CADCAM Lab Manual

IV B.
Tech – I Sem (ME) CAD/CAM LAB
1
IV B.Tech – I Sem (ME)
CAD/CAM LAB
CMR INSTITUTE OF
TECHNOLOGY
UGC AUTONOMOUS
Approved by AICTE, Permanent Affiliation to
JNTUH,
NBA & NAAC Accredited
Kandlakoya (V), Medchal (M), Medchal (D),
Hyderabad- 501401.
www.cmritonline.ac.in
DEPARTMENT OF MECHANICAL
ENGINEERING
CERTIFICATE
ACADEMIC YEAR: 2019-20
This is to certify that the bonafide
record work done by
Mr./Ms.____________________________________
_________________
Bearing H.T No _________________of IV-
B.Tech-I Semester in the CAD-CAM
2
IV B.Tech – I Sem (ME)
CAD/CAM LAB
Laboratory is satisfactorily completed.
FacultyIn-Charge-1
Head of Department
FacultyIn-Charge-2
3
IV B.Tech – I Sem (ME) CAD/CAM LAB
Index:
Page
S.No Name of the experiment no.
1. Course outcomes 3
2. Department of Mechanical Engineering 3-7
3. Safety Measures 7
4. Personal Precautions 7
5. List of experiments 8
6. General introduction 9
DRAFTING: Development of part drawing for various components in the
form of orthographic and isometric views. Representation of dimensioning
7. and tolerances 11-33
PART MODELING: Generation of various 3D models through protrusion,
revolve and sweep. Creation of various features. Study of parent child relation.
Feature based, Boolean based and assembly modeling. Study of various standard
8. translators. Design of simple components 34-44
9. Determination of the deflection and stresses in 2D and 3D trusses and beams 45-55
Determination of deflections, principal and Von-Mises stresses in plane stress,
10 plane strain and axi-symmetric components 56-62
Determination of stresses in 3D and shell structures (at least one example
11 in each case) 63-70
Estimation of natural frequencies and mode shapes, harmonic response of 2D
12 beams 71-78
13 Steady State heat transfer analyses of plane and axi-symmetric components 79-86
Development of the process sheet for components based on tooling and
14 machines 87,88
15 Development of manufacturing defects and tool management systems 89

Study of various Post Processor used in NC machines
16 90-95
Development of NC codes for free form and sculptured surfaces using CAM
software 96-
17 109
Machining of simple components on NC Lathe and Mill by transferring NC 110-
18 Code/from CAM software 119
4
CAD/CAM LAB
1. Course outcomes:
1. Students used various modeling commands for the creation of Orthographic and Isometric
views.
2. 3D wireframe, 3D surface frame and solid models are created by the students.
3. Students made product assemblies from individual solids by performing Boolean operations
4. The analysis of beams and trusses subjected to static, dynamic and thermal loads are
examined by the students.
5. Students are choosed CNC machines for quality parts production
6. Students generated CNC part programs successfully by CNC TRAIN V6 software for the
selected drawing
2. CMR INSTITUTE OF TECHNOLOGY

Vision: To create world class technocrats for societal needs.
Mission: Impart global quality technical education for a better future by providing appropriate
learning environment through continuous improvement and customization.
Quality policy: Strive for global excellence in academics and research to the satisfaction of
students and stakeholders.
DEPARTMENT OF MECHANICAL ENGINEERING
Vision:
To be a centre of excellence committed to provide quality education and research for
nurturing technically competent and socially responsible mechanical engineering
professionals.
Mission:
Provide state of art technical knowledge, research and consultancy with industries
and R&D organizations to meet global and societal challenges in the field of
mechanical engineering.
Program Outcomes
PO 1: Engineering knowledge: Apply knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to solution of complex engineering problems
5
PO2: Problem analysis: Identify, formulate, review, research literature and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences and engineering sciences
PO3: Design/ development of solutions: design solutions for complex engineering problems
and the cultural. Social and environmental considerations
PO4: Current investigations of complex problems: Use research – based knowledge and
research methods including design of experiments, analysis and interpretation of data and
synthesis of the information to provide valid conclusions
PO5: Modern tool usage: create, select, and apply appropriate techniques, resources and
modern engineering and IT tools including prediction and modeling to complex engineering
activities with an understanding of the limitations
PO6: The engineer and society: Apply reasoning informed by the contextual knowledge to
assess social, health, safety legal and cultural issues and the consequent responsibilities
relevant to the professional engineering practice
PO7: Environment and Sustainability: understand the impact of the professional engineering
solutions in societal and environmental contexts and demonstrate the knowledge of and need
for sustainable development
PO8: Ethics: Apply ethical principles and commit to professional ethics and responsibilities
and norms of the engineering practice
PO9: Individual and team work: Function effectively as an individual and as a member or
leader in diverse teams, and in multidisciplinary settings
PO10: Communication: Communicate effectively on complex engineering activities with the

engineering community and with society at large, such as being able to comprehend and write
effective reports and design documentation, make effective presentations and give clear
instructions
PO11 Project management and finance: Demonstrate knowledge and understanding of the
engineering principles and apply these to one’s own work, as a member and leader in a team to
manage projects and in multidisciplinary environments
PO12: life-long learning: Recognize the need for and have the preparations and ability to
engage in independent and life-long learning in broadest context of technological change
Program Educational Objectives

1 PEO - 1 Graduate will have effective foundation in mathematics, science,
engineering, technology, management, humanities and various other interdisciplinary subjects
for successful career in mechanical engineering and related fields..[PO’s: 1,2,3,4,5,7,8,9,10,11
and 12]
6
2 PEO – 2 Graduate will be able to pursue higher education and research and/or
become an entrepreneur/innovator to design and develop mechanical system to address
technical, business and global challenges. [PO’s: 1, 2,3,4,5,6,7,8,9,10 and 12]
3 PEO – 3 Graduate exhibits professional ethics, communication skills, teamwork

and adapts to changing environments of engineering technology by engaging in lifelong
learning.[PO’s: 1,2,3,4,5,6,7,8,9,10,11 and 12]
Course Objectives & Outcomes Mapping
Course Outcomes
Course Objectives
CO-1 CO-2 CO-3 CO-4 CO-5 CO-6
√
Objective-1
Objective-2 √
Objective-3 √
Objective-4 √
Objective-5 √
Objective-6 √
Course outcomes and Program outcomes mapping
No Course Outcomes Po1 Po2 Po3 Po4 Po5 Po6 Po7 Po8 Po9 Po10 Po11 Po12
1 CO - 1 3 3 3 3 3 2 2 2 3 3 3 3
2 CO – 2 3 3 3 3 3 2 3 1 3 3 3 3
3 CO – 3 3 3 3 3 3 2 3 3 2 3 3 3
4 CO – 4 3 3 3 3 3 2 1 3 3 3 2 3
5 CO – 5 3 3 3 3 3 3 3 3 3 3 3 3
6 CO - 6 3 3 3 3 3 2 2 2 3 3 3 3
7
Course Mapping
Course Name PEO1 PEO2 PEO3 PSO1 PSO2 PSO3
√ √ √ √ √ √
CAD/CAM LAB
Course Name Po1 Po2 Po3 Po4 Po5 Po6 Po7 Po8 Po9 Po10 Po11 Po12
√ √ √ √ √ √ √ √ √ √ √ √
CAD/CAM LAB
8
3. Safety Measures:
1. Do not power cables.

2. Start the computer system with Winwod7 or with Window XP.
3. Do not touch Server systems.
4. Open the specified software’s in a proper way.
5. After using the specified software’s, close it properly.
6. K Check the computer system having Antivirus or not.
7. Never work in the lab without the instructor present.
8. Do not touch the CNC machines during the running condition.
9. Send the CNC program to CNC machines after checking simulation.
10. Wear apron only.
4. Personal Precautions:
1. Keep long hair tied back so that it cannot fall forward onto a computer and CNC
machines.
2. Stand away from the CNC machines, because work piece or tool may come out rapidly.
9
CAD/CAM LAB
(For the A.Y 2019– 20)
5. List of Experiments (Any 08 of the following):
1. DRAFTING: Development of part drawing for various component s in the form of

orthographic and isometric views. Representation of dimensioning and tolerances.
2. PART MODELING: Generation of various 3D models through protrusion, revolve and

sweep. Creation of various features. Study of parent child relation. Feature based, Boolean
based and assembly modeling. Study of various standard translators. Design of simple
components.
3. Determination of the deflection and stresses in 2D and 3D trusses and beams.
4. Determination of deflections, principal and Von-Mises stresses in plane stress, plane strain
and axi-symmetric components.
5. Determination of stresses in 3D and shell structures (at least one example in each case).
6. Estimation of natural frequencies and mode shapes, harmonic response of 2D beams.
7. Steady State heat transfer analyses of plane and axi-symmetric components.
8. Development of the process sheet for components based on tooling and machines.
9. Development of manufacturing defects and tool management systems
10. Study of various Post Processor used in NC machines.
11. Development of NC codes for free form and sculptured surfaces using CAM software.
12. Machining of simple components on NC lathe and Mill by transferring NC Code/from

CAM software
10
6. General introduction
1. All the students must follow the prescribed dress code (apron) wear their ID cards
2. All the students should sign in login register.
3. All students must carry their observation books and records without fail.
4. Students must take the permission of the laboratory staff before handling the machines in
order to avoid any injury.
5. The students must have basic understanding about the theory and procedure of the
experiment to be conducted.
6. Power supply to the computer should be given in the presence of lab technician.
only .
7. Do not LEAN on and do not come CLOSE to the CNC machines.
8. Every student is required to handle the computer with care and follow proper precautions.
9. Students should ensure that their work areas are clean.
10. At the end of each experiment, the student must take initials from the staff on the data /
observations taken after completing the necessary calculations.
11. Students should attend regularly to all lab classes.
12. Day- to- day evaluation of student performance is carried out and recorded for finalizing
internal marks.
This laboratory covers creation of 2D modeling, 3D wire frame modeling and solid modeling
using AutoCAD database. The analysis of 2D and 3D trusses and beams, plain stress, plain
strain, axi-symmetric components, analysis of shell structures, Thermal analysis of plain and
axi-symmetric components, estimation of natural frequencies can be done by ANSYS software.
Manufacturing of simple components on XLTURN, XLMILL CNC machines can be
performed with help of CNC TRAIN V6 software and process sheets developed for the CNC
machines. CAM Simulation of the created model can be performed using CNC TRAIN V8
software. Here, basic introduction to AutoCAD is discussed and introduction to ANSYS,
XLTURN, XLMILL, and CNC TRAIN V8 discussed at the respective experiments.
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INDEX
S. Page Date of Date of
Experiment Signature
No No Experiment Submission
DRAFTING: Development of part
drawing for various component s in the
1 form of orthographic and isometric views.
Representation of dimensioning
and tolerances 12-34
PART MODELING: Generation of various
3D models through protrusion, revolve and
sweep. Creation of various features. Study
2 of parent child relation. Feature based,
Boolean based and assembly modeling.
Study of various standard translators.
Design of simple components 35-45
Determination of the deflection and
3
stresses in 2D and 3D trusses and beams 46-56
Determination of deflections, principal and
4 Von-Mises stresses in plane stress, plane
strain and axi-symmetric components 57-63
Determination of stresses in 3D
5 and shell structures (at least one
example in each case) 64-71
Estimation of natural frequencies and
6 mode shapes, harmonic response of 2D
beams 72-79
Steady State heat transfer analyses of plane
7
and axi-symmetric components 80-87
Development of the process sheet for
8 components based on tooling and
machines 88,89
Development of manufacturing defects
9
and tool management systems 90
Study of various Post Processor used in NC
10 machines
91-96
Development of NC codes for free form
11 and sculptured surfaces using CAM
software
97- 110
Machining of simple components on NC
12 lathe and Mill by transferring NC 111-
Code/from CAM software 120
Introduction to AutoCAD
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Drafting is one of the first computer applications used by many users. It refers to the
engineering model, communicated for manufacturing.
BASIC FACILITIES IN AUTOCAD:
The released AutoCAD 2016 has the familiar windows look and feel, in terms of the various
icons and an easier interface. It has set of dropdown windows for various menu options. The
basic facilities in AutoCAD 2016 are
New: This allows for starting a new drawing.

Open: This allows opening an old drawing for editing.
Save: Allows saving the current drawing.
Save as: Allows saving the current drawing with new name.
Export: Allows for exporting the current drawing into other format. Suitable for other programs
such as 3D studio.
Example:-
BMP: Device-independent bit map.

DWG: AutoCAD drawing file
DWF: AutoCAD drawing web format.
DXF: AutoCAD R14 drawing inter change.
SCREEN DISPLAY:
In the display screen the status line is the bottom most line. On the right side, a column is
displayed for providing the possible menu selections. The column can be removed from the
screen if necessary by changing the option in the AutoCAD set up. At the bottom a command
area is provided which is generally designed for three lines. Rest of screen is designed for the
drawing area.
Menu:
AutoCAD is a completely menu driven system. Also number of menu commands is available.
1. Direct command entry.

2. Through the side bar menu.
3. Through the pop-up window from the menu bar.
4. Through the button bars located in any portion of the screen.
Planning for a drawing:
This is carried out by set up operations.
Units:
This lets us set up the units in which the AutoCAD would have to work. It would be working in
default co-ordinates called as drawing units. This is achieved by using “units” command. It
offers following types of units. Scientific, Decimal, Engineering, Architectural, Fractional.
13
Co-ordinate system:
It generally uses the rectangular Cartesian co-ordinate (x, y, & z axes) system which follows
right hand rule. Co-ordinates can be inputted into the system in a number of ways by direct
input of co-ordinate values in their respective order. There are three types of coordinate
systems. I.Global/modal coordinate system ii. User coordinate system and iii. Screen
coordinate system
Limits:
It is normally necessary to specify the limits of the drawing that one is about to use. The
actual size of drawing would have to be specified using limit command.
Limits establish the size of the drawing and the associated drawing guide such as grids,
rulers’ etc……in proper format. However, limits check option is kept on, and then
AutoCAD would not allow you to specify any point beyond the limits.
Grid:
Working on a plane drawing area is difficult since there is no means for the user to understand
or correlate the relative position or straightness of the various objects or entities made in the
drawing. The grid command controls the display of a grid of alignment to assist the placement
of objects in the drawing.
SNAP:
The resolution of the cursor can be effectively controlled by using SNAP command. When the
cursor is moving in the drawing area, it moves in increments of the snap spacing value
specified. This is useful for inputting data through the digitizer or mouse. Functional key: F9
ORTHO:
It allows to control “orthogonal” drawing mode. As a result all lines and traces drawn while this
mode is on are constrained to be horizontal or vertical. Functional key: F8
Help:
AutoCAD provides complete help at any point of working in the program.
Object properties:
Line type:
AutoCAD allows the user to draw various types of lines in the drawing. To change the line type
of existing object, use the “CHANGE “command. To control large line type use “LAYER”
command. It can also load line type definitions from a library file.
BASIC GEOMETRIC COMMANDS:
14
The various entities that can be used for making an AutoCAD drawing in 2D are:
POINT, LINE, ARC, CIRCLE, ELLIPSE, POLYGON, POLYLINE, DOUGH NUT, SKETCH,
TEXT, BLOCK.
i.Point:
It is used to specify a point or a node in the drawing for any given purpose. It is also used as
NODE in object snap option. It is also possible to specify the co-ordinates in incremental
format as the distance from the current cursor position in the drawing area. The distance is
specified by using the “@” parameter before the actual value.
ii.Line:
It allows you to draw straight line. You can specify the desired end points using either 2D or 3D
co-ordinates. To erase the latest line segment without exiting the line command enters“U”.
Lines may be constrained to horizontal or vertical by the “ORTHO” command. The close
option uses the start point of the first line in the current line command.
iii.Circle:
It is used to draw a full circle. We can specify a circle in many ways. For specifying the circle
we need at least two values.
•
Centre point and radius.
•
Centre point and diameter.
•
2p\3p\ttr methods.
iv.Arc:
It enables to draw an arc as specified by following methods. Three points on the arc.


Start point, centre and end point.

Start, centre and included angle.

Start, centre and length of chord.

Start, end and radius.

Start, end and included angle.
Start, end and direction of start.
The arc is always drawn in counter clock wise direction. Depending on the data available it is
necessary to plan carefully the sequence in which the data is specified. Drawing a circle is
easier than arc. The arc will be generated in which the points are specified.
LAYERS:
A layer is basically one which contains some information which can be geometric or alpha-
numeric. The reason of distributes all the information present in the drawing into various layers
is that at any given time some of the layers can be deleted from the view(off) or can be made
visible(on). This helps in organizing the information in a drawing. Thus each layer may be
considered as a transparent sheet having some information.
Each layer has a name which can be up to 31 characters.

Default layer name given by AutoCAD is 0.
15
A layer could be ON or OFF. When a layer is ON the information present in it would be visible on
screen.
A layer is either “current or inactive”.
If the current layer is ON then the information being entered would be visible on screen.
Each layer has a color associated with it. The color of individual information can be altered by using
“CHANGE” command or by using “COLOR” command.
DISPLAY CONTROL COMMAND:
Zoom is used to change the scale of display. This can be used to magnify a part of the drawing
to any higher scale of or closely observing some file details in the drawing. There are number
of options available within zoom.
SCALE<X>: A numeric zoom factor. A value less than 1 zoom out and greater than 1 zoom in.
ALL: Zoom out to original drawing limits.
DYNAMIC: Graphically selects any portion of the drawing as your next screen view.
CENTRE : Pick a centre and picture top and bottom by selecting two end points of height.
EXTENTS: Shows everything in the file.
LEFT : Pick a lower left corner and a height of how much drawing information you want to
Display to fill up the screen.
I. Previous: Restores the last zoom setting.
Choosing the dynamic option displays all the drawing up to limits in a small window. So that
the entire drawing is visible in the display screen. The current visible window would be shown
in rectangular linked to the cursor.
II.Pan:
It allows you to move the display window in any direction without changing the display
magnification. This means the display being seen is through a window in an opaque sheet
covering the drawing limits.
OBJECT SNAP:
By selecting the OSNAP option the system would be able to automatically calculate the tangent
point in the region selected. The various OSANP options are as follows.
CENTRE: center or arc or circle.
ENDPOINT: closest end point if line/arc etc.
INSERTION: insertion point of text/block etc.
INTERSECTION: intersection of lines/arcs/circles etc.
MIDPOINT: midpoint of lines/arcs/circles etc.
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NEAREST: nearest point on line/arc/circle.
NODE: nearest point entity.
PERPENDICULAR: perpendicular to line/arc/circle.
QUADRANT: quadrant point of arc or circle.
TANGENT: tangent to arc or circle.
TEXT HANDLING:
AutoCAD provides a large range of text entering capabilities including various fonts and other
text handling features.
EDITING/MODIFY OF A DRAWING:
Editing capabilities are the most useful part of AutoCAD to export the productivity potential,
making use of the already existing objects in the drawing.
ARRAY: places multiple copies of objects with a single command.
BREAK: cuts existing objects and /or erase portions of objects.
CHANGE: Changes spatial properties of some objects.
COPY: makes copies of objects.
ERASE: Allows selecting objects in the drawing file and erasing them.
MIRROR: creates a mirror image.
MOVE: picks up existing objects and puts them in another location of drawing.
ROTATE: Turns existing object to any angular position.
SCALE: Scales object up or down to your specification.
I.MOVE
It is used to move one or more existing drawing entities from one location to another location.
You can draw the object into position on the screen by giving base point and second point. The
selected objects will follow the movements of the screen.
OBJECT: the default selects a set by picking individual objects.
WINDOW: objects are completely inside a window drawn by the cursor control device.
LAST: uses only the last object created.
CROSSING: works like a window; it also includes any object which is partially
17
within the Window.
REMOVE: it removes any objects that are accidentally selected by any of the object.
ADD: used o adding when the remove option is specified.
MULTIPLE: allows multiple objects in close proximity.
PREVIOUS: adds the entire previous selection list to the current selection list.
UNDO: undo the last selection operation.
SELECT ALL: selects all objects in drawing.
WINDOW POLYGON: Here, rectangular window is replaced by polygon of as many vertices

as required.
CROSSING POLYGON: similar to the window polygon except that the polygon here is not
would be selected.
II.COPY
This command is used to duplicate one or more existing drawing entities at another location
without erasing original. You can drag the object into position on the screen. The selected
object will follow the movements of the screen.
To make multiple copies, respond to the base point prompt with ‘’M’’. When you have made
required number of copies give a null response to the second point prompt to come out of the
copy command.
III.CHAMFER
It creates a bevel between two intersecting lines at a given distance from their intersection. It
can also trim the lines from the bevel edge and connect the trimmed ends with a new line of
TRIMMODE variable is set to 1. Chamfer can only be applied between line segments and not
any other objects.
IV.FILLET
It connects two lines, arcs, or circles with a smooth curve of specified radius. It adjusts the
length of the original lines or arcs so their ends exactly on the fillet arc. The fillet valve
specified remains in force until it is altered by another valve. If the fillet radius is ‘’0’’ then two
lines will meet exactly at a point which is normally used to make a sharp corner. Filleting can
also be done to two circles, a line and a circle, a line and an arc and a circle and an arc.
V.OFFSET
This command constructs an entity parallel to another entity at either a specified point. You can
OFFSET a line, arc, circle or polygon. Offset lines are parallel, while the offset circles and arcs
make concentric circles. Once object is selected it is highlighter on the screen.
V.ARRAY
18
It makes multiple copies of selected objects in a rectangular or polar pattern. For a rectangular
array you are asked for the number of columns & rows and the spacing between them. The
array is built along a base line defined by the current snap rotation angle set by the “SNAP
ROTATE” command.
For polar array a centre point needs to be supplied. you must supply two of following…
•
The number of items in the array.
•
The number of degrees to fill
•
The angle between items in the array.
DIMENSIONING:
After creating the various views of the model or after preparing the drawing it is necessary to
add dimensions at the appropriate places. AutoCAD provides semi automatic dimensions. As a
result once dimensions are created, AutoCAD gives great control over the way the dimensions
may appear in the drawing. The dimension familiars are as follows.
I.Linear dimensions
ii.Diameter dimensions
iii.Radial dimensions
iv.Angular dimensions
v.Ordinate dimensions
vi.Leader dimensions
vii.Aligned dimensions
3D- MODELING
Creates 3D polygon mesh objects in common geometric shapes that can be hidden, shaded, or
rendered.
Command entry: 3d
Enter an option
[Box/Cone/Dish/Dome/Mesh/Pyramid/Sphere/Torus/Wedge]:
1. BOX
Creates a 3D box polygon mesh.

Specify corner point of box:
Specify length of box: Specify a distance
Specify width of box or [Cube]: Specify a distance or enter C
2. CUBE
Creates a cube using the length for the width and height of the box.
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3. CONE
Creates a cone-shaped polygon mesh.
4. PYRAMID
Creates a pyramid or a tetrahedron.
Specify first corner point for base of pyramid: Specify a point (1)
Specify second corner point for base of pyramid: Specify a point (2)
Specify third corner point for base of pyramid: Specify a point (3)
Specify fourth corner point for base of pyramid or [Tetrahedron]: Specify a point (4) or enter t
Experiment No. 1A. Development of part drawing for various components in the form of
orthographic views (without hatching)
Aim:-To develop the given orthographic view by using Auto CAD 2D commands and to
specify its dimensions.
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Software required: AUTOCAD 2016 Database.
Commands in use: LIMITS, LINE, CIRCLE, DIMLINEAR, DIMDIA, etc.
Procedure: In order to obtain given model the following procedure will be followed (Note:
Procedure for drawing.1 is given. You have to know the procedures of drawing.2 to
21
drawing.12)
Command: Limits:
Specify lower left corner: (0, 0)
Specify upper right corner: (200,150)
Command: ZOOM: [All/Center/Previous/Scale/Window/Object]: All
Command: LINE:
Specify the start point:
Specify the length of the line (end point):84
Command: Offset:
Specify the distance of the offset: 30
Select the object for offset:
Specify point on side to offset:



Command: Circle:
Specify the center point of the circle (p/2p/ttr):
Specify the radius of the circle (diameter): d
Specify the diameter of the circle (diameter): 28
Command: Circle:
Command: Circle:
Command: Circle:
Command: Array:
Polar array
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No. of objects: 6
Select the object:
Select the center:
Preview
Accept Modify Cancel
Accept
Command: Circle:
Command: Circle:
Specify the radius of the circle (diameter): r
Command: Fillet:
Specify the first point (r/d/length): r
Specify the radius of the fillet: 10
Specify the second point:
Command: Fillet:
Specify the first point (r/d/length): r
Specify the radius of the fillet: 8
Specify the second point:
Command: Line: → Tangent

Specify the length of the line (end point):
Command: Line: → Tangent

Specify the length of the line (end point):
Command: Trim:
Specify the part to be trim (rad/trim/erase):
Command: DIMLIN and DIMRAD:
DIMLIN and DIMRAD are used to specify the dimensions of the model.
PRECAUTIONS:
23
1. Limits should be given before drawing the object.

2. Object should be drawn from a specific point of location only.
3. Ensure that proper sequence should be followed to draw an object.
Result: Hence by using Auto CAD 2016 2D commands, i have drawn the orthographic view of
the given model and dimensions are specified.
Questions
1. What are the basic geometric commands?
Ans ----------------------------------------------------------------------------------------------------
2. What are the co-ordinate systems used in AutoCAD?
Ans ----------------------------------------------------------------------------------------------------
3. What is the purpose of limits command used in AutoCAD?
Ans ----------------------------------------------------------------------------------------------------
4. What is the use of SNAP command?
Ans ----------------------------------------------------------------------------------------------------
5. What is the use of GRID command?
Ans ----------------------------------------------------------------------------------------------------
6. What are the types of lines used in AutoCAD?
Ans ----------------------------------------------------------------------------------------------------
7. Define Parametric and non parametric curves.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
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25
Experiment No. 1B.Development of part drawing for various components in the form of
orthographic views (with hatching)
Aim: To develop the given orthographic view by using Auto CAD 2D commands and to
26
Commands in use: LIMITS, LINE, CIRCLE, HATCH, DIMLINEAR, DIMDIA, etc.
Procedure: In order to obtain given model the following procedure will be followed
(Note: Procedure for drawing.1 is given. You have to know the procedures of drawing.2 to
drawing.10)
Command: Limits:
Command: LINE:
Specify the length of the line (end point): say 100

Command: Offset:

Command: Circle:
Command: Circle:
Command: Circle:
Command: Circle:
27
Command: Circle:
Command: Circle:
Command: Circle:
Specify the radius of the circle (diameter): r
Command: Circle:
Command: Circle:
Command: Region:
Specify the region:
One loop and one region created.
Command: Hatch: → pick point

Select the points:
Select the width: 10
Set current
Command: Trim:
Specify the part to be trim (rad/trim/erase):
PRECAUTIONS:

Result: Hence by using Auto CAD 2016 2D commands, i have drawn the orthographic view of
the given model and dimensions are specified.
28
Questions
1. Which functional key is used to activate ORTHO command?

Ans ----------------------------------------------------------------------------------------------------
2. How many methods are there to draw circles and arcs?

Ans ----------------------------------------------------------------------------------------------------
3. What are the display control commands?
Ans ---------------------------------------------------------------------------------------------------
4. Explain about OSNAP.
Ans ----------------------------------------------------------------------------------------------------
5. Differentiate between BREAK command and TRIM command.

Ans ----------------------------------------------------------------------------------------------------
6. When do you use hatching for a drawing?

Ans --------------------------------------------------------------------------------------------------
29
Experiment No. 1C: Development of part drawing for various components in the form of
isometric views.
Aim: To develop the given isometric view by using Auto CAD 2D commands and to
30
Commands in use: LIMITS, LINE, CIRCLE, 3D ORBIT, VIEW, DIMLINEAR, DIMDIA,

etc.
drawing.12)
Command: Limits:
SELECT THE ISOMETRIC VIEW POSITION: S-W
Command: LINE: (for showing front view)

Specify first point: (0, 0)
Specify next point or (undo): 16(2700)
Specify next point or (close/undo): 50(900) ↑
Specify next point or (close/undo): 18(2700)
Specify next point or (close/undo): 50(900) ↓
Specify next point or (close/undo):7 (900) ↑
Specify next point or (close/undo): 8
OR
Specify next point or (close/undo): C
Specify next point or (close/undo): ESC
Command: LINE :( showing top view)

Specify next point or (undo): 52
OR
31

Command: LINE :( showing left side view)

OR
Command: LINE :( showing right side view)
SIMILARLY CREATE RIGHT SIDE VIEW
Command: LINE :( showing back view)

OR
Command: REGION :( for right side view)
Select line drawn closed loop object:

One region is created.
Command: Circle:
Specify center point by taking line intersecting method, after that
32
Command: Circle:
Command: LINE
Command: LINE:
Draw two lines, showing line of intersection. i.e. center point
Command: Circle:
Command: Circle:
Command: 3D ORBIT: Used for rotation and viewing of the object.

-Draw geometric entities in the remaining views. This can be possible by rotation.
PRECAUTIONS:

Result: Hence by using Auto CAD 2016 2D commands, i have drawn the isometric view of the
given model and dimensions are specified.
Questions
1. What are the editing commands used in AutoCAD?

Ans ----------------------------------------------------------------------------------------------------
2. Define PAN and ZOOM commands.
Ans ----------------------------------------------------------------------------------------------------
3. Define array. What are the types of arrays?
Ans ----------------------------------------------------------------------------------------------------
4. Define Chamfer and Fillet.
Ans ----------------------------------------------------------------------------------------------------
5. Define Isometric view and Isometric projection.
Ans --------------------------------------------------------------------------------------------------
33
34
35
Experiment No. 2A: Generation of 3D solid model through protrusion and using Boolean
operations
AIM: To develop the given 3D solid model by using Auto CAD 2D & 3D commands and to
36
Commands in use: LIMITS, LINE, CIRCLE, EXTUDE, SOLID, SHADE, SOLID EDITING,
UCS, VIEW, PAN, 3D ORBIT, DIMLINEAR, DIMDIA, etc.
drawing.16)
COMMAND: Limits:
DEVELOP THE 2D VIEW BY USING 2D COMMANDS
Command: LINE :( showing front view)

Specify first point: 0, 0
Specify next point or (undo): 10 → in x-direction
Specify next point or (close/undo): 47 ↑ (in x-direction)
Specify next point or (close/undo): 40 →
Specify next point or (close/undo): 47↓
Specify next point or (close/undo):10 →
Specify next point or (close/undo):7 ↓
Specify next point or (close/undo): 19 ←
Specify next point or (close/undo): 47 ↑
Specify next point or (close/undo): 47 ↓
Specify next point or (close/undo):7 ↑
OR
Command: REGION :( for front view)

Select line drawn closed loop object:
One region is created.
Command: EXTRUDE:
Select the object to be extruded:

Select the height to be extruded: 34
Specify the angle: 00
37
3D WIEFRAME MODEL WIL BE CREATED

Command: 3D ORBIT:
By selecting the 3D orbit, the created object will be rotated.
Command: SHADE:
Select the object to be shade (3D wire frame model):
Selected 3D wire frame model to become a solid
Command: UCS:
Select three points on the top of the object in x, y, z directions.
And z-axis should be shown in upward or downward
direction.
Command: LINE :
Draw two lines, showing line of intersection. I.e. center point
Command: OFFSET:
Offset distance: 13 in x-direction
Offset distance: 11 in y-direction
Command: TRIM:
Trim the extended lines of the created rectangular box.
Command: EXTRUDE:
Select the object to be extruded: (rectangle)
Select the height to be extruded: 8
Command: UNION:
Select the objects to be union (base part and sub part)
Command: Circle:
At the midpoint of the rectangular box, draw the circle with 14mm diameter.
Command: EXTRUDE:
Select the object to be extruded: (circle)
Select the height to be extruded: -15
Command: SUBTRACT:
Select the base object:
Select the object to be subtracted: (i.e. circle)
Select depth of subtraction: Z = -15 OR through hole.
Note: Base object and sub object can be created separately. The sub part can be moved on
to the base part on the required view (i.e. on top view or side views, etc) by using MOVE
Command. Assembly will be done by using UNION command.
Command: VIEW:
38
Rotate and view the object

PRECAUTIONS:

Result: Hence by using Auto CAD 2016 2D&3D commands, i have drawn the given solid
model and dimensions are specified
Questions
1. What is 21/2 dimensioning?
Ans ----------------------------------------------------------------------------------------------------
2. What are the types of geometric modeling methods?
Ans ----------------------------------------------------------------------------------------------------
3. What are the Boolean operators? Explain.
Ans ----------------------------------------------------------------------------------------------------
4. What is the use of UCS?
Ans ----------------------------------------------------------------------------------------------------
5. Define Extrusion.
Ans ----------------------------------------------------------------------------------------------------
39
40
41
42
Experiment No. 2B. Generation of 3D solid model through Revolve command (Creation
of solid cylinder)
Aim: To develop the given 3D solid model by using Auto CAD 2D & 3D commands and to
Commands in use: LIMITS, LINE, CIRCLE, EXTUDE, SOLID, SHADE, SOLID EDITING,
UCS, VIEW, PAN, 3D ORBIT, DIMLINEAR, DIMDIA, etc.
COMMAND: Limits:
Command: RECTANGLE:
Specify the next point: (width) =10
Specify the height: 50
Command: REVOLVE:
Select the object: (i.e. rectangle)
Specify the base point: (i.e. lower right corner point)
Select the axis: (i.e. the vertical line at right side)
Specify the angle of rotation: 3600 → the solid cylinder is created.
NOTE: If you a create hollow cylinder, draw a rectangle and draw a line (i.e. axis) which
is at some distance from one side of the rectangle. Then
Select the object: (i.e. rectangle)
Select the object: (i.e. axis)
Command: SHADE:
Specify the revolve object:
The object can be shaded.
PRECAUTIONS:

Result: Hence by using auto cad 2016 2D& 3D commands, i have drawn solid cylinder
through solid of revolution and dimensions are specified.
43
Questions
1. Differentiate between Model coordinate system and User coordinate system.
Ans ----------------------------------------------------------------------------------------------------
2. Differentiate between B-representation and C-representation.

Ans ----------------------------------------------------------------------------------------------------
44
Experiment No. 2C: Generation of solid Primitives using solid Primitives icons. (Creation
of Box and cylinder)
Aim: To develop the given solid primitives by using Auto CAD solid primitive
icons/commands and to specify its dimensions.
Commands in use: LIMITS, LINE, CIRCLE, SOLID, SHADE, SOLID EDITING, UCS,
VIEW, PAN, 3D ORBIT, DIMLINEAR, DIMDIA, etc.
Command: Limits:

Command: ZOOM:[All/Center/Previous/Scale/Window/Object] : All
Creation of Box
Command: BOX:
Specify first corner:
Specify other corner: 60
Specify the box height: 60
OR
Creation of cylinder
Command: CYLINDER:
Specify the center of cylinder:
Specify the base radius (or diameter): R=10
Specify the height: 50
OR
NOTE: Similarly other primitives like Cone, Frustum of cone, wedge are created.
PRECAUTIONS:

Result: Hence by using auto cad 2016 2D& 3D commands, I have drawn the given solid
primitives and dimensions are specified.
45
Questions
1. List out the solid primitives.
Ans ----------------------------------------------------------------------------------------------------
2. Differentiate between shading and Rendering.

Ans ---------------------------------------------------------------------------------------------------
INTRODUCTION TO ANSYS
46
ANSYS is a general-purpose finite element-modeling and analysis package for numerically

solving a wide variety of mechanical problems.
These problems include:
 Static/dynamic structural analysis (both linear and non-linear)

 Heat transfer and Fluid problems,
 Acoustic and Electro-magnetic problems.
1. A finite element problem can have the following three stages

• Preprocessing: defining the problem
• Solution: assigning loads, constraints and solving
• Post processing: further processing and viewing of the results
2. ANSYS Interface
• Graphical Interface
• Command File Coding
3. ANSYS Files
A large number of files are created when you run ANSYS. They are
• file.db - Database file (binary). This file stores the geometry, boundary conditions and
any solutions.
• file.dbb - Backup of the database file (binary).
• file.err - Error file (text). Listing of all error and warning messages.
• file.out - Output of all ANSYS operations (text). This is what normally scrolls in the
output window during an ANSYS session.
• file.log - Log file or listing of ANSYS commands (text). Listing of all equivalent
ANSYS command line commands used during the current session.
Depending on the operations carried out, other files may have been written. These files may
contain results, etc.
4. Performing Analysis using ANSYS
A typical ANSYS analysis has three distinct steps:
Step I: Pre - Processor

• Different stages of Pre – Processor
– Geometric modeling
– Adding geometric attributes
– Adding material properties
– FEM meshing
– Different geometric boundary conditions
– Prescribing load boundary conditions
Geometric Modeling
• Creating the model by using geometric entities

• Key points
47
• Lines, straight lines, curved

• Plane areas
• Solid entities like Cube, Cylinder, Sphere
Importing the model from other modeling soft wares
Selecting the Element Type
• 1D, 2D and 3D elements
Element Characteristic Shape
• Point - A point element is typically defined by one node, e.g., a mass element.
• Line - A line element is typically represented by a line or arc connecting two or three
nodes. Examples are beams, spars, pipes, and axisymmetric shells.
• Area - An area element has a triangular or quadrilateral shape and may be a 2-D solid
element or a shell element.
• Volume - A volume element has a tetrahedral or brick shape and is usually a 3-D solid
element.
FEM Meshing
• Free meshing - A free mesh has no restrictions in terms of element shapes, and has no
specified pattern applied to it.
• Mapped meshing - A mapped mesh is restricted in terms of the element shape it
contains and the pattern of the mesh. In addition, a mapped mesh typically has a regular
pattern, with obvious rows of elements.
Fig 4: Free and Mapped Meshes
Geometric Boundary Conditions
• Boundary displacement constraints

Load Boundary Conditions
• Mechanical loads
• Thermal loads
The main goal of a finite element analysis is to examine how a structure or component
responds to certain loading conditions. Specifying the proper loading conditions is, therefore, a
key step in the analysis. You can apply loads on the model in a variety of ways in the ANSYS
program.
48
Loading
The word loads in ANSYS terminology includes boundary conditions and externally or
internally applied forcing functions
Structural: displacements, forces, pressures, temperatures (for thermal strain), gravity
Thermal: temperatures, heat flow rates, convections, internal heat generation, infinite surface
Magnetic: magnetic potentials, magnetic flux, magnetic current segments, source current
Density, infinite surface
Electric: electric potentials (voltage), electric current, electric charges, charge densities,
Infinite surface
Fluid: velocities, pressures
Structural Analysis
There are seven types of structural analyses available in the ANSYS family of products. The
primary unknowns (nodal degrees of freedom) calculated in a structural analysis are
displacements. Other quantities, such as strains, stresses, and reaction forces, are then derived
from the nodal displacements
Types of Structural Analysis
• Static Analysis
• Modal Analysis
• Harmonic Analysis
• Transient Dynamic Analysis
• Spectrum Analysis
• Buckling Analysis
• Explicit Dynamic Analysis
Static Analysis
Used to determine displacements, stresses, etc. under static loading conditions. Both linear and
nonlinear static analyses can be carried out. Nonlinearities can include plasticity, stress
stiffening, large deflection, large strain, hyper elasticity, contact surfaces, and creep.
Modal Analysis
Used to calculate the natural frequencies and mode shapes of a structure. Different mode
extraction methods are available.
Harmonic Analysis
Used to determine the response of a structure to harmonically time-varying loads
Transient Dynamic Analysis
49
Used to determine the response of a structure to arbitrarily time-varying loads. All

nonlinearities mentioned under Static Analysis above are allowed.
Spectrum Analysis
An extension of the modal analysis, used to calculate stresses and strains due to a response
spectrum or a PSD input (random vibrations).
Buckling Analysis
Used to calculate the buckling loads and determine the buckling mode shape. Both linear
(Eigen value) buckling and nonlinear buckling analyses are possible.
Several special-purposes
• Explicit Dynamic Analysis

• Fracture mechanics
• Composites
• Fatigue
• Beam Analyses
Elements Used in Structural Analyses
Most types of structural analyses can use any of these elements.
Category Element Name(s)
Spars LINK1, LINK8, LINK10, LINK180
Beams BEAM3, BEAM4, BEAM23, BEAM24, BEAM44,

BEAM54, BEAM188, BEAM189
Pipes PIPE16, PIPE17, PIPE18, PIPE20, PIPE59, PIPE60
2-D Solids PLANE2, PLANE25, PLANE42, HYPER56, HYPER74,

PLANE82, PLANE83, HYPER84, VISCO88, VISCO106,
VISCO108, PLANE145, PLANE146, PLANE182,
PLANE183
3-D Solids SOLID45, SOLID46, HYPER58, SOLID64, SOLID65,

HYPER86, VISCO89, SOLID92, SOLID95, VISCO107,
SOLID147, SOLID148, HYPER158, SOLID185, SOLID186,
SOLID187, SOLID191
Shells SHELL28, SHELL41, SHELL43, SHELL51, SHELL61,

SHELL63, SHELL91, SHELL93, SHELL99, SHELL150,
SHELL181
Types of Solution Methods
50
Two solution methods are available for solving structural problems in the ANSYS family of
products:
• The h-method
• The p-method.
The h-method can be used for any type of analysis, but the p-method can be used only for
linear structural static analyses. Depending on the problem to be solved, the h-method usually
requires a finer mesh than the p-method. The p-method provides an excellent way to solve a
problem to a desired level of accuracy while using a coarse mesh.
Performing a Static Analysis
The procedure for a static analysis consists of these tasks:

1. Build the Model
2. Apply the Loads
3. Solution Options
4. Solve the Analysis
5. Review the Results
Experiment No. 3A. Simple Static Analysis 2D Trusses
51
Aim: To determine the deflection and stresses in 2D truss for the truss system shown below.
Software required: ANSYS15.0.7 Database.
Procedure: In order to obtain analysis of the given problem the following procedure will be
followed
(E = 200GPa, A = 3250mm2).
Preprocessing: Defining the Problem
In the Utility menu bar select File > Change Title:
Define the Type of Element
From the Preprocessor Menu, select: Element Type > Add/Edit/Delete.

For this example, we will use the 2D spar element
Select the element shown and click 'OK'. You should see 'Type 1 LINK1' in the 'Element Types'
window.
Define Geometric Properties
We now need to specify geometric properties for our elements:

In the Preprocessor menu, select Real Constants > Add/Edit/Delete
Enter the cross-sectional area (3250mm):
Element Material Properties
You then need to specify material properties:

In the 'Preprocessor' menu select Material Props > Material Models
Double click on Structural > Linear > Elastic > Isotropic
Enter the Young’s Modulus (EX): 200000
Enter Key points
The overall geometry is defined in ANSYS using key points which specify various principal
coordinates to define the body. We are going to define 7 key points for the simplified structure
as given in the following table. From the 'ANSYS Main Menu' select:
Preprocessor > Modeling > Create > Key points > In Active CS
Key point coordinate
52
x y
1 0 0
2 1800 3118
3 3600 0
4 5400 3118
5 7200 0
6 9000 3118
7 10800 0
(These key points are depicted by numbers in the above figure)
Form Lines
The key points must now be connected; we will use the mouse to select the key points to form
the lines.
In the main menu select: Preprocessor > Modeling > Create > Lines > Lines > In Active Coord.
When you're done, click on 'OK' in the 'Lines in Active Coord' window, and minimize the
'Lines' menu and the 'Create' menu. Your ANSYS Graphics window should look similar to the
following figure.
Mesh Size
The last step before meshing is to tell ANSYS what size the elements should be..
In the Preprocessor menu select Meshing > Size Cntrls > ManualSize > Lines > All Lines
In the size 'NDIV' field, enter the desired number of divisions per line.
Mesh
In the 'Preprocessor' menu select Meshing > Mesh > Lines and click 'Pick All' in the 'Mesh
Lines' Window
Saving Your Work
53
On the Utility Menu select File > Save as.... Select the name and location where you want to
save your file.
Solution Phase: Assigning Loads and Solving
Open up the 'Solution' menu (from the same 'ANSYS Main Menu').
Define Analysis Type
First you must tell ANSYS how you want it to solve this problem:
From the Solution Menu, select Analysis Type > New Analysis>'Static'
Apply Constraints
In the Solution menu, select Define Loads > Apply > Structural > Displacement > On Key
points
Apply Loads
As shown in the diagram, there are four downward loads of 280kN, 210kN, 280kN, and 360kN
at key points 1, 3, 5, and 7 respectively.
Select Define Loads > Apply > Structural > Force/Moment > on Keypoints.
Select the first Keypoint (left end of the truss) and click 'OK' in the 'Apply F/M on KPs'
window.
Select FY in the 'Direction of force/mom'.
Enter a value of -280000 in the 'Force/moment value' box and click 'OK'.
Apply the remaining loads in the same manner.
The applied loads and constraints should now appear as shown below.
Solving the System
In the 'Solution' menu select Solve > Current LS. This indicates that we desire the solution
under the current Load Step (LS).
Post processing:-
Reaction Forces
54
A list of the resulting reaction forces can be obtained for this element
From the Main Menu select General Postproc > List Results > Reaction Solu.
Select 'All struc forc F' as shown above and click 'OK'
These values agree with the reaction forces calculated by hand above.
Deformation
In the General Post proc menu, select Plot Results > Deformed Shape.
Select 'Def + undef edge' and click 'OK' to view both the deformed and the undeformed object.
Observe the value of the maximum deflection in the upper left hand corner (DMX=7.409). One
should also observe that the constrained degrees of freedom appear to have a deflection of 0 (as
expected!)
Deflection
From the 'General Postproc' menu select Plot results > Contour Plot > Nodal Solution.
Utility Menu select Plot Controls > Style > Contours > Uniform Contours...
Fill in the following window as shown and click 'OK'.
The deflection can also be obtained as a list as shown below
General Postproc > List Results > Nodal Solution select 'DOF Solution' and 'ALL DOFs' from
the lists in the 'List Nodal Solution' window and click 'OK'. This means that we want to see a
listing of all degrees of freedom from the solution.
If you wanted to save these results to a file, select 'File' within the results window (at the upper
left-hand corner of this list window) and select 'Save as'.
Axial Stress: The Element Table is different for each element, therefore, we need to look at the
help file for LINK1 (Type help link1 into the Input Line).
From the General Postprocessor menu select Element Table > Define Table
Click on 'Add...'
Enter 'SAXL' in the 'Lab' box. This specifies the name of the item you are defining. Next, in the
'Item, Comp' boxes, select 'By sequence number' and ‘LS,’ Then enter 1 after LS, in the
selection box
Click on 'OK' and close the 'Element Table Data' window.
Plot the Stresses by selecting Element Table > Plot Elem Table
Utility Menu > PlotCtrls > Style > Contours > Uniform Contours
Results: Maximum deflection------------mm; Element stresses------------------------N/mm2
Questions
1. Define FEM.----------------------------------------------------------------------------------------
2. Define truss and beam.------------------------------------------------------------------------------
3. Stiffness matrix of truss---------------------------------------------------------------------------
Experiment: 3B. Simple Static Analysis of a Cantilever beam
55
Aim: To determination the deflection and stresses in 2D beams also determine the nodal
deflections, reaction forces for the beam system shown below.
Followed (Poisson ratio.0.30, Load=10KN downward)
Preference: Structural
Select the element type: Preprocessor →element type→ Add/Edit/delete→ add → 2beam
188→ ok→ close.
Define material properties: Preprocessor →material properties→ material models → structural

→ elastic→ isotropic→ enter the values of Young’s modulus(2e5) and Poisson’s ratio(0.3).
Close the window.
Section: Beam → common section → enter B: 0.1 and H: 0.1 in the table shown→ok
Define model:
Create nodes : Preprocessor → modeling →create → nodes → in active coordinate system →
enter the value of first key node as x1=0,y1=0,z1=0 . Click ‘apply’. Enter the second node as
x2=0.5, y2= 0, z2=0, Enter the third node as x2=1, y2= 0, z2=0 →Click ‘ok’.
Create elements: Preprocessor → modeling → create → elements → thru nodes →in active
coordinate system → select the nodes 1 and 2; nodes 2 and 3, Say ‘ok’ (or mouse centre click).
Solution:
Applying boundary conditions:
Preprocessor → loads →apply → structural → displacement → on nodes → select node 1 →

say apply → select All dof → say ‘ok’. (Here we are constraining for all degrees of freedom.)
56
Preprocessor →loads →force/moment → on nodes →select node 2 →say apply → select FY

→ enter the given value -10,000N (-ve sign is for down ward direction).
Save _db.
Solve:
Main menu →solution → solve → current LS → say ok in the menu that appears.
After completing the solution a menu appears that contains “solution done”, say ‘ok’.
Main menu →finish
General Post Processor:
Viewing the results:
Deformed solution: Main menu → general post processor → plot results → deformed shape or
deformed and undeformed → say ‘ok’.
Maximum and minimum stress values: Main menu → general post processor → element table
→ write element table → by sequence num → select NMISC → say ‘ok’.
Main menu → general post processor → element table → plot element table →NMISC →don
not average → say ‘ok’.
Displacement and stress: general post processor → counter plot → nodal solution →DOF
solution → Y-component of displacement:------------
general post processor → counter plot →element solution →DOF solution → Y-component of
stress:------------
Nodal solution: general post processor →list results→ DOF solution → Y-component of
displacement:------------------
Results: Maximum deflection------------mm; Element stresses------------------------N/mm2
Nodal deflections---------------------------------------------------------------------
Support reactions-------------------------N
Questions
1. Stiffness matrix of beam----------------------------------------------------------------------------

2. Define natural coordinate system for two noded 1D element.
Ans ----------------------------------------------------------------------------------------------------
3. Stiffness matrix of 1D structural element------------------------------------------------------
4. Define Galerkin’s approach.
Ans ---------------------------------------------------------------------------------------------------
Experiment: 4A. Plane stress problem
57
Aim: To determination of deflections, principal and Von-Mises stresses in plane stress

components.
followed.
Figure shows a rectangular plate 60x30x10mm made of steel. The plate is held fixed at the left
end and subjected to a concentrated load of magnitude P= 100N.
P
A
30
60 10
Material properties (Steel): E (Young’s Modulus) = 200GPa, υ (Poisson’s ratio) =0.3
Preprocessing:
Main menu → Preprocessor → Structural → ok

Element type: Preprocessor → Element type → Add/Edit/Delete → Add → solid → Quad 4
node 42 → ok.
Options → Element behavior k3 → Select plane stress with thickness → ok.
Close.
Real constants (Geometric properties): Preprocessor → Real constants → Add (for element
type plane 42) → ok → thickness → 10 → ok → close.
Material properties: Preprocessor → Material models → structural → elastic → isotropic →

enter the values of E and υ. Ok close material properties box.
Save_db
Modeling: Rectangular area can be modeled in two ways. In first method key points can be
created specifying the four corners and can be joined by lines. And then area can be created by
using lines. For creating key points and lines same method can be adopted that is discussed in
the earlier exercises. Here the second method is discussed, that is creating the area directly.
Preprocessor → Modeling → Create → areas → by two corners → specify the origin, width
and height in the dialogue box appeared → ok
Meshing:
58
Preprocessor → Meshing → mesh tool → element attributes → areas (check for element
number, material number, real constants set number) → ok.
Size controls → areas set → select the area → enter the element size → ok.
Mesh → areas → free/mapped → mesh → select the area → ok.
Boundary conditions:
Preprocessor → loads →structural → displacement → select the line AB → apply → all dof →
ok.
Preprocessor → loads → structural → force/moment → select the extreme top right key point
→ apply → select FY and enter the value with -ve sign (-ve sign for downward direction) → ok
Solution:
Main menu → solution → solve → current LS → ok.

Main menu → finish
Plotting the results:
Main menu → General post processor → plot results → deformed shape → select deformed
and undeformed → ok.
Utility bar → plot ctrls → animation → deformed shape → select the number of frames → ok.
Stop and close to come out of the animation
General post processor → contour plot → nodal solution → stress → von Mises stress → ok.
Results: Deflection------------mm; Principal stresses------------------------N/mm2 and
Von-Mises stresses----------------------------------------------------N/mm2
Questions
1. List of various analysis software. ---------------------------------------------------------------

2. Which is the efficient analysis software? --------------------------------------------------------
3. Why do you use analysis software’s for solving problems?
Ans ---------------------------------------------------------------------------------------------------
4. Define plain stress.
Ans --------------------------------------------------------------------------------------------------
5. Define Boundary Condition problems.
Ans ----------------------------------------------------------------------------------------------------
Experiment: 4B. Plane Strain Problem
Aim: To determination of deflections, principal and Von-Mises stresses in plane strain

components.
59
followed.
R = 4 in
0.25 in
15.5 in
R = 1/8 in
R = 1/16 in
2 in 2 in
For model validation purposes, the stresses in the vessel walls away from any notches
can be estimated using the thin-walled pressure vessel equations. Although the model does not
specifically meet the criteria for the “thin-walled” assumption, these equations will still provide
reasonably accurate values for model validation purposes. For a pressure vessel subjected to
internal pressure only, the radial stress (σr) should vary from –p (−1.7 ksi) on the inner surface
to zero on the outer surface. The hoop and longitudinal stresses are calculated as (p = 1700 psi,
r = 4 in, t = 0.5 or 0.25 in):
σ h ≈ prt = 27.2 ksi (thin section) or 13.6 ksi (thick section)

σ l ≈ pr2t =13.6 ksi (thin section) or 6.8 ksi (thick section)
ANSYS Analysis:
Set the Working Directory to C:\temp, define Job Name as ‘Pressure Vessel’, and click
Run. Then define Title and Preferences.
Utility Menu → File →Change Job name: Enter ‘Pressure_Vessel’ OK
Utility Menu File Change Title: Enter ‘Stress Analysis of an Axisymmetric Pressure Vessel’
OK
Preferences: Preferences for GUI Filtering Select ‘Structural’ and ‘h-method’ OK
Preprocessor to define the model geometry:
Define Element Type (Axisymmetric Option) and Material Properties.
Preprocessor:
Element Type Add/Edit/Delete: Add→ Structural →Solid Quad 8 node 82 (PLANE82)
(define ‘Element type reference number’ as 1) →OK →Click Options→ Select
‘Axisymmetric’ for K3 (Element behavior) OK →Close
Material Props: Material Models →Double Click Structural →Linear→ Elastic →Isotropic
Enter 14.5e6 for EX and 0.21 for PRXY Click OK →Click Exit (under ‘Material’)
Begin creating the geometry by defining two Circles for the spherical end cap, and
Subtract Areas to create the vessel wall.
60
Modeling:
Create Areas Circle: Solid Circle Enter 0 for WP X, 0 for WP Y, and 4 for Radius Apply
Enter 0 for WP X, 0 for WP Y, and 4.25 for Radius OK
Operate Booleans Subtract:

Areas select (with the mouse) Area 2 (bigger circle) OK →Select Area 1 (smaller circle) OK
Create Lines through the center of the Circles and Divide the Areas along these Lines.
Create Lines:
Lines: Straight line→ Click on the Key points on the outer circle which are on the X-axis to
create a Line parallel to the X-axis (Circles are divided into four arcs by ANSYS, with a Key
point placed at the end of each arc). Similarly, click on the Key points on the outer circle which
are on the Y-axis to create a Line parallel to the Y-axis OK
Operate Booleans Divide

Area by Line Select (with the mouse) the remaining Area (annulus) →OK →Select the two
Lines that we have created OK
Delete: Area and below Select the three Areas in the first, second, and third quadrants OK
Define two Rectangles to create the walls of the cylindrical portion of the vessel (thick and
thin sections). Define a Circle to create the circumferential groove on the inside of the vessel.
Create Areas Rectangle: By Dimensions Enter 4 and 4.5 for X-coordinates and 0 and 7.75
for Y-coordinates Click Apply Enter 4.25 and 4.5 for X-coordinates and 6.75 and 7.75 for Y-
coordinates OK
Create Areas Circle: Solid Circle Enter 4 for WP X, 2 for WP Y, and 1/8 for Radius OK
Subtract Areas to eliminate unused segments, and then add all Areas to create a single Area for
meshing.
Operate Booleans Subtract:

Areas Select (with the mouse) the bigger rectangle→ OK →Select the small rectangle and
circle OK
Operate Booleans Add: Areas
Select ‘Pick All’ → OK
Create Line Fillets at the two transitions between the thick and thin sections.
Utility Menu Plot Lines
Utility Menu Plot Ctrls Numbering: Click ‘Line numbers’ on → OK

Create Lines: Line →Fillet →Select (with the mouse) the two Lines near the lower Fillet →OK
Enter 1/16 for Fillet radius Apply Select the two Lines near the upper Fillet OK Enter 1/4 for
Fillet radius →OK
Create Areas within the two Fillets and add these Areas to the main Area. First zoom in on
the area of interest using the plot controls.
Create Areas Arbitrary: By Lines select (with the mouse) the Fillet and adjacent two Lines
OK
Repeat for the other Fillet.
Operate Booleans Add: Areas→ Select ‘Pick All’ OK
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Utility Menu Plot Lines

The geometry should appear as shown below in the figure
In this example, the irregular geometry will be Free Meshed with Quad Elements. Better
control of Element sizing and distribution can be obtained with Mapped Meshing, but this
would require that additional sub-Areas be defined within the main Area that has regular (four-
sided) geometry. Using Free Meshing, all Elements in the model will be approximately the
same size. In the first run, we will choose a Global Size (approximate Element edge length) of
0.1 in.
Meshing:
Mesh Tool→ Under ‘Size Controls: Global’ click Set Enter 0.1 for ‘Element edge length’→
OK→ Under ‘Mesh:’ select Areas, Quad and Free Click Mesh Select (with the mouse) the
Area →OK
Enter the Solution Menu to define boundary conditions and loads and run the analysis:
Solution → Analysis Type→ New Analysis → Select Static OK
The Boundary Conditions and Loads can now be applied. ANSYS will automatically apply
the Axisymmetric Boundary Conditions along the Y-axis. However, we must apply the
Symmetry Boundary Conditions along the upper edge of the model. Finally, the Pressure can
be applied on all lines that make up the inner surface of the vessel. The magnitude should be
input as the actual value – no reduction is needed to account for axisymmetry (ANSYS
automatically makes the necessary adjustment of Loads in an axisymmetric model).
Define Loads → Apply → Structural →Displacement
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Symmetry B.C. On Lines→ Select the Line on top of the model (19) → OK
Define Loads→ Apply →Structural →Pressure→ On Lines Select (with the mouse) all the
Lines on the inside of the vessel (20, 12, 16, 17 and 2) →OK →Enter 1700 for ‘Load PRES
value’ OK
The pressure will be indicated by arrows, as shown above in the figure on the right.
Save the Database and initiate the Solution using the current Load Step (LS).
ANSYS Toolbar SAVE_DB
Solution→ Solve→ Current LS →OK →Close the information window when solution is
done Close the /STATUS Command window
General Postprocessor to examine the results:
First, plot the Deformed Shape.

General Postprocessor→ Plot Results →Deformed Shape →Select Def + undeformed OK
A Contour Plot of any stress component can be created. The radial, hoop (tangential), and
longitudinal stresses should be checked to verify the model. Also, stress values at any
particular node can be checked by using the “Query Results” command, selecting the desired
component, and then picking the appropriate node. For this model, along the cylindrical
portion of the vessel, x represents the radial direction, y represents the longitudinal direction,
and z represents the hoop (tangential) direction. Power graphics must be disabled to query
results at nodes.
ANSYS Toolbar→ POWRGRAPH → Select OFF OK

General Postproc→ Plot Results →Contour Plot→ Nodal Solu →Select ‘Stress’ and ‘X-
Component of stress’ (or Y or Z) OK
General Postproc →Query Results↓ Nodal Solution→ Select ‘Stress’ and ‘X- direction
SX’ (or SY or SZ) →OK →Select Nodes in the region of interest (may be helpful to zoom
in on region)
Compare the finite element stresses to the values calculated using the thin-wall equations. If the
values are within reason (away from notches, etc.), proceed. For the purposes of failure
analysis, we must select an appropriate failure theory. A plot of the von Mises stress is useful
for identifying critical locations in the vessel. However, since the vessel is made of cast iron
(brittle material), the “Maximum-Normal-Stress” failure criterion may be more appropriate (or
Coulomb-Mohr or other similar failure theories). Create Contour Plots of the von Mises and 1st
Principal stresses.
General Postproc→ Plot Results→ Contour Plot →Nodal Solu→ Select ‘Stress’ and ‘von
Mises stress’ OK
General Postproc→ Plot Results →Contour Plot→ Nodal Solu Select ‘Stress’ and ‘1st
Principal stress’ OK
The plot of the model can be expanded around the axisymmetric axis to get a better view of
the full model. For this plot, Power graphics must be enabled.
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ANSYS Toolbar→ POWRGRAPH → Select ON OK
Utility Menu→ Plot Ctrls Style→ Symmetry Expansion 2-D Axi-Symmetric… Select ‘Full
expansion’ OK
Note the locations of the maximum stresses in the vessel. Are the critical locations where
you would expect them to be? If not, why? Do you think the current model is accurate, or
might there be some discretization error? Record the magnitudes and locations of the
maximum stresses, and then refine the mesh and re-run the analysis to check for possible
discretization error.
Results: Deflections------------mm; Principal stresses------------------------N/mm2 and
Von-Mises stresses----------------------------------------------------N/mm2
Questions
1. What are the methods available to solve FEM problems?

Ans ----------------------------------------------------------------------------------------------------
2. Define Rayleigh-Ritz method.
Ans ---------------------------------------------------------------------------------------------------
3. What is the difference between FEM and FEA?
Ans ---------------------------------------------------------------------------------------------------
4. Define plain strain.
Ans ----------------------------------------------------------------------------------------------------
5. What are the types of 3D elements used in FEM?
Ans ----------------------------------------------------------------------------------------------------
Experiment: 5. Stresses in 3D Shell Component
AIM: To determine stresses in 3D Shell component
64
Problem
Finding the stresses in a thick open-ended cylinder with an internal pressure (such as a pipe
discharging to the atmosphere). The steel cylinder below has an inner radius of 5 inches and an
outer radius of 11 inches.
A cross section is shown below
In both drawings the length is arbitrary and represents a segment of a long, open-ended
cylinder. The Y axis is the axis of symmetry. The cylinder can be generated by revolving a
rectangle 6 inches wide and of arbitrary height 360 degrees about the Y axis.
65
For the 3D analysis we will make use of symmetry and analyze one quadrant of the cylinder. If
Y is the axis of revolution of the cylinder, both the X-Y and Y-Z planes are planes of symmetry.
Since the height of the segment considered is arbitrary, we will use a segment 1 inch in height
for the finite element model. The geometry is shown below.
The geometry is created using ANSYS geometry commands. (Alternatively the geometry could
be created in a solid modeler such as Pro/ENGINEER, CATIA, Solid Works, etc and imported
into ANSYS for FEM analysis.
The ANSYS solution to this problem is given next for an internal pressure of 1000 psi.
1. Start ANSYS
Use a tetrahedron element for the FEM modeling.
2. Preprocessor -> Element Type -> Add/Edit/Delete -> Add -> select Tet 10node 92 -> OK
-> Close
Enter material property data for steel.
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3. Preprocessor -> Material Props -> Material Models . . . -> Structural -> Linear ->
Elastic -> Isotropic ->Enter EX = 3.e7 and PRXY = 0.3 -> OK -> Close.
Create geometry for rectangle 1 inch by 6 inches starting 5 inches from Y axis. This rectangular
area will be revolved 90 degrees about the Y axis to produce the desired volume.
4. Preprocessor -> Create -> Areas -> Rectangle ->By 2 Corners
Define two key points on the Y axis for revolving purposes.
5. In the gray box 'Pick a menu item or enter an ANSYS command' enter.
K, 10, 0.0, 0.0, 0.0 (Return) Defines key point number 10 at (0, 0, 0)
K, 11, 0.0, 5.0, 0.0 (Return) Defines key point number 11 at (0, 5, 0)
(Key points 1,2,3,4 are already used by ANSYS to define the rectangle, so we used numbers 10
and 11.)
Revolve the area
6. Preprocessor -> Operate -> Extrude -> Areas -> About Axis
Pick the area then pick the two key points on the Y axis.
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Now create a mesh of tetrahedral elements using the default settings.
5. Preprocessor -> Mesh -> Volumes -> Free (Pick the solid we just created.)
Define loads and boundary conditions. Apply an internal pressure of 1000 psi and displacement
constraints that prevent points moving across planes of symmetry and also restrain rigid body
movement in the Y direction.
6.Preprocessor -> Loads ->Apply ->Displacement -> On Areas Pick the radial surface
parallel to the X-Y plane and set uz = 0 . Pick the radial surface parallel to the Z-Y plane and
set ux = 0. Pick the
Bottom (or top surface) and set Uy = 0 . This last constraint simply prevents rigid body motion
in the Y direction.
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Note: Use Cntl + Right Mouse to rotate the solid so as to get a better view of the area you
want to pick. It may also help to activate the area numbers and plot them. Then pick the area
number of interest, eg,
PlotCntls -> Numbering . . . turn area numbers ON
Plot -> Areas
Preprocessor -> Loads ->Apply ->Pressure -> On Areas Pick the inner area of the cylinder).
Enter a pressure of 1000
For
large
69
3D problems it is often much faster to use the optional Preconditioned Conjugate

Gradient method for solving the equations.
7. Solution -> Sol'n Control . . . -> Sol'n Options -> Pre-Condition CG -> OK
Solution -> Solve -> Current LS ->OK
Check the deformed shape to see if it's reasonable. (The dotted line is the undeformed shape.)
8. General Post Processor -> Plot Results -> Deformed Shape . . . ->Def +undeformed ->
OK
Examine the stresses ----------
9. General Postprocessor -> Plot Results -> Element Solu . . . (Pick Sx).
SX --------------------------------------
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The theoretical solution for this problem is:
At the inside of the cylinder Sx = -1000 psi and Sz = 1520.8 psi
At the outside of the cylinder Sz= 0 psi and Sz = 520.8psi.
The upper arrow shows Sx normal to the Z-Y plane which corresponds to the cylinder hoop
stress. The scale at the bottom indicates a maximum value of 1526 psi which is close to the
theoretical value of 1521.
The lower arrow shows Sx in a direction normal to the inner surface of the cylinder with a scale
value of -1007, close to the internal pressure of 1000 psi.
Thus the ANSYS calculated results seem to agree pretty well with the theory. But we need to
examine the stresses more closely at the boundaries.
Number the nodes and elements.
10. PlotCntls -> Numbering . . . -> Turn on Node & Element Numbers Zoom in on the
inside wall of the cylinder.
INSIDE ------------------------------------
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When the element stress solution contour plots are relatively smooth across element
boundaries, as in this case, it indicates that the solution is reasonably accurate. Nodal Stress
quantities can then be trusted as good representations of the solution. List the stress results for
node 764.
11. List -> Results ->Nodal Solution . . . -> Stress -> Components -> OK.
The following x, y, z values are in global coordinates
Node SX SY SZ SXY SYZ SXZ
764 -998.74 0.17087e-01 1521.7 0.98118e-01-0.50417 5.3997
Result: Note that Sx = -998.74 is only 0.126 % different from the exact value of 1000, and Sz
(hoop) = 1521.7 is only 0.06 % different from the theoretical value of 1520.8.
Questions
1. Differentiate between Finite Element Method and Finite difference Method.
Ans ----------------------------------------------------------------------------------------------------
2. When do you use Penalty approach for solving FEM problems?
Ans ----------------------------------------------------------------------------------------------------
3. Define shape functions.
Ans ----------------------------------------------------------------------------------------------------
72
Experiment: 6. Harmonic Analysis of a Cantilever Beam
Aim: To determine the Frequency response of cantilever Beam
We will now conduct a harmonic forced response test by applying a cyclic load (harmonic) at
the end of the beam. The frequency of the load will be varied from 1 - 100 Hz. The figure
below depicts the beam with the application of the load.
PROCEDURE:
The simple cantilever beam is used in all of the Dynamic Analysis Tutorials. If you haven't
created the model in ANSYS, please use the links below. Both the command line codes and the
GUI commands are shown in the respective links.
Solution: Assigning Loads and Solving
1. Define Analysis Type (Harmonic)

Solution > Analysis Type > New Analysis > Harmonic
ANTYPE, 3
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2. Set options for analysis type:
Select: Solution > Analysis Type > Analysis Options..
The following window will appear
As shown, select the Full Solution method, the Real + imaginary DOF printout format and do
not use lumped mass approx.
Click ‘OK’. The following window will appear. Use the default settings (shown below).
3. Apply Constraints
Select Solution > Define Loads > Apply > Structural > Displacement > On Nodes
The following window will appear once you select the node at x=0 (Note small changes in
the window compared to the static examples):
74
Constrain all DOF as shown in the above window.
4. Apply Loads:
Select Solution > Define Loads > Apply > Structural > Force/Moment > On Nodes
Select the node at x=1
The following window will appear. Fill it in as shown to apply a load with a real value of 100
and an imaginary value of 0 in the positive 'y' direction.
Note: By specifying a real and imaginary value of the load we are providing information on
magnitude and phase of the load. In this case the magnitude of the load is 100 N and its phase
is 0. Phase information is important when you have two or more cyclic loads being applied to
the structure as these loads could be in or out of phase. For harmonic analysis, all loads
75
applied to a structure must have the same frequency.

5. Set the frequency range
Select Solution > Load Step Opts > Time/Frequency > Freq and Sub steps
As shown in the window below, specify a frequency range of 0 - 100Hz, 100 sub steps.
By doing this we will be subjecting the beam to loads at 1 Hz, 2 Hz, 3 Hz, ..... 100 Hz. We will
specify a stepped boundary condition (KBC) as this will ensure that the same amplitude (100
N) will be applied for each of the frequencies. The ramped option, on the other hand, would
ramp up the amplitude where at 1 Hz the amplitude would be 1 N and at 100 Hz the amplitude
would be 100 N.
You should now have the following in the ANSYS Graphics window.
6. Solve the System

Solution > Solve > Current LS
SOLVE
76
POST PROCESSING: Viewing the Results
We want to observe the response at x=1 (where the load was applied) as a function of
frequency. We cannot do this with General Post Processing (POST1); rather we must use
TimeHist Post Processing (POST26). POST26 is used to observe certain variables as a
function of either time or frequency.
Open the TimeHist Processing (POST26) Menu
Select TimeHist Postpro from the ANSYS Main Menu.
Define Variables
In here we have to define variables that we want to see plotted. By default, Variable 1 is
assigned either Time or Frequency. In our case it is assigned Frequency. We want to see the
displacement UY at the node at x=1, which is node #2. (To get a list of nodes and their
attributes, select Utility Menu > List > nodes). Select TimeHist Postpro > Variable
Viewer... and the following window should pop up.
Select Add (the green '+' sign in the upper left corner) from this window and the following
window should appear.
77
3. List Stored Variables
In the 'Time History Variables' window click the 'List' button, 3 buttons to the left of 'Add'
The following window will appear listing the data:
4. Plot UY vs. frequency
In the 'Time History Variables' window click the 'Plot' button, 2 buttons to the left of 'A.
78
Note that we get peaks at frequencies of approximately 8.3 and 51 Hz. This corresponds with
the predicted frequencies of 8.311 and 51.94Hz.To get a better view of the response, view the
log scale of UY.
Select Utility Menu > PlotCtrls > Style > Graphs > Modify Axis
The following window will appear
As marked by an 'A' in the above window, change the Y-axis scale to 'Logarithmic'
Select Utility Menu > Plot > Replot You should now see the following
79
Result: This is the response at node 2 for the cyclic load applied at this node from 0 - 100 Hz
Questions
1. Define Eigen value and Eigen vector.

Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
2. Define consistent mass and lumped mass.
Ans
----------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------
3. Define parametric, super parametric and sub parametric elements.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
4. What is the Poisson ratio and young’s modulus of aluminum?
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
5. What is the Poisson ratio and young’s modulus of titanium?
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
6. What is the total deflection of Cantilever beam carrying point load at its end?
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
80
Experiment: 7A.Steady State heat transfer analyses of plane Slab
Aim: To determination of deflections, thermal stresses in a plane slab.
followed.
Preprocessing:
Element type: Preprocessor  Element Type  Add/Edit/Delete  Add Thermal Solid (in
library of element types - left box)  Quad 4node 55  OK  Close
Plane55 will produce either quadrilateral or triangular elements for thermal analysis
Material Properties: Preprocessor  Material props  Isotropic  Type in a number to

identify the material OK
Enter Thermal Conductivity value KXX = 20
For entering the value of KXX for the second material, Material models editnew
modeltype in a number to identify the material OK
Enter Thermal conductivity value KXX = 50
Modeling:
81
Preprocessor  modeling  Create  Rectangle ( in the Areas section )  By Dimensions 

Enter dimensions X1,Y1 and X2,Y2 for the left bottom corner and right top corner of the 1st
rectangular area respectively  OK
Preprocessor  modeling  Create  Rectangle ( in the Areas section )  By Dimensions 
Enter dimensions X1,Y1 and X2,Y2 for the left bottom corner and right top corner of the 2nd
rectangular area respectively  OK  Plot  Areas
Preprocessor  modeling  Create  Circle  By Dimensions  Enter the circle radius as
RAD1  OK. This creates a circle at the left corner of our first rectangle. We want to cut a
hole in the rectangle. So we must move this circle from the left bottom corner to the center of
the 1st rectangle.
Move  modify  Areas  Pick the circular are with the mouse  OK
Enter the x and y offsets to place the circular area in the center of our 1st rectangular box.
Plot  Replot.
Now we must subtract the circular area from the first rectangle to create the circular hole
Operate  Subtract  Areas  Enter 1  Apply Enter 3  OK
This should result in a circular hole in area 1.
Operate  Glue  Areas  Pick all  OK
This will renumber the areas. Now Area 1 is the rectangular area with the hole and Area 2 is the
other rectangular area.
File  Save as Jobname.db
Meshing:
Preprocessor  Meshing  Size controls  Manual size Global  Enter edge length
that you want to allow  Enter this in the Size field  OK.
Preprocessor  Meshing  Mesh tool  Mesh  Areas Free  Pick all  OK.
Plot  Elements
We have not yet specified the material properties for the two rectangles. These properties are
usually assigned to the elements. Now that we have nodes and elements we can go ahead and
do that.
Select  Entities  Areas  OK This opens up a green box on top  Enter 1  OK.
Select  Entities  Elements  Click on the box which says By Num and select Attached to
 Areas  OK
Plot  Replot
Now enter mpchg,1,all in the command prompt.
This sets properties corresponding to material 1 defined earlier to the selected elements.
Select  Everything
Repeat above procedure to select elements attached to area 2 (rectangle on the right side) and
set the properties to those of material number 2 defined earlier. Be sure to "select everything"
once you have finished.
PlotCtrls  Numbering  Elem  Attrib numbering  select "Material numbers" OK

File  Save db
82
Boundary conditions:
Applying temperature boundary conditions

SolutionApplyTemperatureOn nodes Box  Draw a box around the left edge of the
model to pick these nodes OK  Enter the temperature 200  OK
Repeat above procedure to apply the temperature boundary condition on the right boundary.
Applying heat transfer coefficient on top surface:
Apply  Convection on Lines BoxDraw a box around the top edge of the model to pick
the lines along the top edge  OK  Enter h of 150 for VALI and fluid temperature of 30 for
VAL2  OK
PlotCtrls  Symbols  Surface Load Symbols  select "Convert FilmCoef"
Show pres and convert as  select "Arrows"  OK.
Applying heat flux on the circular hole surface:
PlotCtrls  Pan, Zoom, Rotate  Box Zoom  Zoom the circular area
Apply  Heat flux  On lines  Pick 4 lines of circle
Apply Heat flux  On lines  OK  Enter the heat flux of 100 for VALI  OK
Command: sbctran \ret (grey box on top)
PlotCtrls  Symbols  Surface Load Symbols  select "Heat Fluxes"
Show pres and convert as  select "Arrows"  OK  Fit
Save_db
Solution:
Solution  Solve Current LS  Close  OK  Close  Finish
Post processing:
General Postprocessor  Plot results  Nodal Solution  OK  Finish
Results: Deflections------------mm; Thermal stresses------------------------N/mm2
Questions
1. Write 1D heat conduction equation in plain slab.

Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
2. Write 1D heat transfer equation in thin fins.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
3. Define acoustic.
Ans
----------------------------------------------------------------------------------------------------------
83
---------------------------------------------------------------------------------------------------
4. Define Newton law of cooling.
Ans
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----------------------------------------------------------------------------------------------------
Experiment: 7B. Thermal Stress of a cylinder Using Axisymmetric Elements
Problem:
A steel cylinder with inner radius 5 inches and outer radius 10 inches is 40 inches long and has
spherical end caps. The interior of the cylinder is kept at 75 deg F, and heat is lost on the
exterior by convection to a fluid whose temperature is 40 deg F. The convection coefficient is
0.56 BTU/hr-sq.in-F. Calculate the stresses in the cylinder caused by the temperature
distribution.
Aim: To Calculate the Stresses in the cylinder caused by the temperature distribution
1. Start ANSYS and assign a job name to the project. Run Interactive -> set working
directory and jobname.
2. Preferences -> Thermal will show -> OK
3. A quadrant of a section through the cylinder is created using ANSYS area creation tools.
84
4. Preprocessor -> Element Type -> Add/Edit/Delete -> Add -> Solid 8 node 77 -> OK ->
Options -> K3 Axi-symmetric -> OK
5. Preprocessor -> Material Props -> Isotropic -> Material Number 1 -> OK
EX = 3.E7 (psi)
DENS = 7.36E-4 (lb sec2/in4)
ALPHAX = 6.5E-6
PRXY = 0.3
KXX = 0.69 (BTU/hr-in-F)
6. Mesh the area using methods discussed in previous examples.
7. Preprocessor -> Loads -> Apply -> Temperatures -> Nodes
Select the nodes on the interior and set the temperature to 75.
8. Preprocessor -> Loads -> Apply -> Convection -> Lines
85
Select the lines defining the outer surface and set the coefficient to 0.56 and the fluid
temp to 40.
9. Preprocessor -> Loads -> Apply -> Heat Flux -> Lines
Select the vertical and horizontal lines of symmetry and set the heat flux to zero.
86
10. Solution -> Solve current LS
11. General Postprocessor -> Plot Results -> Nodal Solution -> Temperature
The temperature on the interior is 75 F and on the outside wall it is found to be 43.
12. File -> Save Jobname.db
13. Preprocessor -> Loads -> Delete -> Delete All -> Delete All Opts.
14. Preferences -> Structural will show, Thermal will NOT show.
15. Preprocessor -> Element Type -> Switch Element Type -> OK (This changes the
element to structural)
16. Preprocessor -> Loads -> Apply -> Displacements -> Nodes
(Fix nodes on vertical and horizontal lines of symmetry from crossing the lines of
symmetry.)
17. Preprocessor -> Loads -> Apply -> Temperature -> From Thermal Analysis
Select Jobname.RTH (If it isn't present, look for the default 'file.RTH' in the root
directory)
87
18. Solution -> Solve Current LS
19. General Postprocessor -> Plot Results -> Element Solution - Von Mises Stress
RESULT: The Von Mises stress is seen to be a maximum in the end cap on the interior of the
cylinder and would govern a yield-based design decision.
88
Questions
1. Which scientist first used the name ‘Finite Element’?

Ans ----------------------------------------------------------------------------------------------------
2. Differentiate between Finite Element Method and Mechanics of Solids.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
3. Define Global stiffness matrix.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
4. What is the Poisson ratio and young’s modulus of steel?
Ans ----------------------------------------------------------------------------------------------------
5. What is the Poisson ratio and young’s modulus of cast ion?
Ans ----------------------------------------------------------------------------------------------------
6. What is the total deflection of simply supported beam carrying point load at its mid?
Ans ----------------------------------------------------------------------------------------------------
7. Write 1D heat transfer equation in thin fins.
Ans
----------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------
89
Experiment No. 8A. Process Sheet for Lathe Components
Aim: To develop the process sheet for stepped turn, taper turn, multiple turn and drill
components (produced on Lathe) based on tooling and machines.
1. Raw materials in the form of rod coming from the suppliers can move to Engineering
Workshop for cutting required size of work pieces.
2. Then these work pieces are move to the Machine Tools laboratory for facing operation on
conventional Lathe and check their sizes, from there these are transported to CNC Lathe
machine.
3. Open the dome; Fix the work piece in the chuck of the Lathe. Then close the dome.
4. Check all the connections properly given to the computer system from the Lathe and the
proper positioning of cutting tools in the turret (i.e. fix the required cutting tools in turret)
5. Switch on the computer system and enter the correct program for individual jobs. Then
check the individual simulations of the jobs and save the programs. If these simulations are
correct go for manufacturing, otherwise correct programs and again verify simulations.
6. ON the switch for supplying power to the XL TURN. Then switch on MCU and release the
emergence button provided on the Lathe.
7. Click on ‘MACHINE LINK’ in the ‘’Machine option’’ provided in the CNC software. So
that the Lathe can be active/connected with the CNC software.
8. Press on ‘HOME’ button (and after that press on Z then X). So tools turret can move to its
home position.
9. Press on ‘Rapid’ button and move the tool towards work piece for tool offset. After that
press on ‘SDL CW’ then spindle rotates at default speed. Change the speed to 500rpm.
10. Press on ‘Manual’ button and change the feed to 30mm per minute. Move the tool at the
outer surface to touches the job, then press on DATUM and X, enter diameter (i.e. X25) in
the dialog box. Similarly move the tool at the end face to touches the job now press on
DATUM and Z and the Z value shows zero.
11. Press on ‘HOME’ button and press on Z and X. So the tool again moves to home position
and save the CNC program.
12. Press on AUTO --- RESET --- CYCLE START button. Then tools perform the required
Machining operations on the selected jobs. After that click on ‘OK’ (showing end of the
program) which is display in dialog box.
13. Delink the machine by pressing on MACHINE LINK in the ‘’Machine option’’.
14. Close the emergence button; switch off the MCU and main power supply button.
15. Remove the finish part from CNC lathe and check its final dimensions using measuring
instruments.
Results: The given experiment is done using CNC XLTURN machine.
Questions
1. Define CAPP.
Ans ----------------------------------------------------------------------------------------------------
2. What are the types of CAPP systems?
Ans ----------------------------------------------------------------------------------------------------
3. List out various Variant type CAPP software’s.-------------------------------------------------
Experiment No. 8B. Process Sheet for Milling Components
90
Aim: To develop the process sheet for square slot, circular slot, profile cutting, square
pocketing, circular pocketing, and drilling components (produced on milling machine) based
on tooling and machines.
1. Raw materials in the form of plates coming from the suppliers can move to Engineering
Workshop for cutting of required size of components.
2. Then these components are move to the Machine Tools laboratory for facing operation on
conventional surface gridding machine/Lathe and check their sizes, from there these are
transferred CNC milling machine.
3. Load the job onto the work table of XLMILL. And close the cover/dome.
4. Check all connections properly given to the computer system from milling machine and
properly fix the required tool (i.e. end mill or drill bite) in the spindle.
5. Switch on the computer system and enter the correct program for individual jobs. Then
check the individual simulations of the jobs and save the programs. If these simulations are
correct go for manufacturing, otherwise correct programs and again check simulations.
6. ON the switch for supplying power to the XL MILL. Then switch on MCU and release the
emergence button provided on the XLMILL.
7. Click on ‘MACHINE LINK’ in the ‘’Machine option’’ provided in the CNC software. Then
XL MILL can be active or connected with the CNC software.
8. Press on ‘HOME’ button (and after that press on Z, Y, X). So cutting tool holder can move
to the home position.
9. Press on ‘Rapid’ button and move the tool towards work piece for tool offset. And press on
‘
SDL CW’ then spindle rotates at default speed. Change the speed to 500rpm.
10. Press on ‘Manual’ button and change the feed to 30mm per minute. Move the tool to touch
the job at the center of the work piece, then select DATUM and press on X, Y and Z so
that it shows 0 readings and floating zero start from there.
11. Press on ‘HOME’ button and press on Z, Y and X. So the tool again moves to home
Position and save the CNC program.
12. Press on AUTO --- RESET --- CYCLE START buttons. Then tools perform the required
Machining operations on the selected job. After that click on ‘OK’ (showing end of the
program) which is display in dialog box.
13. Delink the machine by pressing on MACHINE LINK in the ‘’Machine option’’.
14. Close the emergence button; switch off the MCU and main power supply button.
15. Remove the finish part from XLMILL and check its final dimensions using measuring
instruments.
Results: The given experiment is done using CNC XLMILL machine.
Questions
1. Define Group Technology.------------------------------------------------------------------------

2. List out various Generative type of CAPP software’s. ---------------------------------------
3. List out various Hybrid type of CAPP software’s. --------------------------------------------
Experiment No. 9 Development of Manufacturing Defects and Tool Management Systems
Aim: To study the development of manufacturing defects and tool management systems in
91
CNC machines.
In general the manufacturing defects in the CNC jobs can not develop, because of accurate
position of Work piece and tool. The tool path can be specified exactly in CNC program.
The manufacturing defects of CNC work pieces are due to the following.
1. The continuous usage of cutting tools (i.e. single point, multi point cutting tools, drills
bites etc.) beyond their life. Due to this usage of cutting tools, their tips may become
rough and cannot produce the required size of the work piece.
2. If the cutting tools do not running at specified speed on a suitable job, there will be a
chance of development of surface defects showing rough surface.
3. If the MCU do not control the worktable movement to the exact position against the
tool, there may be chance of developing surface defects.
4. The already available defects like air bubbles, water drops promotes manufacturing
defects on CNC jobs.
5. If the MCU not sending instruction blocks in sequence, there is a chance of getting
surface defects on work piece.
6. If the drill bites making holes on the work piece with improper size (i.e. diameter
varying from top to bottom) can produce the manufacturing defects.
7. If the work piece and tool cannot move relative to each other, then there is chance of
getting defects on the work piece.
8. The heat produced in the cutting operations can also promote defects in work piece.
9. By giving incorrect depth of cut and feed can also lead to the defects in work piece.
In order to avoid manufacturing defects in the work pieces, proper cutting tools,
specified feed &speed and depth of cut will be selected.
Result: In this study, the formation of manufacturing defects in the work pieces can overcome
by using proper tool management systems.
Questions
1. What are the manufacturing defects in CNC components?

Ans
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----------------------------------------------------------------------------------------------------
2. What are the parameters to promote manufacturing defects?
Ans
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---------------------------------------------------------------------------------------------------
3. How to overcome the manufacturing defects?
Ans
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Experiment No. 10. Study of Various Post Processors used in NC machines
92
Aim: To study of various post processor used in NC/CNC/DNC machines
Definition: The software that converts CL-file CAD/CAM data to specific machine tool
commands is called a Post Processor.
Introduction: Post Processor software is an essential component of any Computer Aided

Design/Computer Aided Manufacturing (CAD/CAM) system used to produce machined parts.
This generic intermediate output merely represents the path of cutter will take while machining
your part. It does not reflect, and is not optimized for, the SPECIFIC CNC Control and
Machine Tool capabilities of the machine you will actually use to cut the part.
At this generic “breakpoint,” the Post Processor software - sometimes called a LINK - comes
in. It takes the CL-file and processes it into the specific form of RS-274 or RS-232C NC data
required by your CNC and Machine Tool combination.
The quality of the final RS-274 or RS-232C part program (the extent to which it fully,
optimally, and accurately uses the capabilities of your machine tool) completely depends on the
sophistication and capabilities of the Post Processor software.
A poor Post Processor can mean longer cycle times. It can also produce incorrect NC data
which can scrap parts, damage equipment, or injure personnel. Inaccurate NC data output can
lower part quality and decrease cutting tool life. In short, without the best Post Processor, you
are missing out on the highest part throughput and part quality. You are also missing out on
producing parts at the lowest cost.
Table.1.Various post processors used in NC/CNC MACHINES are
S.No Software Post Processors

1 Spost Spost post processor
2 PostHASTE PostHASTE post processor
3 SOLIDCAM SOLIDCAM post processor
4 DolphineCAD/CAM USA DolphineCAD/CAM USA post processor
5 MasterCAM MasterCAM post processor
6 HSM work HSM work post processor
7 Edge CAM Edge CAM post processor
8 D2NC SOLIDCAM software post processor
9 ArtCAM ArtCAM post processor
10 AutoCAD RAMS software post processor
11 SharpCAM SharpCAM post processor
12 ArtCAM SURFCAM SURFCAM post processor
13 CamBam CamBam post processor
14 BobCAD-CAM BobCAD-CAM post processor
Experiment No. 10A.The SPost Post Processor
S-POST is a standard post processor program that comes included in SURFCAM with over 50
93
S-POST post processors for major CNC machine manufactures. S-POST has an “easy to use”
generator module that presents dynamic menus, context sensitive help and a powerful Factory
Interface Language (FIL) utility designed to improve the user's productivity.
The SPost post processor system contains two post processors: SPOSTM.EXE used with
mills and wire EDM and SPOSTL.EXE used with lathes. These programs are stored in
the SURFCAM\Surf2000\SPost directory. The posts for the SPOST system are saved in
the SURFCAM\PostLib\SPost directory as files with names in the form of either
UNCX01.Pnn for mill/wire EDM posts or UNCL01.Pnn for lathe posts. The nn in these
file names is the machine number that is assigned by the person who creates the post.
Creating SPOST Posts and FIL Files

Posts are created in the SPost system using a program called SPOSTCFG.EXE. This post
configuration program is stored in the SURFCAM\Surf2000\SPost directory.
For a detailed explanation of SPost, refer to the online SPost Reference Manual and to the
online SPost FIL Manual.
Often a post has an accompanying FIL (Factory Interface Language) file whose function is
to handle special circumstances regarding the machine that cannot be addressed by a post
file alone. Refer to the online SPost FIL Manual, Chapter 1: Fil Introduction starting on
page 1 if you need to create your own FIL file for a particular machine. FIL files are saved
in the SURFCAM\PostLib\SPost directory with names in a form that is similar to the
names of posts: UNCX01.Fnn for mill and wire EDM machines and UNCL01.Fnn for
lathe machines. The nn in a FIL file name is the same as the nn in its corresponding post
file name.
Experiment No. 10B. POSTHASTE Post Processor
Name Haas 4 axis Vertical machining center

Section 1 - Letter formatting - O >4 (O can be up to 4 digits.)
N >4
G >2 (G can be up to 2 digits.)
X ->3.>4 (All these letters are formatted Y ->3.>4 to allow a minus sign, then up Z ->3.>4
to 3 digits before the decimal, I ->3.>4 and up to 4 digits after.)
J ->3.>4
Q ->3.>4
R ->3.>4
P ->3.>4
A ->4.>4 Limit -8000 8000 (For Rotary axis.)
F >3.1
K ->3.>4
H >2
D >2
T >2
M >2
S >4
Section 2 - Miscellaneous parameters - ModalGs 0 1 2 3 73 74 76 80 81 82 83 84 85
94
Sequence#s N 0 1 1 Char, Freq, Inc., First
HCode X (Axis letters.) VCode Y

Dcode Z FeedCode F
Feed G1 (Motion G codes.) Rapid G0
Cw G2
Ccw G3
CtrCode I J (Circle info… ) CtrIncremental? Y
Comment ( ) (Comment start / end. ) Spindle 3 4 5 (M codes: Cw, Ccw, Off ) Coolant 8 9 7
(M codes: On, Off, Mist.) DComp 41 42 40 (G codes: Left, Right, Off )
RotaryFeed F[InvTime] Rotary feed rate FeedType G 95 94 93 IPR, IPM, InvTime
Section 3 - The NC code sequences -StartCode O[Program#] G91

G28 X2 Y-2 Z-2 G90
End
1stToolChange
N[Block] T[Tool] M6
G0 G40 G80 G[Work] X[H] Y[V] A[RotAngle]
G43 Z[D] H[Lcomp] M[Direct] S[Speed] M[Cool]
End
ToolChange (Secondary tool changes.) M9

G28 G49 Z0 S100
N[Block] T[Tool] M6
G0 G40 G80 G[Work] X[H] Y[V] A[RotAngle]
G43 Z[D] H[Lcomp] M[Direct] S[Speed] M[Cool]
End
Index X (How to rapid w/ rotary motion.) G0 Z[RPlane]

G[Work] X[H] Y[V] A[RotAngle] Z[D]
End
Infeed (Apply cuttercomp) G1 Z[D] F[Plunge]

G[Side] X[H] Y[V] D[DComp] F[FRate]
end
Outfeed (Remove cuttercomp) G1 G40 X[H] Y[V]

Z[D]
end
EndCode
G0 G28 G49 Z0 S100
G28 G91 X0 Y0 A0 T[Tool1] M6 G90 M30
End
Experiment No. 10C. SolidCAM Post Processor
Do the following to open a part:
95
Double click the SolidWorks icon and open Basic Training.SLDPRT part.
Before starting SolidCAM, you need to do the following settings that will enable you
to select the right post processor and the machine associated with the post processor. To do
the settings:
Click SolidCAM tab in SolidWorks.
Click SolidCAM Settings.
In SolidCAM Settings, you must concentrate on the following 2 tabs in the settings area:
 The path for machine simulation files

 The location of the post processor
Path for Machine Simulation Files
96
Post Processor Location
By default, the post processor files and the machine simulation files are
located on this path: /root/Program Files/SolidCAM/Gpptool. But, it is a
good practice to create sepa-rate folders in the root directory for the post
processor and the machine simulation. For example, C:/GPP &
C:/Machine_Sim. The advantage of creating separate folders is that the post
processor and machine simulation files remain intact even when the
SolidCAM version is uninstalled or upgraded.
Click OK to exit the SolidCAM Settings window.
Click the SolidCAM tab.
Click New > Milling.
Experiment No. 10D. Dolphin CAD-CAM Post Processor
Dolphin CAD-CAM offers 2D & 3D CNC machining functionality to

streamline the programming phase of turning CAD geometry into tool path
for machining and ultimately an NC file that is used by the CNC machine
tool.
Haas post processors are easily configured for Haas VF1 through VF 2 & VF
3 Vertical and Horizontal Machining Centers as well as Haas DT Mini Mills.
The Haas CNC lathes also require post processors when programming with a
CAM system.
So, what makes Dolphin CAD-CAM Mill software the perfect match for
Haas CNC machines?
97
– 2.5, 3 & 4 Axis Machining Capabilities at a Hobby Price

– Seamless Post Processing to Haas Controllers
– Easy To Use
– Plenty of “Help” and tutorials to get you started
2D or 3D Haas CNC milling can require different tool paths that include:
- Pocketing
- Profiling
- Plunge or Drill-Roughing
- Facing
- Engraving
-3DContouring
As shown in Table 2, the programming times differed only by a few minutes

in the first three cases. When it needs to be done the same geometry using
Shop Mill, the time spent is three times more. If there is the need to rotate the
machine table, the programming time of that operation increases an order of
magnitude. When the geometry entails the rotation of any angle, the user is
forced to indicate which is the new reference point before the rotation, which
value (in degrees) of tilt and another reference point after. This requires
either the technical drawing to have more information than usual or commits
the operator to manually calculate the new reference points.
NXCam SolidCam MasterCam ShopMill

Preparing 00:55 00:35 01:35 01:05
Facing 01:30 00:55 01:05 00:35
Contour 02:00 01:05 00:55 01:10
Box 01:40 01:10 01:10 01:25
Drill 02:05 00:40 00:40 01:10
Thread Drilling 01:10 00:45 00:45 00:30
Tilt Facing 01:45 01:10 02:30 20:35
o
Drill 90 01:45 00:55 02:35 02:05
Total (mm:ss) 12:50 07:15 11:15 28:35
Table 3 – CAM Programming time of the case
study
Result: Hence different post processors used in NC machines are studied.
Questions
1. Define Processor.
----------------------------------------------------------------------------------
2. What is preprocessor?
------------------------------------------------------------------------------
3. Define Post Processor.
-----------------------------------------------------------------------------
4. What are the types of Post processors?
98
Ans
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------------------------------------------------------------------------------------
--------------------------------------
5. What are the functions of Post processors?
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
-------------------------------------
Experiment No. 11. Development of NC codes for free form and

sculptured surfaces using CAM software.
MTAB XLMILL
Experiment No.11A. Circular Pocket ( radius=20)
Aim: To generate CNC program for a circular pocket from a circular

drawing (Figure.1) of
radius 20mm.
Database required: CNC TRAIN V8 software
Procedure: click on CNC Design→ Press on New Drawing → press on

Draw→ Pick circle icon and draw it in the graphics area for getting required
shape → Press on ‘Select’ then press on symbol ‘>’ provided inside the
drawing, so that the drawing will be selected→ Press on ‘Build CNC’→
Press on ‘Create Tool Path’→ Press on ‘Create Full CNC Program’→ Press
on ‘CNC Train’. Then we see the CNC program generated by the software
like this as shown below. Press on Green icon for simulation, Yellow icon for
pause and Red icon to stop the cycle provided in the software.
Editing of a drawing: Press on ‘select’ icon provided at the bottom of the

graphics area→ press on symbol ‘>’ provided inside the drawing→ press on
‘Option’→ click on Erase.
%
O1000 (New Part)
N15 G00 G17 G21 G40 G80 G90
N18 G28 G91 Z0
N21 G17 T03 M6
N24 G90 G43 H03 M8
N27 G00 Z0.
N30 S2000 M03
N33 G00 X37.5 Y40.
N36 G00 Z0.
N39 G170 R2. P0 Q-5. X37.5 Y40. Z20. K20.
N42 G171 P50 B2000 R200. F300.
N45 G0 G28 G91 Z0 M9
99
N48 G0 G40 G80 G90

N51 M30
%
Result: The circular pocket is generated for the selected soft work piece by
CNC TrainV8 simulation software.
100
Questions
1. List out the various types of CAM simulation software’s.
Ans
------------------------------------------------------------------------------------
----------------
2. What is the use and limitations of CNC Train V8 software for milling
101
operations?
Ans
------------------------------------------------------------------------------------
----------------
3. Is it possible to edit the CNC Train V8 programs?
-------------------------------------------
Experiment No.11B.Rectangular Pocket (Length I=50,Width J=25)
Aim: To generate Rectangular Pocket CNC program from a Rectangular

drawing (Figure.2) of
length =50, Width =25

Draw→ Pick Rectangle icon and draw it in the graphics area for getting
required shape → Press on ‘Select’ then press on symbol ‘>’ provided on
drawing, so that the drawing will be selected→ Press on ‘Build CNC’→

%
O1000(New Part)
N15 G00 G17 G21 G40 G80 G90
N18 G28 G91 Z0
N21 G17 T03 M6
N24 G90 G43 H03 M8
N27 G00 Z0.
N30 S2000 M03
N33 G00 X76.25 Y42.5
N36 G00 Z0.
N39 G172 I50. J25. K0.P0Q-5. R2. X51.25 Y30. Z20.
N42 G173 I0.000 K0.000 P50 T1 S2000 R200. F300. Z2.
N45 G0 G28 G91 Z0 M9
N48 G0 G40 G80 G90
N51 M30
%
Result: The Rectangular pocket is generated for the selected soft work piece
by CNC TrainV8 simulation software.
102
103
Questions
1. What is the application CNC Train V8 software?

Ans
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---------------------------------------------------------------------------------------------
104
---------------------------------------------------------------------------------------------
------------------------------------------------------------
Experiment No.11C. One Type of Slot
Aim: To generate a CNC program for a slot from the given drawing
(Figure.3).

Draw→ Pick line icon and circle icon and draw it in the graphics area for
getting required shape→ Press on ‘Select’ then press on symbol ‘>’ provided
on drawing, so that the drawing will be selected→ Press on ‘Build CNC’→

%
O1000(New Part)
N15 G00 G17 G21 G40 G80 G90
N18 G28 G91 Z0
N21 G17 T03 M6
N24 G90 G43 H03 M8
N27 G00 Z0.
N30 S2000 M03
N33 G00 X32.5 Y42.5 (Move to start of first profile after Tool Change
N36 G00 Z0. ( Move down to intial depth
N39 G01 Z-5. F200.
N42 X77.5 Y42.5 F300.
N45 G00 Z2. (Move to retract at end of profile
N48 G00 X32.5 Y42.5 ( Move to profile start position
N51 G01 Z-10. F200.
N54 X77.5 Y42.5 F300.
N63 G01 Z-15. F200.
N66 X77.5 Y42.5 F300.
N75 G01 Z20. F200.
N78 G01 X77.5 Y42.5 F300.
N87 G00 Z0. (Move to intial depth at end of profile
N90 G00 X32.5 Y62.5 (Move to start of next profile
105
N93 G01 Z-5. F200.

N96 X77.5 Y62.5 F300.
N105 G01 Z-10. F200.
N108 X77.5 Y62.5 F300.
N117 G01 Z-15. F200.
N120 X77.5 Y62.5 F300.
N129 G01 Z20. F200.
N132 G01 X77.5 Y62.5 F300.
N147 G01 Z-5. F200.
N150 X32.5 Y42.5 F300.
N159 G01 Z-10. F200.
N162 X32.5 Y42.5 F300.
N171 G01 Z-15. F200.
N174 X32.5 Y42.5 F300.
N183 G01 Z20. F200.
N186 G01 X32.5 Y42.5 F300.
N201 G01 Z-5. F200.
N204 G02 X77.5 Y42.5 I0. J-10. F300.
N213 G01 Z-10. F200.
N216 G02 X77.5 Y42.5 I0. J-10. F300.
N225 G01 Z-15. F200.
N228 G02 X77.5 Y42.5 I0. J-10. F300.
N237 G01 Z20. F200.
N240 G02 X77.5 Y42.5 I0. J-10. F300.
106

N255 G01 Z-5. F200.
N258 G01 X47.5 Y42.5 F300.
N267 G01 Z-10. F200.
N270 X47.5 Y42.5 F300.
N279 G01 Z-15. F200.
N282 X47.5 Y42.5 F300.
N291 G01 Z20. F200.
N294 G01 X47.5 Y42.5 F300.
N306 G00 X65. Y62.5 (Move to start of next profile
N309 G01 Z-5. F200.
N312 X65. Y42.5 F300.
N318 G00 X65. Y62.5 ( Move to profile start position
N321 G01 Z-10. F200.
N324 X65. Y42.5 F300.
N333 G01 Z-15. F200.
N336 X65. Y42.5 F300.
N345 G01 Z20. F200.
N348 G01 X65. Y42.5 F300.
N357 G00 Z0.
N360 G0 G28 G91 Z0 M9
N363 G0 G40 G80 G90
N366 M30
%
Result: The Required slot is generated for the selected soft work piece by
107
108
109
MTAB XLTURN
Experiment No.11D. Simple Turning
Aim: To generate CNC program for Simple Turning from a given drawing
(Figure.1).

Draw→ Pick line icon and draw it in the graphics area for getting required
shape→ Press on ‘Select’ then press on symbol ‘>’ provided on drawing, so
that the drawing will be selected→ Press on ‘Build CNC’→ Press on ‘Create
Tool Path’→ Press on ‘Create Full CNC Program’→ Press on ‘CNC Train’.
Then we see the CNC program generated by the software like this as shown
below. Press on Green icon for simulation, Yellow icon for pause and Red
icon to stop the cycle provided in the software.
%
O1000(New Part)
N15 G0 G21 G40 G80 G98
N20 G28 U0 W0
N25 M06 T0101
N30 M03 S2000
N35 G1 X20. Z0.
N40 X30. Z0.
N45 X30. Z0.
N50 X40. Z-7.5
N55 X40. Z-20.
N60 X40. Z-20.
N65 X10. Z-20.
N70 X10. Z-7.5
N75 G28 U0 W0
N80 G40 G80
N85 M05
N90 M30
%
Result: The Simple Turning is generated for the selected soft work piece by
110
Questions
1. Differentiate between CNC Train V8 software and CNC Train V6

software developed by MTAB.
Ans
------------------------------------------------------------------------------------
111
------------------------------------------------------------------------------------
-------------------------------------
Experiment No.11E. Step Turning
Aim: To generate CNC program for Step Turning from a given drawing
(Figure.2).

%
O1000(New Part)
N15 G0 G21 G40 G80 G98
N20 G28 U0 W0
N25 M06 T0101
N30 M03 S2000
N35 G1 X15. Z0.
N40 X25. Z-5.
N45 X35. Z-5.
N50 X35. Z-12.5
N55 X40. Z-12.5
N60 X40. Z-22.5
N65 X15. Z-22.5
N70 X15. Z-22.5
N75 X15. Z-12.5
N80 X5. Z-12.5
N85 X5. Z-5.
N90 X15. Z-5.
N95 G28 U0 W0
N100 G40 G80
N105 M05
N110 M30
%
Result: The Step Turning is generated for the selected soft work piece by
112
Questions
113
1. What is the use and limitations of CNC Train V8 software for turning
operations?
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
------------------------------------------------------------
Experiment No.11F. Step Turning & Taper Turning
Aim: To generate CNC program for combine Step turning & Taper turning
from a given
Drawing (Figure.3).

%
O1000(New Part)
N15 G0 G21 G40 G80 G98
N20 G28 U0 W0
N25 M06 T0101
N30 M03 S2000
N35 G1 X15. Z0.
N40 X5. Z-12.5
N45 X35. Z-12.5
N50 X10. Z-22.5
N55 X10. Z-22.5
N60 X40. Z-22.5
N65 G28 U0 W0
N70 G40 G80
N75 M05
N80 M30
%
Result: The selected combine turning operation is generated for the selected
soft work piece by CNC TrainV8 simulation software.
114
115
Questions
1. Is CNC Train V8 software can import 2D and 3D CAD models?

Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
------------------------------------------------------------
116
Experiment No. 12 Machining of simple components on NC lathe and

Mill by transferring NC Code/from CAM software
Introduction to basic concepts for part programming
Part programming contains geometric information about the part and motion
information to move the cutting tool with respect to the work-piece. The first
thing to be defined is the Coordinate System and then some-one can continue
with the Syntax of Part Programming. The main 3 Axes forming a right-hand
coordinate system, by convention z axis moves the cutting tool away from
the work-piece, in details:
The z axis, parallel to the spindle for rotating work-piece, and parallel to the
machine tool axis for rotating tool, as a milling, drilling, or boring machine.
The x axis, in the direction of the tool movement for the first case, and points
to the right when some-one is facing the machine.
There can be more axes because of secondary slide motions in addition to the
primary x, y and z directions, and the rotary motions around axes parallel to
x, y and z axes. These axes can be labeled u, v and w (for the first case) and
a, b and c (for the second).
The machine tools can be classified according to the number of axes they
provide to control position and orientation. For example, there are 2-axis, 3-
axis and 5-axis milling machines.
 Various formats and well defined syntax with variations due to

differences between machines
 Use of a sequence of blocks containing commands to set machine
parameters as speed etc.
 Each command has an identifying letter followed by an associated
number
Some identifying letters for the commands:
 Sequence number (N code)

 Preparatory command (G code)
 Dimension words (X, Y, Z, A and B words)
 Feed commands (F code)
 Speed commands (S code)
 Tool selection (T code)
 Miscellaneous (M code)
Formats for the commands arranged to form a block:
 Fixed sequential format

 Block address format
 Tab sequential format
 Word address format
117
For example: N040 G00 X0 Y0 Z300 T01 M06
N: identifier number, G: preparatory commands,

X, Y and Z: coordinates along the x, y and z axis
T: the tool number and M: miscellaneous commands
PART PROGRAMMING – LAB SESSION CNC LATHE
Some important ‘G’ – Codes used in CNC Lathe Programs
• G00 – Rapid Traverse

• G01 – Feed or Control Traverse/ linear interpolation
• G02 – Circular interpolation (C.W)
• G03 – Circular interpolation (C.C.W)
• G04 – Dwell
• G20 – Inch data input
• G21 – mm data input
• G28 – Reference point return
• G40 – Tool nose radius compensation cancel
• G41 – Tool nose radius compensation Left
• G42 – Tool nose radius compensation Right
• G70 – Finishing Cycle
• G71 – Stock Removal in Turning
• G72 – Stock Removal in Facing
• G73 – Pattern repeating
• G74 – Peck Drilling in Z- axis
• G75 – Peck Grooving in X- axis
• G76 – Thread cutting cycle
• G90 – Cutting cycle A
• G92 – Thread Cutting cycle
• G94 – Cutting cycle B
• G96 – Constant surface speed control
• G97 – Constant surface speed control cancel
• G98 – Feed per minute
• G99 – Feed per revolution
Some Important ‘M’ – Codes in CNC Lathe Programs
• M00 – Program stop

• M01 – Optional stop
• M02 – Program end
• M03 – Spindle rotation Forward (C.W)
• M04 – Spindle rotation Reverse (C.C.W)
• M05 – Spindle Stop
• M06 – Tool Change
• M08 – Coolant On
• M09 – Coolant Off
• M10 – Vice Open
• M11 – Vice Close
• M30 – Program end and tape rewind
118
• M38 – Guard Open

• M39 – Guard Close
• M98 – Subprogram Call
• M99 – Subprogram Exit
• M62 …… M77 – Internal, External signals On & Off
Experiment No. 12 Machining of simple components on NC lathe and
Mill by transferring NC Code/from CAM software
Experiment No. 12A. Step Turning (using G90)
Aim: To reduce f25mm rod in to stepped rod of f20mm, f15mm & f10mm.
[Billet X25 Z70]

G21 G98
G28 U0 W0
M06 T01
M03 S1200
G00 X25 Z2
G90 X24.5 Z-45 F50
X24
X23
X22
X21
X20
G90 X19.5 Z-30 F50
X19
X18
X17
X16
X15
G90 X14.5 Z-15 F50
X14
X13
X12
X11
X10
G28 U0 W0
M05
M30
Result: Hence the step tuning is performed on the given billet.
Questions
1. Which G-code is used for turning canned cycle?

----------------------------------------------
2. G98 stands for---------------------------------------- on CNC lathe.
3. Differentiate between TAB sequential format and fixed sequential
format.
119
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
6. Define
NC.-------------------------------------------------------------------------------
------------------------------------------------------------------------------------
----------------------------------
Experiment No. 12B. Taper Turning (using G90)
Aim: To reduce f25mm x length 70 mm rod into a taper rod of f23mm x

f25mm for 45 mm
length.
[Billet X25 Z70]

G21 G8
G28 U0 W0
M06 T01
M03 S1200
G00 X25 Z2
G90 X25 Z-45 R-0.5 F50
X25 R-1.0
X25 R-1.5
X25 R-2.0
X25 R-2.5
X25 R-3.0
X25 R-3.5
G28 U0 W0
M05
M30
R=18-25/2=-3.5
Result: Hence the taper tuning is performed on the given billet.
Questions
1. What is R in this experiment?

Ans
------------------------------------------------------------------------------------
----------------
2. Differentiate between M02 and M30.
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
3. Is M03 M07 can be used in the same NC block?
120
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
4. What is CNC system?
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
---------------------------------------
Experiment No: 12C. Multiple Turning (using G71 & G70)
Aim: To perform multiple turning on the given billet.

To reduce f25mm rod in to the shape as shown in the figure
G71 U R [U – Rough depth of cut, R – Retract amount]
G71 P Q U W F [P – Start line, Q – End line]
[Billet X25 Z70]

G21 G98
G28 U0 W0
M06 T3
M03 S1000
G00 X26 Z1
G71 U0.5 R1
G71 P10 Q20 U0.1 W0.1 F50
N10 G01 X8
Z0
G01 X13 Z-9
G01 X13 Z-19
G02 X19 Z-22 R3
G01 X19 Z-32
N20 G03 X25 Z-35 R3
G70 P10 Q20 S1300
G28 U0 W0
M05
M30
Result: Hence the multiple tuning performed on the given billet.
121
Questions
1. What is the syntax for G71 cycle?

-------------------------------------------------------------
2. What are the secondary motion command with respective x, y and z
coordinates?
Ans
------------------------------------------------------------------------------------
----------------
5. M06 stands for---------------------------------------- on CNC lathe.
Experiment No: 12D. Drilling Cycles (using G74)
Aim: To perform drilling operation on the given billet.
To make f12mm drilled hole in a f25mm rod for a 30mm length

G74 R R – Retract amount
G74 X Z Q F Z – Drill Depth,
Q – Peck increment in microns
[Billet X25 Z70]

G21 G98
G28 U0 W0
M06 T2 [T2 Centre Drill]
M03 S800
G00 X0 Z2
G74 R1
G74 X0 Z-5 Q500 F50
G28 U0 W0
M06 T4 [T4 f6mm Drill]
G00 X0 Z2
G74 R1
G74 X0 Z-30 Q500 F40
G28 U0 W0
M06 T6 [T6 f12mm Drill]
G00 X0 Z2
122
G74 R1
G74 X0 Z-30 Q500 F40
G28 U0 W0
M05
M30
Result: Hence the taper grooving is performed on the given billet.
Questions
1. What is the CNC turret?

Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
2. Differentiate between NC and CNC systems.
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
PART PROGRAMMING – LAB SESSION CNC MILL
Additional or Alternative G – Codes used in CNC Mill
• G73 – Peck Drill Cycle

• G80 – Canned Cycle Cancel
• G81--G83 – Other types of Drilling Cycles
• G85-- G88 – Types of Boring Cycles
• G90 – Absolute Zero
• G91 – Incremental Command
• G94 – Feed per Minute
• G95 – Feed per Revolution
• G98 – Return to Initial Point in Canned Cycle
• G99 – Return to Reference point in Canned cycle
• G170 & G171 – Circular Pocketing
• G172 & G173 – Rectangular Pocketing
Additional or Alternative M – Codes used in CNC Mill
• M20 – ATC arm IN

• M21 – ATC arm BACK
• M22 – ATC arm Down
123
• M23 – ATC arm UP

• M27 – ATC Position reset to Tool one
• M32 – ATC Rotation one step CW
• M33 – ATC Rotation one step CCW
• M34 – ATC Rotation half step CW
• M70 – Mirror in X axis ON
• M71 – Mirror in Y axis ON
• M80 – Mirror in X axis OFF
• M81 – Mirror in Y axis OFF
Experiment No: 12E. Square Slot
Aim: To marking Square slot on a flat plate on the given billet.
Consider origin at the center of the billet.
[BILLET X90 Y90 Z12]
G21 G94
G28 G91 X0 Y0 Z0
M03 S1200
G00 G90 X0 Y0
G00 G90 Z5
G00 X-25 Y-25
G01 Z-1 F50
G01 X-25 Y25
G01 X25 Y25
G01 X25 Y-25
G01 X-25 Y-25
G00 G90 Z5
G28 G91 Z0
G28 G91 X0 Y0
M05
M30
124
Result: Hence the square slot is performed on the given billet.
Questions
1. Explain G90 and G91 on XL MILL machine.

Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
2. Define Floating zero and fixed zero on XL MILL machine.
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
3. G94 stands for---------------------------------------- on CNC milling
machine.
machine.
machine.
Experiment No: 12F. Circular Slot
AIM: To marking Circular Cut of f 60 on a flat plate with work piece zero
at the center
G21 G94
G28 G91 X0 Y0 Z0
M03 S1200
G00 G90 X0 Y0
G00 G90 Z5
G00 X-30 Y0
G01 Z-1 F50
G02 I30 F50
G00 G90 Z5
G28 G91 Z0
125
G28 G91 X0 Y0
M05
M30
Result: Hence the circular slot is performed on the given billet.
Questions
1. What is maximum feed of this CNC milling machine?

Ans
------------------------------------------------------------------------------------
----------------
2. What is the spindle speed range in this CNC milling machine?
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
3. M04 stands for---------------------------------------- on CNC milling
machine.
4. M13 stands for---------------------------------------- on CNC milling
machine.
machine.
Experiment No: 12G. Profile Cutting
Aim: To perform profile cutting
G21 G94
G91 G28 X0 Y0 Z0
M06 T01
126
M03 S1500
G90 G00 X30 Y20
G00 Z5
G01 Z-1 F60
G01 X60 Y20
G03 X70 Y30 R10
G01 X70 Y60
G02 X60 Y70 R10
G01 X30 Y70
G03 X20 Y60 R10
G01 X20 Y30
G01 X30 Y20
G01 Z5
G91 G28 X0 Y0 Z0
M05
M30
Result: Hence the profile cutting operation performed on the given billet.
Questions
1. Explain DNC system.

Ans
------------------------------------------------------------------------------------
----------------
2. Is it possible to make drilling on a given work piece using XL MILL
machine?
Ans
------------------------------------------------------------------------------------
----------------
3. What are the features of CNC milling machine?
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
4. Differentiate between end mill and drill bite.
Ans
------------------------------------------------------------------------------------
------------------------------------------------------------------------------------
--------------------------------------
127

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IV B.

Tech – I Sem (ME) CAD/CAM LAB

ACADEMIC YEAR: 2019-20

This is to certify that the bonafide

record work done by

Bearing H.T No _________________of IV-

B.Tech-I Semester in the CAD-CAM

Laboratory is satisfactorily completed.

2. Department of Mechanical Engineering 3-7

15 Development of manufacturing defects and tool management systems 89

2. CMR INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

PO 1: Engineering knowledge: Apply knowledge of mathematics, science, engineering

PO10: Communication: Communicate effectively on complex engineering activities with the

Program Educational Objectives

3 PEO – 3 Graduate exhibits professional ethics, communication skills, teamwork

Course Objectives & Outcomes Mapping

Course outcomes and Program outcomes mapping

1. Do not power cables.

(For the A.Y 2019– 20)

5. List of Experiments (Any 08 of the following):

1. DRAFTING: Development of part drawing for various component s in the form of

2. PART MODELING: Generation of various 3D models through protrusion, revolve and

3. Determination of the deflection and stresses in 2D and 3D trusses and beams.

6. Estimation of natural frequencies and mode shapes, harmonic response of 2D beams.

7. Steady State heat transfer analyses of plane and axi-symmetric components.

9. Development of manufacturing defects and tool management systems

10. Study of various Post Processor used in NC machines.

12. Machining of simple components on NC lathe and Mill by transferring NC Code/from

2. All the students should sign in login register.

9. Students should ensure that their work areas are clean.

11. Students should attend regularly to all lab classes.

BASIC FACILITIES IN AUTOCAD:

New: This allows for starting a new drawing.

BMP: Device-independent bit map.

1. Direct command entry.

Planning for a drawing:

This is carried out by set up operations.

BASIC GEOMETRIC COMMANDS:

Each layer has a name which can be up to 31 characters.

DISPLAY CONTROL COMMAND:

ALL: Zoom out to original drawing limits.

EXTENTS: Shows everything in the file.

I. Previous: Restores the last zoom setting.

CENTRE: center or arc or circle.

ENDPOINT: closest end point if line/arc etc.

INSERTION: insertion point of text/block etc.

INTERSECTION: intersection of lines/arcs/circles etc.

MIDPOINT: midpoint of lines/arcs/circles etc.

NEAREST: nearest point on line/arc/circle.

NODE: nearest point entity.

PERPENDICULAR: perpendicular to line/arc/circle.

QUADRANT: quadrant point of arc or circle.

TANGENT: tangent to arc or circle.

ARRAY: places multiple copies of objects with a single command.

BREAK: cuts existing objects and /or erase portions of objects.

CHANGE: Changes spatial properties of some objects.

COPY: makes copies of objects.

MIRROR: creates a mirror image.

ROTATE: Turns existing object to any angular position.

SCALE: Scales object up or down to your specification.

OBJECT: the default selects a set by picking individual objects.

LAST: uses only the last object created.