specified by machine tool manufacturers G81 - drilling cycle (Prolight Mill) G82 - straight drilling cycle with dwell (Prolight Mill) G83 - drilling cycle (EMCO Lathe) G83 - peck drilling cycle (Prolight Mill) G84 - taping cycle (EMCO Lathe) G85 - reaming cycle (EMCO Lathe)

50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63.

G85 - boring cycle (Prolight mill) G86 - boring with spindle off and dwell cycle (Prolight Mill) G89 - boring cycle with dwell (Prolight Mill) G90 - absolute dimension program G91 - incremental dimensions G92 - Spindle speed limit G93 - Coordinate system setting G94 - Feed rate in ipm (EMCO Lathe) G95 - Feed rate in ipr (EMCO Lathe) G96 - Surface cutting speed (EMCO Lathe) G97 - Rotational speed rpm (EMCO Lathe) G98 - withdraw the tool to the starting point or feed per minute G99 - withdraw the tool to a safe plane or feed per revolution G101 - Spline interpolation (Prolight Mill)

MISCELLANIOUS FUNCTION (M CODES): M codes are instructions describing miscellaneous functions like calling the tool, spindle rotation, coolant supply etc. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. M00 - program stop M01 - optional stop using stop button M02 - end of program M03 - spindle on CW M04 - spindle on CCW M05 - spindle off M06 - tool change M07 - flood with coolant M08 - mist with coolant M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill) M09 - coolant off M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill) M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change M17 - subroutine end M20 - tailstock back (EMCO Lathe) M20 - Chain to next program (Prolight Mill) M21 - tailstock forward (EMCO Lathe) M22 - Write current position to data file (Prolight Mill) M25 - open chuck (EMCO Lathe) M25 - set output #1 off (Prolight Mill) M26 - close chuck (EMCO Lathe) M26 - set output #1 on (Prolight Mill) M30 - end of tape (rewind) M35 - set output #2 off (Prolight Mill) M36 - set output #2 on (Prolight Mill) M38 - put stepper motors on low power standby (Prolight Mill) M47 - restart a program continuously, or a fixed number of times (Prolight Mill) M71 - puff blowing on (EMCO Lathe) M72 - puff blowing off (EMCO Lathe) M96 - compensate for rounded external curves M97 - compensate for sharp external curves M98 - subprogram call M99 - return from subprogram, jump instruction M101 - move x-axis home (Prolight Mill) M102 - move y-axis home (Prolight Mill) M103 - move z-axis home (Prolight Mill)

SPECIAL CYCLES Special Cycles or Canned Cycles are a preprogrammed sequences of repetitive tool motion that are built into the control system f or common operations such as drilling, tapping, boring, and pocketing. Its purpose is to reduce the amount of program code that would normally have to be written. Canned cycles are G codes that are options purchased with a CNC, but some are standard equipment depending on the manufacturer. Drilling cycle (G81, G82 or G83) are used to drill multiple holes

without programming each move separately. Using this cycle reduces the amount of code that would normally have to be written. Facing cycle (G77) is used to clean up rough stock material

(normally on top of the part) which can be located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written. Rectangular pocket cycle (G78) is used to clear out material which is located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written. Circular pocket cycle (G79) is used to clear out material which is located within a circular area. Using this cycle reduces the amount of code that would normally have to be written. INTERPOLATATION Linear Interpolation Linear Interpolation consists of any programmed points linked together by straight lines, whether the points are close together or far apart (Fig. 11). Curves can be produced with linear interpolationby breaking them into short, straight-line segments. This method has limitations, because a very large number of points

would have to be programmed to describe the curve in order to produce a contour shape.

Fig. 3 Two-dimensional linear interpolation

Circular Interpolation The development of MCUs capable of circular interpolation has greatly simplified the process of programming arcs and circles. To program an arc (Fig. 12), the MCU requires only the coordinate positions (the XY axes) of the circle center, the radius of the circle, the start point and end point of the arc being cut, and the direction in which the arc is to be cut (clockwise or counterclockwise) See Fig. 12. The information required may vary with different MCUs.

Fig. 4 Two-dimensional circular interpolation The functions of a few common G-codes

RESULT:

Thus the part programming fundamentals of CNC Machining is studied EXPT. NO: 3 DATE :

STUDY OF CAM PACKAGES

Computer-aided manufacturing (CAM): The computer-aided manufacturing is the use of computer software to control machine tools and related mac hinery in the manufacturing of work pieces. This is not the only definition for CAM, but it is the most common CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and t ooling with more precise dimensions and material consist ency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, whic h then controls the machine tool Over time, the historical shortcomings of CAM are being attenuated, both by providers of niche solutions and by providers of high-end solutions. This is occurring primarily in three arenas: 1. Ease of use 2. Manufacturing complexity 3. Integration with PLM and the extended enterprise Ease in use: For the user who is just getting started as a CAM user, out-ofthe-box capabilities providing Process Wizards, templates, libraries, machine tool k its, automat ed f eature based mac hining and job function specific tailor able user interfaces build user confidence and speed the learning curve.

User confidence is further built on 3D visualization through a closer integration with the 3D CAD environment, including error-avoiding simulations and optimizations. Manufacturing complexity: The manufacturing environment is increasingly complex. The need for CAM and PLM tools by the manufacturing engineer, NC programmer or machinist is similar to the need for c omput er assistance by the pilot of modern aircraft systems. The modern machinery cannot be properly used without this assistance. Today's CAM systems support the full range of machine tools including: turning, 5 axis machining and wire EDM. Todays CAM user can easily generate streamlined tool paths, optimized tool axis tilt for higher feed rates and optimized Z axis depth cuts as well as driving non-cutting operations such as the Specification of probing motions. Integration with PLM and the extended enterprise: Todays competitive and successful companies have used PLM to integrate manufacturing with ent erprise operations from concept through field support of the finished product. To ensure ease of use appropriate to user objectives, modern CAM solutions are scalable from a st and-alone CAM system to a fully integrated multi-CAD 3D solution-set. These solutions are c reated to meet the full needs of manufacturing personnel including part planning, shop documentation, resource management and data management and exchange. According to the latest analysis of the CAM software market produced by CIM data, Inc., Mas ter CAM from CNC Software Inc. with more than 135,000 installations, is more than twice as popular as its nearest competitor. Master cam is a Windows based CAD/CAM package for 2-axis through 5axis milling and turning, 2-axis and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and 2D and 3D routing. The CAD functions are more advanced than what is needed to do simple editing of part files for use with the CAM f unction. Some users say that it is more than they need and that the CAD function is more design-oriented than machinist orient ed. Other users

say that the extended design-oriented functionality of the CAD package gives them the ability to create complex designs without having to buy a standalone CAD pack age. ABOUT EDGECAM EdgeCAM is a complete manufacturing solution to meet all your programming needs, including Surface, Rotary and Multiplane Machining, 2 and 4 Axis Wire EDM, 2, 4 and C & Y Axis Turning. With its standard Microsoft Windows interface, EdgeCAM frees you from learning about and maintaining several different systems, maximising your efficiency in producing CNC code. Before you use the EdgeCAM system and related documentation, you should be familiar with CAD/CAM systems, equipment, methods and terminology. You also need to have some experience of the MS-DOS operating system and the appropriate Microsoft Windows graphical user environment. The complete EdgeCAM system provides: 2D/3D Design and Modelling 2 to 3 Axis Machining 5 Axis Trimming and Deflashing 2 to 4 Axis (C and Y) Multi-Axis Turning 2 to 4 Axis Wire Erosion Tools, PCIs and PDIs Editor Code Wizard Edge Communications

Main stages in using Edge CAM:

Key Features of EdgeCAM Easily creates rendered, 3D wire-frame and surface geometry. Milling, Wire EDM, Turning and Surface machining disciplines supported. Supports advanced machine tool capabilities such as thread milling, rotary and multiplane, C & Y axis. Imports industry standard formats IGES, SAT, DWG, DXF and VDA. Operational Programming simplifies the programming task and minimises user input. EdgeCAMs Sequence Window lets you delete, edit or re-order machining instructions simply and quickly, using a tree -view interface.

EdgeCAM Solid Machinist provides the ability to directly load and machine solid files without the need for translation. Solid Machinist supports both prismatic and surface milling including multi-plane.

RESULT: Thus, the various features of CAM packages were studied and understood. EXPT. NO: 4 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. PROGRAM: N10 G21 G98 N20 G28 U0 W0 N30 M06 T01 N40 M03 S1200 N50 G00 Z2 N60 G00 X28 N70 G94 X-0.5 Z-0.5 Z-1 Z-1.5 Z-2 N80 G71 U.5 R1 N90 G71 P100 Q130 U.1 W.1 F80 N100 G01 X22 Z0 N110 G01 X22 Z-50 N120 G01 X28 Z-50 N130 G01 X28 Z2 : PLAIN TURNING & FACING

N140 G28 U0 W0 N150 M05 N160 M30 RESULT: Thus, the plain facing and turning operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

EXPT. NO: 5 DATE AIM: :

STEP TURNING & FACING

To simulate the cnc program for given work piece according to the dimensions. PROGRAM:

N10 G21 G98 N20 G28 U0 W0 N30 M06 T01 N40 M03 S1200 N50 G00 X28 Z2 N60 G71 U.5 R1 N70 G71 P80 Q130 U.1 W.1 F50 N80 G01 X15 Z-15 N90 G01 X20 Z-15 N100 G01 X20 Z-30 N110 G01 X25 Z-30 N120 G01 X25 Z-45 N130 G01 X28 Z-45

N140 G28 U0 W0 N150 M05 N160 M30

RESULT: Thus, the step turning and facing operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

TAPER TURNING AND CIRCULAR INTERPOLATION

EXPT. NO: 6 DATE AIM: To simulate the cnc program for given work piece according to the :

dimensions.

PROGRAM: N10 G21 G98 N20 G28 U0 W0 N30 M06 T1 N40 M03 S1500 N50 G00 Z2 N60 G00 X28 N70 G94 X-1 Z-.5 F1.2 Z-1 Z-1.5 Z-2 N80 G71 U0.5 R1 N90 G71 P100 Q120 U0.1 W0.1 F80 N100 G01 X20 Z0 N110 G01 X20 Z-25 N120 G01 X28 Z-25 N140 G71 U0.5 R1 N150 G71 P160 Q180 U0.1 W0.1 F100 N160 G01 X20 Z0 N170 G01 X20 Z-25 N180 G01 X28 Z-50 N190 G01 X17.5 Z0 N200 G01 X17.5 Z-22.5 N210 G02 X20 Z-25 R2.5 N220 G28 U0 W0

N230 M05 N240 M30

RESULT: Thus, the Taper Turning and Circular Interpolationoperations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

THREAD CUTTING OPERATIONS

EXPT. NO: 7 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. :

PROGRAM: N10 G 21 G98 N20 G 28 U0 W0 N30 M06 T01

N40 M03 S1200 N50 G 00 X28 Z2 N60 G 71 U.5 R1 N70 G 71 P80 Q130 U.1 W.1 F50 N80 G 00 X15 Z0 N90 G 01 X15 Z-15 N100 G01 X20 Z-15 N110 G01 X20 Z-30 N120 G01 X25 Z-30 N130 G01 X28 Z-30 N140 G01 F30 N150 S1500 N160 G70 P1 Q2 N170 G28 U0 W0 N180 M06 T03 N190 M03 S600 N200 G00 X15.5 Z2 N210 G76 P021560 Q050 R.02 N220 G76 X13.774 Z-13 P613 Q100 F1 N230 G28 U0 W0 N240 M05 N250 M30
RESULT: Thus, the Thread Cutting Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

DRILLING AND GROOVING EXPT. NO: 8 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. :

PROGRAM:
N10 G21 G98 N20 G28 U0 W0 N30 M06 T01 N40 M03 S1200 N50 G00 X0 Z1 N60 G01 Z-3 F0.2 N70 G00 Z1 N80 G01 Z-6 N90 G00 Z1 N100 G01 Z-9 N110 G00 Z1

N120 G01 Z-12 N130 G01 Z1 N140 G01 Z-15 N150 G00 Z1 N160 G01 Z-18 N170 G00 Z1 N180 G01 Z-21 N190 G00 Z1 N200 G28 U0 W0 N210 M06 T02 N220 M03 S1200 N230 G00 X40 Z-15 N240 G01 X33 N250 G00 X40 Z-15 N260 G00 X-27 N270 G01 X33 N280 G00 X40 N290 G28 U0 W0 N300 M05 N310 M30 RESULT: Thus, the Drilling and Grooving Operations were simulated on the given work piece according to the dimensions

All dimensions are in mm

CONTOUR MILLING
EXPT. NO: 9 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. :

PROGRAM: N10 G21 G94 N20 G91 G28 Z0 N30 G28 X0 Y0 N40 M06 T01 N50 M03 S1500 N60 G90 G00 X-25 Y-25 Z5 N70 G01 Z-1 F30 N80 G01 X25 Y-25 N90 G01 X25 Y15 N100 G03 X15 Y25 R10 N110 G01 X-15 Y25 N120 G02 X-25 Y15 R10 N130 G01 X-25 Y-25 N140 G00 Z5 N150 G91 G28 Z0 N160 G28 X0 Y0

N170 M05 N180 M30

RESULT: Thus, the Contour Milling Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

CIRCULAR POCKETING

EXPT. NO: 10 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. :

PROGRAM: N10 G21 G94 N20 G28 Z0 N30 G28 X0 Y0 N40 M06 T01 N50 M03 S1500 N60 G90 G00 X0 Y0 Z10 N70 G01 Z0 F50 N80 G170 R0 P0 Q3 X0 Y0 Z6 I0 J0 K20 N90 G171 P75 Z1500 R75 F250 B1800 J130 N100 G01 Z5 N110 G28 X0 Y0 N120 M05 N130 M30

RESULT:

Thus, the Circular Pocketing Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

RECTANGULAR POCKETING
EXPT. NO: 11 DATE AIM: To simulate the cnc program for given work piece according to the dimensions. :

PROGRAM:

N10 G21 G94 N20 G91 G28 Z0 N30 M06 T01 N40 G28 X0 Y0 N50 M03 S1200 N60 G90 G00 X0 Y0 Z10 N70 G01 Z0 F50 N80 G172 P0 Q2 R5 X-25 Y-20 Z-4 I 50 J50 K0 N90 G173 P50 S1500 R80 F90 B1200 J60 Z5 T1 I 0 K0 N100 G00 Z10 N110 G91 G28 Z0 N120 G28 X0 Y0 N130 M05 N140 M30

RESULT: Thus, the Rectangular Pocketing Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

PECK DRILLING
EXPT. NO: 12 DATE :

AIM: To simulate the cnc program for given work piece according to the dimensions.

PROGRAM: N10 G21 G94 N20 G28 X0 Y0 N30 G00 Z5 N40 M06 T01 N50 M03 S1500 N60 G83 X25 Y25 Z-10 R9 Q3 F120 X-25 Y25 X-25 Y-25 X25 Y-25

N70 G00 G80 G90 Z15 N80 M05 N90 M30

RESULT: Thus, the Peck Drilling Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

LINEAR AND CIRCULAR SLOTTING

EXPT. NO: 13 DATE :

AIM: To simulate the cnc program for given work piece according to the dimensions.

PROGRAM:
BILLET EDGE TOOL G91 G28 Z0 G28 X0 Y0 M06 T01 G50 S2000 M03 S12000 G90 G00 X-25 Y-40 G01 Z-5 F40 G01 X25 Y-40 G03 X25 Y-40 G03 X40 Y-25 R15 G01 X40 Y25 G02 X-25 Y40 G03 X-40 Y25 R15 G01 X-40 Y-25 G02 X-25 Y-40 R15 G00 Z2 M05 G91 G28 X0 Y0 Z0 M30 X100 Y1000 MOVE DEF T01 D01 Z10

X-50 Y-50

G21 G94 G40

RESULT: `Thus, the Linear and Circular Slotting Operations were simulated on the given work piece according to the dimensions.

All dimensions are in mm

STUDY ABOUT CNC CODE GENERATION FOR MACHNING

EXPT. NO: 14 DATE :

AIM: To Study about CNC Code Generation for Machning SEQUENCE OF CODE GENENERATION Open solid model parts generated in CAD packages. Change view - select Isometric and zoom. Create stock representing the raw billet. Specify the stock material. Find 'Features' in the model: holes, pockets and bosses. Save your work. Specify a ToolStore database. Create machining for the features, using operations. Use Simulator to provide a visual confidence check of your machining. Edit operations. Generate the CNC code Loading the Cad Model 1) In the Standard toolbar (or File menu) click the Open button. 2) .In the Open dialog that appears, navigate to the folder: installation folder\Cam\Examples\tutorial\Solid Machinist\Parasolid i. For example: ii. C:\Program Files\EdgeCAM\Cam\Examples\tutorial\Solid Machinist\Parasolid 3) From this folder open prismatic milling.x_t

Selecting the Isometric View Right-click on the View Caption and in the menu that opens click Isometric.

Zooming In And Out Enlarge or reduce the size of the part on the screen: Roll the top of the mouse wheel away from you to zoom in. Roll the top of the mouse wheel towards you to zoom out. Creating the Stock Stock represents the billet of material from which the part is to be machined. To create the stock:

1. Click the Geometry menu and click Stock/Fixture. 2. In the dialog that opens make these settings. Click Automatic Stock first. 3. Click OK to add the stock. An outline appears showing added stock.

Showing Translucent Stock 1. In the Display toolbar (to the right of the Standard toolbar) click the Toggle Stock button. The stock display changes to 'translucent'. 2. Click the button again to switch back (to 'wireframe').

Finding the Features

Features are pre-identified areas of the model that you can base your machining on. To find features: 1. In the Standard toolbar check the CPL Selector setting. If it is not Top, click the current setting and in the list that opens click Top

2. Click the Solids menu and click Feature Finder. 3. In the Feature Finder dialog that opens, make these settings and click the OK button to find the features. 4. Note how the Features Window is automatically displayed, showing a 'tree' view of the newlyfound.

Specifying the Material Speeds and feeds are automatically calculated. These are based on the material being machined, so you need to specify this: 1. Click the Options menu and click Model. 2. In the Model dialog that opens click Browse. 3. In the dialog that opens scroll down the list in the All tab, then click Steel 150 HB to select it, then click Select. 4. Click OK to close the Model

Specifying the Tool Store Database selecting pre-defined tools from the ToolStore. Using the ToolStore you can access tools from different databases, and need to ensure you are using the correct one, which is the example database that is installed with EdgeCAM: 1. Click the Options menu and click Preferences. 2. In the Preferences dialog that opens click the Tool Libraries tab. 3. The Name entry should be installation folder\Cam\tstore\tstore.mdb for example: c:\program files\EdgeCAM\Cam\tstore\tstore.mdb If this is not the entry, click the Browse button and use the browser to navigate to this file and open it. 4. Click OK to close the dialog.

Drilling the Hole Drill the hole through the centre of the part: 1. In the Operations toolbar click the Hole Operation button. 2. The Status Bar now prompts you to 'Select Points'. Click on the Features window tab and in the Features window rest the cursor on the 1: Through hole feature. The hole feature in the centre of the part changes colour to confirm where this is.

3. Click on the feature to select it (the hole feature in the part changes colour again to show this). 4. Move the cursor (now a cross) back into the Graphics area and right-click to terminate the points selection.

5. Now the Hole dialog opens. Leave all the settings unchanged, apart from setting Clearance to 20. Click OK.

6. The Hole operation is now created. Click the Sequence window tab, then click the '+' symbol for the Hole operation to see the instructions within the operation. (In the Graphics Area you see a graphic for the automaticallyselected tool. Note how this has been given the diameter of the hole.)

7. The Status Bar now prompts you to 'Digitise Stock'. Rest the cursor on one of the lines comprising the top profile of the stock. The line changes colour and the tooltip indicates 'Stock'. Double-click to select the whole top profile. Then right-click to terminate the stock selection. The Roughing operation is now created. The toolpath is displayed on the part.

8. Click the Sequence window tab. Now click the '+' symbol for the Roughing operation to see the instructions within the operation.

Rest Roughing the Part In the previous roughing operation the tool was too large to remove all the material (the tool could not fit into the pockets, for example). You now 'rest rough' with a smaller tool to remove this material. To do this repeat the previous Roughing operation, but with slight changes. Here is a summary, with the changes marked '*': 1. In the Operations toolbar click Roughing Operation. 2. Select the whole solid. 3. Select no boundaries. 4. In the Roughing Dialog, General tab, set Rest Rough to checked *, set Offset to 0.2, set Digitise Stock to unchecked * (you can leave the other settings as they are). 5. Click the Tooling tab and from the ToolStore select the tool 6 mm Endmill - long series* (you can leave the other settings as they are). 6. Click the Depth tab and set Clearance to 5, Level to 0, Depth to 0 and Cut Increment to 2. Click OK to close the dialog and generate the operation (there will be no prompt for stock). 7. In the Sequence window rest the cursor on 3 Roughing Operation. Tool path for the operation becomes highlighted

Machining the Flat Lands A finishing tool on the flat areas, removing the material left by the0.2 offset in the previous Roughing operations: 1. In the Operations toolbar click the Flatland Operation button.

2. The Status Bar now prompts you to 'Digitise Geometry to machine'. Select the whole solid and terminate, as you did as you did before for the Roughing operations. 3. At the 'Select boundary entities...' prompt right-click to terminate without making a selection. 4. The Flatland Operation dialog now opens. In the General tab make these settings. (The Stand Off Distance leaves an unmachined border round the flats to be removed in subsequent Profiling operations.)

5. Click on the Tooling tab and from the ToolStore select 8 mm Endmill long series as you did before for the Rest Roughing. (Other settings can be left as they are.) 6. Click the Depth tab and set Clearance to 5, Level to -0.1 and Depth to 0. 7. Click OK to close the dialog and generate the operation. Profiling the Inner Profile (Upper Boss) profile finish the upper central boss: 1. In the Operations toolbar click the Profiling Operation button. 2. The Status Bar now prompts you to 'Digitise Profile(s)'. Select the feature in the Features window and terminate as you did when drilling the hole. This time select the 7: 2D Boss feature. 3. After terminating the geometry selection, terminate at the 'Select boundary entities' prompt without making a selection. 4. The Profiling dialog now opens. In the General tab make these settings.

5. Click the Tooling tab and from the ToolStore select the 5 mm diameter SSM-ZX-2 Flute-5 (other settings can be left as they are). 6. Click the Depth tab and set Clearance to 5, Level to 0, Depth to 0, Cut Increment to 2 and Cusp Height to 0. 7. Click OK to close the dialog and generate the toolpath. 8. The tool graphic can sometimes get in the way. In the Display toolbar click the ' ' symbol of the Toolbar Properties button and click Hide. Repeat to show the tool again. Set this as you prefer. With the tool hidden you have an unobstructed view of the part and its newThe tool graphic can sometimes get in the way. In the Display toolbar click the ' ' symbol of the Toolbar Properties button and click Hide. Repeat to show the tool again. Set this as you prefer. With the tool hidden you have an unobstructed view of the part and its new tool path

Profiling the Outer Profile (Lower Boss) machine the outer perimeter of the part. To do this repeat the previous Profiling operation, but with slight changes. Here is a summary, with the changes marked '*': 1. In the Operations toolbar click Profiling Operation. 2. Select the 2: 2D Boss feature *. 3. Select no boundaries. 4. In the Profiling dialog, General tab, set: Offset to 0 and Lead Radius 4. 5. In the Profiling dialog Tooling tab open the ToolStore and select the 5mm diameter SSM-ZX-2 Flute-5. (Other settings can be left as they are.) 6. In the Profiling dialog Depth tab, set: Clearance to 5, Level to 0, Depth to 0, Cut Increment to 2, Cusp Height to 0. Click OK to close the dialog and generate the operation. 7. Rest the cursor on the new operation to highlight its toolpath.

Profiling the Pockets Now start to machine the pockets. To do this repeat the previous Profiling operations, but with slight changes. Here is a summary, with the changes marked 1. In the Operations toolbar click Profiling Operation. 2. Select all four pocket features *. To select all the pockets, click on the 3: 2D Pocket then hold down the Shift key and click on 6: 2D Pocket.

3. Select no boundaries. 4. In the Profiling dialog, General tab, set: Offset to 0 and Lead Radius 4. 5. In the Profiling dialog Tooling tab open the ToolStore and select the 3mm diameter SSM-ZX-2 Flute-3. (Other settings can be left as they are.) 6. In the Profiling dialog Depth tab, set: Clearance to 5, Level to 0, Depth to 0, Cut Increment to 2, Cusp Height to 0. Click OK to close the dialog and generate the operation. 7. Rest the cursor on the new operation to highlight its

Simulating the Machining. In the Main toolbar underneath the Standard toolbar (or in the View menu) click Simulate Machining.

As the simulation continues, click the Speed Control button.

In the Speed Control that appears, drag the slider to the left and right to control

the speed of the simulation. Use these buttons to control the simulation at any time:

Editing the Profiling Operation As used the Operation as a quick way to generate a toolpath using automatic settings. The simulation highlighted a tool collision, but EdgeCAM allows you to 'fine tune' the operation to correct this: 1. In the Sequence window, click the ' +' symbol of the last Profiling operation in the sequence. This expands the operation to show the instructions within it. The last instruction is 'Profiling'. This is the 'cycle', which controls the toolpath. 2. Double-click on Profiling and in the Profiling dialog that opens, click the Links tab and set (Long Links) Type to Clearance.

3. Click OK to close the dialog. Repeat the simulation and collision has been eliminated.

Generating CNC Code Click the Generate Code button in the Main toolbar, underneath the Standard toolbar (or in the File menu). A message dialog now tells you that 'This option is not available in the Student Edition', so this is as far as you can go with the live exercise.

After setting the CNC Name and clicking OK, the code would be generated. With Open Editor checked, the newly generated code is shown loaded into the Editor application.

RESULT Thus the basic study about CNC code generation for machining components of CNC machine have been studied. VIVA VOCE QUESTIONS
1.what are the difference between CAD and CAM? 2.Mention the major components of the CNC machine? 3.What is the expansion of FANUC? 4.What are the important lathe operation? 5.what are the important milling operation? 6.explain about G codes? 7.Mention few important G codes? 8.What is the use M codes? 9.Write about some important M codes? 10.What is the use of box facing cycle?

11.What is the difference between G00 and G01codes? 12.How to make taper turning in lathe ? 13.What is the code for multiple cycle? 14.How to cut the thread in CNC lathe? 15.How to change the tool in CNC program? 16.How to change the tool speed in cnc lathe? 17.what is the difference between absolute and incremental system? 18.what are the axes to be considered while writing program for cnc lathe? 19.what is the file extension of CNC program? 20.what are the codes for coolants on or off? 21.what is the g code for circular pocketing? 22.How to change the depth of cut in milling operation? 23.what is the use of mirroring? 24.what are the functional keys use in fanuc programming? 25.what is use of dry run option? 26What are the important modeling operation? 27.What are the advantages of CATIA? 28.who is the developer of CATIA? 29.what is the expansion of CATIA? 30.what is the use of RIB command? 31.What are important toolbars in catia? 32.explain about dressing feature in CATIA? 33.How to use Revolve command in catia? 34.What are the important options in sketcher mode? 35.How to import and export files from catia? 36.What is the use of transformation? 37.what is the use of AUTO constraint? 38.What is the latest version of CATIA?. 39What is the use of pad command? 40.explain about loft command? 41.what is the use of stiffener command? 42.what is the use of shell command? 43. what is the use of RIB command? 44.What is the use of edge fillet?

45.what is the use of SHAFT command? 46.What is the extension CATIA file? 47.How to apply mirror command? 48.Write about work bench? 49.what is the use of pocket command? 50.What are the features of CATIA