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Me59-Cad - Cam Lab Manual 2010-2011
Me59-Cad - Cam Lab Manual 2010-2011
Me59-Cad - Cam Lab Manual 2010-2011
LABORATORY MANUAL
Prepared by Approved by
Dr.T.Prabaharan
Professor / Mech.
Dr.R.Rajkumar HOD/Mech.
Professor / Mech.
1
SYLLABUS
ME59 CAD/CAM LAB LTPC 0032
OBJECTIVES:
- To be able to understand and handle design problems in a systematic manner.
- To gain practical experience in handling 2D drafting and 3D modeling software
systems.
- To be able to apply CAD in real life applications.
- To understand the concepts G and M codes and manual part programming.
- To expose students to modern control systems (Fanuc, Siemens etc)
- To know the application of various CNC machines
- To expose students to modern CNC application machines EDM, EDM wire cut and
Rapid Prototyping
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LIST OF EXPERIMENTS
CAD
3
TENTATIVE SCHEDULE FOR CAD LAB
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INSTRUCTIONS TO STUDENTS
1. Students are required to remove their footwear outside the center and keep it in the box
provided for the same.
2. Students should leave their belongings outside the lab except their observation note
book, the concerned books/manuals and calculators.
3. Students are requested not to place their legs on the wall or on the table.
4. Students should refrain from leaning on the table and sitting on it.
6. Students should not use any disks brought from outside without prior permission from
the concerned staff.
7. Students can get the required manual or disks from the staff after signing in the
appropriate register.
8. Students should collect their printouts before leaving the lab for that particular session.
9. Before leaving the Terminal, the students should logout properly and leave their chairs
in position.
10. Students are not allowed to take any manual outside the center.
1. Get permission from the concerned staff before switch ON the CNC machines.
2. Ensure the proper power supply for the system and machine.
4. If any problem occurs in the system or machine immediately inform to the concerned
staff. Don’t try to rectify the problem by yourself.
5. Your batch is responsible for the CNC machine and its system while doing the lab
exercise assigned to your batch.
******
5
CONTENTS
2. Solid modeling 8
7. Exercises in Assembly 26
6
A) COMPUTER AIDED DESIGN (CAD)
According to Shigley, the design process is an iterative procedure involving the following six
phases:
1. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation
Phase 3 (synthesis) includes defining the design problem, design conceptualization, searching for
design information, modeling and simulation.
Phase 4 (analysis and optimization) may includes parameter study, finite element analysis, etc.
Although computers are being utilized more and more in the design process, their use is still
limited to the last four steps in the design and they are mainly used as a tool that helps the
designer, rather than as a replacement for the designer.
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Geometric Modeling
The term geometric modeling (or representation) means a method of describing commonly used
curves and surfaces in terms of values of a few parameters.
2. SOLID MODELING
A solid modeling system is usually an interactive computer graphics system that is intended to
create true three-dimensional components and assemblies. Recent advances in CAD software,
computers, and graphical displays have made it possible to use solid representations of
components being considered in the design process. These solid models can be employed in
numerous ways.
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4. CADCAE/CAM Data Exchange
Computer databases are now replacing paper blueprints in defining product geometry and
non-geometry for all phases of product design, analysis, and manufacturing. It becomes
increasingly important to find effective procedures for transferring data among CAD/CAE/CAM
systems.
The need to exchange modeling data is directly motivated by the need to integrate and automate
the design and manufacturing process to obtain the maximum benefits from CAD/CAE/CAM
systems.
(2) Nonshape data includes graphics data such as shaded images, and model global data as
measuring units of the database and the resolution of storing the database numerical values.
(3) Design data has to do with the information that designers generate from geometric models for
analysis purposes. e.g., mass property and finite element mesh data.
(4) Manufacturing data consists of information such as tooling, NC tool paths, tolerancing,
process planning, tool design, and bill of materials.
IGES is focused on CAD-to-CAD exchange where primarily shape and nonshape data were to be
transferred from one system to another. PDES is previous called Product Data Exchange
Standard. It is for the exchange of complete product descriptions which covers the four types of
modeling data (i.e., shape, nonshape, design and manufacturing).
Other data exchange interfaces include: STL, Neutral, SET, ECAD, VDA, STEP, PDGS,
CATIA, Render, CGM, VRML, PATRAN, TIFF, etc.
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5. SOLID WORKS SOFTWARE OVERVIEW
Solid Works is a computer-aided design (CAD) system for mechanical assembly, part modeling,
and drawing production. Developed with STREAM technology, Solid Works is designed to
increase software performance with an interface that ensures maximized user productivity and
return on investment.
Solid Works STREAM technology boosts essential CAD user productivity by capturing
engineers' solid modeling design intentions through inference logic and decision-management
concepts. STREAM technology makes Solid Works easy to learn, easy to use, and more
productive than any other mid-range CAD system on the market.
You can create drawings that display various views, sections, details, dimensions, notes, and
annotations. You can also add feature control frames, datum frames, weld symbols, and surface
texture symbols to your drawings. Ensuring that the dimensions and annotations on your
drawings conform to your company’s standards or international standards is easy—as in
Microsoft Office products, you can capture these settings in styles and templates.
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Base Features in Part Modeling
Extrude: Extension in third axis of the profile
Fig. 5.1
Revolve : Revolve the profile about axis of symmetry
Fig. 5.2
Sweep : Extrusion of a cross section along a path
Fig. 5.3
Blend / Loft : Blending of different cross sections along a path
Fig. 5.4
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Editing & Engineering Features in Part Modeling
Round : Modify the sharp edge to curved edge
Shell : Removes a surface or surfaces from the solid then hollows out the
inside of the solid, leaving a shell of a specified wall thickness.
Fig. 5.5
Fig. 5.6
Fig. 5.7
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6. PART MODELING AND ASSEMBLY IN SOLID WORKS
Important steps
1. Choose the best profile for sketching.
2. Choose the proper sketch plane.
3. Create a new part.
4. Create a sketch.
5. Extrude a sketch as a boss.
6. Extrude a sketch as a cut.
7. Create Hole Wizard holes.
8. Insert fillets on a solid.
9. Make a basic drawing of a part.
10. Make a change to a dimension.
11. Demonstrate the associatively between the model and its drawings.
Terminology
Moving to 3D requires some new terminology. The SolidWorks software employs many
terms that you will become familiar with through using the product. Many are terms that you will
recognize from design and manufacturing such as cuts and bosses.
Feature
All cuts, bosses, planes and sketches that you create are considered Features. Sketched
features are those based on sketches (boss and cut), applied features are based on edges or faces
(fillet).
Plane
Planes are flat and infinite. They are represented on the screen with visible edges. They
are used as the primary sketch surface for creating boss and cut features.
Parallel Plane
Creates a reference plane parallel to a part face or reference plane at an offset value you
define. You can define the offset value using the cursor or by typing a value in the Distance box
on the ribbon bar.
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Sketch
In the SolidWorks system, the name used to describe a 2D profile is sketch. Sketches are
created on flat faces and planes within the model. They are generally used as the basis for bosses
and cuts, although they can exist independently.
Although there are many ways to create features and shape the solid, for this lesson, only
extrusions will be discussed. An extrusion will extend a profile along a path normal to
the profile plane for some distance. The movement along that path becomes the solid model.
Extruded cutout
A Cut is used to remove material from the model. This is the opposite of the boss. Like
the boss, cuts begin as 2D sketches and remove material by extrusion, revolution, or other
methods.
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Revolved Boss/ Base
1. Create a sketch that contains one or more profiles and a centerline, line, or edge to use as
the axis around which the feature revolves.
Constructs a protrusion by fitting through a series of cross sections. You can define the
cross sections using profiles drawn within the command, sketches, or edges of existing features.
The cross sections must be closed, planar elements.
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View Options
SolidWorks gives you the option of representing your solid models in one of several
different ways. They are listed below, with their icons:
Symbol Description
Shaded
Wireframe
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BASIC FEATURES
Insert (from menu bar) > Select Extrude > Click Sketcher icon (from dash board) > Select a
plane (from main window) > Click Sketch (from section dialogue box) > Select References
(check reference status fully placed) > Close (reference dialogue box) > Sketch a figure (edit
dimensions if required) > Click (blue color to continue) > Enter depth value (at prompt in
dash board) > click preview (at dash board) > click (green color on dash board) > file > save >
click (green color)
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REVOLVE
Insert > Revolve > Select Sketcher (icon from dash board) > Select plane for sketching >
Click sketch > Select References > Close reference > Draw figure > Draw centre line as axis
(along which it should revolve) > Click (blue color) > Specify angle (in dash board upto
which it should rotate) > preview > click (green color)
SWEEP
Insert > Sweep > Protrusion > Click Sketch Trajectory (from sweep trajectory menu
manager) > Select a Plane > Okay (for direction) > Default (sketch view) > Select References >
Close (reference dialogue box) > Draw Trajectory > Click (blue color) > Sketch Cross section
(at the intersection of two yellow color axes) > Click (blue color) > Preview > OK (to accept)
BLEND
Insert > Blend > Protrusion > (from blend options) Select Parallel > Regular section > Sketch
section > Done > (from Attributes) Select Straight > Done > (from Set up plane) Select a Plane >
Okay (direction) > Default (sketch view) > Select References (check whether it is fully placed) >
Close (reference dialogue box) > Draw section 1 > Right click mouse and select Toggle section
> Draw section 2 > Click (blue color to continue) > Enter depth value at prompt (between
section 1 and 2) and click (green color) > Preview (from Protrusion dialogue box) > OK (to
accept drawing)
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EDITING & ENGINEERING FEATURES
Round
CHAMFER
Edge Chamfer:
Create a basic feature > Insert > Chamfer > Edge Chamfer > Select Sets option (from dash
board) > Select edges (as reference for chamfering with ctrl key pressed) > select one option
from dash board (for example D x D) > Enter value for D at prompt) > Preview > Click (green
color to accept)
CUT
Create a basic feature > Insert > extrude > select sketcher icon > select sketch plane (to insert
cut) > click sketch > select references > close (reference dialogue box) > draw a figure > click
(blue color) > select type of depth (from dash board) > enter depth value > flip in required >
click remove material icon (on the dash board) > click flip direction if required > preview > click
(green color on dash board to accept)
HOLE
Create a basic feature > Insert > Hole > (from dash board) Select
Simple > Click Placement > Select a surface (for primary
reference) > Select linear > Click No Items under secondary
reference > Select 2 edges (with ctrl key pressed) > Enter edge
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offset values > (In dash board) Enter diameter of hole > Select type of dept > Enter depth value >
Preview > Click (green color to accept)
PATTERN
Create a basic feature (for example with hold included) > select a part
from model tree (example – hole, to be patterned and which is having
reference dimensions) > right click mouse on it > select pattern >
select dimension option (from dash board) > select 1st reference
dimension (from main window by placing cursor on dimension for
direction 1) > enter increment value > select 2nd reference dimension
(for direction 2) > enter increment value > enter number of items (for
direction 1 & 2 at dash board) > click (green color to accept pattern)
SHELL
Create a basic feature > insert > shell > select surfaces with ctrl key pressed (which are to be
shelled) > enter thickness at the prompt > click (green color to accept)
RIB
Create a basic feature > insert > rib > click sketcher icon > select a plane (along with rib should
form) > click sketch > select references > close (reference dialogue box) > draw an open section
for rib formation > click (blue color to continue) > specify thickness of the rib (at prompt) >
flip direction (if required at prompt and also flip direction on screen to face inside) > preview >
click (green color to accept drawing)
ASSEMBLY OPERATION
ASSEMBLY CONSTRAINTS
Mate
Mate constraint two surfaces touch one another, coincident and facing each other shown
in fig.
Mate Offset
Mate offset constraint makes two planar surfaces parallel and facing each other. The
offset value determines the distance between two surfaces shown in fig.
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Align
Align constraint makes two planes coplanar, coincident and facing in the same direction.
It also aligns revolved surfaces or axes to make them coaxial shown in fig.
Align Offset
This constraint aligns two planar surfaces at an offset, parallel and facing in the same
direction shown in fig.
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Insert
Insert constraint inserts a male revolved surface into a female revolved surface, align axes
shown in fig. 1.17.
Orient
The orient constraint orients two planar surfaces so that they are parallel and facing in the
same direction, offset is not specified. See fig. 1.18.
Coord Sys
The coordinate system constraint places a component in an assembly by aligning its
coordinate system with a coordinate system in the assembly shown in fig.
Tangent
The Tangent, pnt on line, pnt on surface and Edge on srf constraints are used to
control the contact of a surface at the tangency of another surface, at a point or at an edge. In
most cases, a combination of the constraints will be required.
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6. EXERCISES IN 3D PART MODELING
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Fig. 6.3 Fig. 6.4
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Fig. 6.7 Fig. 6.8
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7. EXERCISES IN ASSEMBLY
Fig. 7.1
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Fig. 7.2
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8. ADDITIONAL EXERCISES IN PART MODELING
Fig. 8.1
Fig. 8.2
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ADDITIONAL EXERCISE IN ASSEMBLY MODELING
Fig. 8.3
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B) COMPUTER AIDED MANUFACTURING (CAM)
Preparatory Functions
Miscellaneous functions
M00 – Program stop
M01 – Optional stop
M03 – Spindle clockwise
M04 – Spindle counter clockwise
M05 – Spindle halt
M08 – Coolant on
M09 – Coolant off
M10 – Chuck or collet close
M11 – Chuck or collet open
M30 – Program End
M40 – Chuck outer clamping
M41 – Chuck inner clamping
Syntax
G00 X Z ;
G01 X Z F ;
G02 X Z R F ;
G03 X Z R F ;
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G04 X ; (Time in seconds)
G28 U W ;
G70 P Q F ;
P – Start sequence
Q – End sequence
F – Feed
G71 U R ;
G71 P Q u w F ;
U – Depth of cut
R – Relief in X direction
P – Start sequence
Q – End sequence
u – Stock amount for finish – X axis
w – Stock amount for finish – Z axis Finishing allowance
F – Feed
G72 W R ;
G72 P Q W F ;
G73 U W R ;
G73 P Q u w F ;
U – Depth of cut
W – Relief in Z direction
R – Number of passes
P – Start sequence
Q – End sequence
u – Stock amount for finish – X axis
w – Stock amount for finish – Z axis Finishing allowance
F – Feed
G74 R ;
G74 Z Q F ;
G75 R ;
G75 X Z P Q F ;
G76 P Q R ;
G76 X Z q p F ;
P – Number of idle passes
Q – First pass depth of cut
R – Relief
X – Thread minor dia
Z – Thread Length
q – Second pass depth of cut
p – Thread height
F – Pitch
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10. EXERCISE IN PRODUCTION LATHE USING SINGLE TOOL
AIM:
To write, simulate and execute a CNC program for the job of given dimensions as
shown in the figure using CNC 250 – Production lathe.
PROCEDURE:
RESULT:
Fig. 10.1
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11. EXERCISE IN PRODUCTION LATHE USING MULTI TOOL
AIM:
To write, simulate and execute a CNC program for the job of given dimensions as
shown in the figure using CNC 250 – Production lathe.
PROCEDURE:
RESULT:
Fig. 11.1
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Manual Part Programming in CNC Milling
Machine Configuration
Model : Star Mill with ATC
Make : MTAB
Working Table Size : 360mm x 130mm
Longitudinal Traverse [X] : 160mm
Cross Traverse [Y] : 90mm
Head Traverse [Z] : 115mm
Accuracy : 0.001mm
Directives
[BILLET - Define Billet Size
[EDGEMOVE - Offset from the program zero to the lower left corner of the billet
[TOOLDEF - Define diameter and length of a tool
[STEP - Step by step execution of program
[NOSTEP - Cancel step by step execution of program
[SHOW - Show the operation being simulated
[NOSHOW - Stop the operation being simulated
!TUTORIAL - To display user interactive message at the bottom
[CLEAR - It will clear the interactive message display
General Notations
X X coordinate value
Y Y coordinate value
Z Z coordinate value
D Diameter of tool
T Tool Number
F Feed rate
S Spindle speed
R Radius of arc
G functions
Function Operation
G00 Positioning (Rapid traverse)
G01 Linear interpolation (Cutting feed)
G02 Circular interpolation / Helical CW
G03 Circular interpolation / Helical CCW
G04 Dwell Exact stop
G20 Imperial units (inches)
G21 Metric units (mm)
G28 Return to reference point
G40 Tool radius compensation cancel
G41 Left hand radius compensation
G42 Right hand radius compensation
G49 Tool length compensation cancel
G90 Absolute command
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Function Operation
G91 Incremental command
G92 Set datum
G94 Feed per minute
G95 Feed per rotation
G170-G171 Circular Pocketing
G172-G173 Rectangular Pocketing
M functions
Function Operation
M00 Program Stop
M02 Program End
M03 Spindle Forward
M04 Spindle Reverse
M05 Spindle Stop
M06 Tool Change
M70 X Mirror on
M71 Y Mirror on
M80 X Mirror Off
M81 Y Mirror Off
M98 Subprogram Call
M99 Subprogram Exit
Aim
1. Writing a NC program for the given profile as shown in the figure.
2. Simulating and executing the program using FANUC Milling software.
Procedure
Result
Fig. 13.2
c
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C) SIMULATION AND NC CODE GENERATION
Fig. 14.1
Aim
To generate NC code for the given profile using CAPSTURN software.
Procedure
Work setup
Draw the Part
Define the Part
Draw the Blank
Define the Blank
Machine the Part
View tool path
Select a machine
Generate NC Program
Result
Thus the NC code was generated for the given profile using the CAPSTURN
software.
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15. MILLING SIMULATION – CL and NC Code generation using CAPSMILL
software
Fig. 15.1
Aim
To generate NC code for the given profile using CAPSMILL software.
Procedure
Work setup
Draw the Part
Define the Part
Draw the Blank
Define the Blank
Machine the Part
View tool path
Select a machine
Generate NC Program
Result
Thus the NC code was generated for the given profile using the CAPSMILL software.
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