Department of Mechanical Engineering

CAD/CAM LAB MANUAL

(Subject Code: A2ME53)
A.Y.: 2019-2020

Document No: DATE OF Compiled by:

AUTHORISED
ISSUE: Mr. J.Laxmi Prasad
BY
MLRIT/ME/CAD/ Mr. N.E.C.Prasad
CAM/LAB 16-06-2019
MANUAL
Head of
Department
Verified By:
(Mechanical)
 INSTITUTE VISION
Promote academic excellence, research, innovation, and entrepreneurial skills to
produce graduates with human values and leadership qualities to serve the nation.

INSTITUTE MISSION
Provide student-centric education and training on cutting-edge technologies to make
the students globally competitive and socially responsible citizens. Create an environment to
strengthen the research, innovation and entrepreneurship to solve societal problems.

DEPARTMENT VISION
The Mechanical Engineering Department endeavours to be recognized globally for
outstanding education and research leading to well qualified engineers, who are innovative,
entrepreneurial and successful in advanced fields of mechanical engineering to cater the ever
changing industrial demands.

DEPARTMENT MISSION
 M1. Impart highest quality education to the students to build their capacity enhancing
their skills to make them globally competitive mechanical engineers and successful
entrepreneurs.
 M2. Provide the students with academic environment of excellence, state of the art
research facilities, leadership, ethical guidelines and lifelong learning needed for a long
productive career.

Program Educational Objectives (PEOs):

 PEO 1 To prepare the students to excel in undergraduate and post graduate in Mechanical
engineering to mould their careers for successful employment in industry, academic and
entrepreneurial activities.
 PEO 2 Graduates of the Mechanical engineering program will analyze and synthesize data
and apply technical concepts which lead to the design of new products, improve upon
existing products and systems and develop technical problem solving skills
 PEO 3 Graduates will excel in a wide range of Mechanical engineering fields such as Design,
Analysis, multi-disciplinary areas.
 PEO 4 Graduates will have excellent oral and written communication skills, cooperative
learning skills, ethical attitude and an ability to relate engineering issues to broader social
environment.
 PEO 5 To provide a passionate academic environment for students that encourage learning of
emerging technologies, acquire leadership qualities and guidelines needed for a successful
career and engage in lifelong learning.
 CAD/CAM LAB
IV B. Tech. - I Semester LTPC
Course Code: A2ME53 - - 32
PART-A
CAD LAB
Course overview:
This is the core course of CATIA V5. This course covers the creation of solid parts without
complex contours. Students will be introduced to the part environment of CATIA V5 and
learn how to work between the Sketcher and Part Design workbenches to create individual
parts. It also covers the various analytical and navigation tools that are available within an
assembly.

Course Objectives:
Upon successful completion of the course, the student will be able to create, constrain and
modify sketches; create and modify parts; perform Boolean operations on parts; integrate
surfaces and apply materials to parts. The student will be able to insert, manipulate, constrain
and modify components in an assembly; work with the links of the assembly; create parts
within the assembly structure; perform measurements, clash analyses and section analyses;
create scenes and annotated views; capture pictures and create xml files for external use and
utilize all of the navigation tools.

Course Outcomes:
1. CO 1: Able to insert, manipulate, constrain and modify components in an assembly.
2. CO 2: Able to work with the links of the assembly and create parts within the
assembly structure.
3. CO 3: Able to create scenes and annotated views.
4. CO 4: Able to perform measurements, clash analyses and section analyses.

SYLLABUS

A. DRAFTING: Development of part drawings for various components in the form of

orthographic and isometric. Representation of Dimensioning and tolerances scanning
and plotting.

B. PART MODELING: Generation of various 3D Models through Protrusion, revolve,

shell sweep Creation of various features. Study of parent child relation. Feature based
and Boolean based modeling surface and Assembly Modeling. Study of various
standard Translators, Design simple components.

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

2. Determination of deflections component and principal and Von-mises stresses in plane
stress, plane strain and Axisymmetric components.
3. Determination of stresses in 3D and shell structures (at least one example in each case)
4. Estimation of natural frequencies and mode shapes Harmonic response of 2D beam.
5. Steady state heat transfer Analysis of plane and Axisymmetric components.

Any Four Software Packages from the following:

Pro-E, I-DEAS, CATIA, UNIGRAPHICS, ANSYS, NISA, CAEFEM, CAM, AUTOCAD, etc.
 PART-B
CAM LAB
Course overview:
Computer Aided Manufacturing is designed to prepare students as entry-level machinists in
many areas, including aerospace, computer industries, job shop, gun smithing, tool and die
making, Computer Numerical Control (CNC) operator, and CNC programmer. Students will
study machining processes and procedures using lathes, mills, drill presses, cylindrical
grinders, and surface grinders.

Course Objectives:
Basic CNC machines operations - Start-up and initialization procedure of the Victor CNC
machines including zero return and G92. Manual operation of the CNC lathe and mill
including turret indexing, tail stock motion, table motion and tool change Manual data input.
DNC Computer assisted programming for the CNC.

Course Outcomes:
1. CO 5: The student can able to perform different operations on CNC lathe and CNC
milling machine.

SYLLABUS

1. To perform facing operation for a given model by using CNC lathe machine
2. To perform parting-off operation for a given model by using CNC lathe machine
3. To perform step turning operation for a given model by using CNC lathe machine
4. To perform thread cutting operation for a given model by using CNC lathe machine
5. To perform different operations on CNC Milling machine.
Mapping Course Outcomes to PO’s and PSO’s:
PO’s PSO’s
COURSE
OUTCOME 1
1 2 3 4 5 6 7 8 9 11 12 13 14
0

CO 1 1 - 2 - 3 - - - - - - 2 3 3

CO 2 1 - 2 - 3 - - - - - - 2 3 3

CO 3 1 - 2 - 3 - - - - - - 2 3 3

CO 4 1 3 1 2 3 - - - - 1 1 2 3 3

CO 5 1 1 - - 3 - - - - - - 2 3 3

Note: 1-slight (low), 2-moderate (medium), 3-substantial (high), if no correlation put ’-‘
 Lab Safety Guidelines
 Obtain authorization from the lab In- charge prior to entering the lab working area.

 Ensure that safety devices are adequate, appropriate and in good working order.

 Wear the appropriate personal protective equipment when conducting work with

hazardous materials or procedures.

 Eye protection should be worn when performing tasks with potential to generate

flying particles or debris. Most power tool related tasks generate such hazards.

 Every Student should know the locations and operating procedures of all safety

equipment including, First AID KIT (s) and Fire extinguisher.

 Know where the fire alarm and the exits are located.

 Laboratories must be locked if no one is in the lab.

 Proper handling and disposal of bio-hazardous materials, including all patient

specimens
 Procedure for conductance of lab
1. Class students are divided in to two batches like B1 and B2 each batch students
allowed the lab alternate week.
2. Batch students are divided in to no. of groups with the strength of 3 students.
3. Students are instructed to come prepared with the experiments which are going do on
that day.
4. All students register their experiment name and signature in log in book.
5. All group students allotted for individual experiments as per the lesson planner
schedule.
6. Faculty explained the theory behind the experimental work and about experimental
test rig as well as operating procedure.
7. Students are conducting the experiments with the help of lab assistants.
8. After conducting the experiments students are allowed to do their calculation work
independently.
9. The lab observation is corrected by the faculty and marks are allotted as per the
rubrics.
 DO’s & DON’Ts
I. DO’S
1. Students should wear ID card in the laboratory.
2. Students should wear apron and shoes while entering into the lab.
3. Students should enter the details in the login register.
4. Students must read the instruction manual before starting the experiment.
5. Students should follow the guidelines given by the technician or staff.
6. Long hair must be tied back and dangling jewelry and loose or baggy clothing must
be secured.
7. Students should be aware of safety equipment like fire extinguisher etc.
8. Students should have the knowledge about first aid box to approach immediately
when injured.
9. Please concentrate on the work and report to the instructor or staff if any unsafe
condition of the equipment.
10. Please shut down the systems and turn off the power after the experiment is
completed.

II. DONT’S
1. Do not use pen-drives and hard disks in the lab.
2. Do not operate any equipment unless you are trained.
3. Don’t operate machinery without technician or staff in the workshop.
4. Don’t talk unnecessarily while doing the experiment.
5. Do not eat, drink or apply cosmetics in the laboratory.
6. Don’t play with electrical panels.
7. Don’t make strange or loud noises in laboratory.
8. Don’t attempt or apply oil, clean, adjust or repair any machine component while it is
running.
9. Do not split and do not make the lab untidy.
10. Do not wander around the room, distract other students, startle other students or
interfere with the laboratory experiments of others.
 INSTRUCTION TO STUDENTS

1. Students are required to remove their footwear outside the center and keep it in the box
provided for the same.
2. Students should leave their belongings outside the lab except their observation note book,
the concerned books/manuals and calculators.
3. Students are requested not to place their legs on the wall or on the table.
4. Students should refrain from leaning on the table and sitting on it.
5. Students should not use any disks or pen drives brought from outside without prior
permission from the concerned staff.
6. Students can get the required lab manual or observation book from the staff after signing
in the lab login register.
7. Students are not allowed to take any manual outside the center.
8. Edibles are strictly prohibited in the lab.
9. No internet browsing allowed during the lab hours.

******
 PART-A
CAD LAB EXPERIMENTS
No. of experiments possible to
Name of the equipment set Cycle
S.No. conduct and name of the
up No.
experiment
1. 2-D drawing practice
1 Computers – (30 no’s) 1
2. 3-D drawing practice
2 AUTOCAD 3. 3-D modeling practice by using 1
CATIA
3 CATIA 4. Assembly of 3-D drawing 1
5. Solving structural problem using 2
ANSYS
4 ANSYS 2
6. Solving thermal analysis
problem using ANSYS 2
What is CAD/CAM?

CAD/CAM (computer-aided design and computer-aided manufacturing) refers to computer

software that is used to both design and manufacture products.

CAD is the use of computer technology for design and design documentation. CAD/CAM
applications are used to both design a product and program manufacturing processes,
specifically, CNC machining. CAM software uses the models and assemblies created in CAD
software to generate tool paths that drive the machines that turn the designs into physical
parts. CAD/CAM software is most often used for machining of prototypes and finished parts.

Why CAD/CAM?
Computer Aided Design and Computer Aided Manufacture is the way things are made these
days. Without this technology we wouldn’t have the range and quality of products available
or, at least, they wouldn’t be available at a price most of us can afford. Hand-building and
manual techniques still very much have their place and Design Education needs to treasure
and foster these skills so that future generations will have the ‘hands-on’ skills to understand
the man-made world and provide the next generation of engineers, designers and technicians.
All of these professionals will be using CAD/CAM techniques or CAD/CAM products in
their work, alongside practical hands-on skill. Design and Technology education has to
reflect modern practice so it is crucial that students have the opportunity to use real
CAD/CAM tools in their designing and making.

DESIGN PROCESS AND ROLE OF CAD

1. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation
SOLID MODELING

A solid modeling system is usually an interactive computer graphics system that is intended
to create true three-dimensional components and assemblies. Recent advances in CAD
software, computers, and graphical displays have made it possible to use solid
representations of components being considered in the design process. These solid
models can be employed in numerous ways.
Advantages of Solid Modeling
A realistic visual display: By producing a shaded visible surface image of the solid,
solid modeling allows a designer to see exactly what has been created.
Easy to deal with different views: Once a part has been created, we have the ability to rotate,
shade, section, or produce almost any view required by a designer.
Single associated model database: The solid modeler provides the only database suitable for
all CAD operations. Almost all information needed for part generation is contained in
the solid model.The algorithm should be able to ensure that it represents physically
possible shape that is complete and unambiguous Applications. e.g., automatic generation
of a mesh for a finite element analysis.

REQUIREMENTS FOR MODELING ASSEMBLING

1. Part modeling and analysis

The part analysis includes the material type, mass and inertial properties, functional
properties of the faces, etc.
2. Hierarchical relationships
An assemble tree and assemble sequence must be given.
3. Mating conditions.
There are two methods for specifying mating conditions:
Specify the location and orientation of each part in the assembly, together with the
representation of the part itself, by providing a 4 x 4 homogeneous transformation matrix.
(i.e., transformation from MCS to WCS).
Specify the spatial relationships between its individual parts as mating conditions.

CAD/CAE/CAM Data Exchange

Computer databases are now replacing paper blueprints in defining product geometry and
non-geometry for all phases of product design, analysis, and manufacturing. It becomes
increasingly important to find effective procedures for transferring data among
CAD/CAE/CAM systems.
The need to exchange modeling data is directly motivated by the need to integrate and
automate the design and manufacturing process to obtain the maximum benefits from
CAD/CAE/CAM systems.
Four Types of Modeling Data to be transferred:
(1) Shape (2) Nonshape (3) Design (4) Manufacturing

(1) Shape data consists of both geometrical and topological information as well as part
features. Entity attributes such as font, color, and layer as well as annotation is considered
part of the entity geometrical information. Topological information applies only to products
described via solid modeling. Features allow high-level concept communication about parts.
Examples are hole, flange, web, pocket, chamfer, etc.

(2) Nonshape data includes graphics data such as shaded images, and model global data as
measuring units of the database and the resolution of storing the database numerical values.

(3) Design data has to do with the information that designers generate from geometric models
for analysis purposes. e.g., mass property and finite element mesh data.
(4) Manufacturing data consists of information such as tooling, NC tool paths, tolerancing,
process planning, tool design, and bill of materials.

Commonly Used CAD Data Exchange Format:

 IGES (Initial Graphics Exchange Specification)
 PDES (Product Data Exchange Using STEP)
 IGES is focused on CAD-to-CAD exchange where primarily shape and nonshape data were to
be transferred from one system to another.
 PDES is previous called Product Data Exchange Standard. It is for the exchange of
complete product descriptions which covers the four types of modeling data (i.e., shape,
nonshape, design and manufacturing).
 Other data exchange interfaces include: STL, Neutral, SET, ECAD, VDA, STEP, PDGS,
CATIA, Render, CGM, VRML, PATRAN, TIFF, etc.
 Base Features in Part Modeling
Pad: Pad in third axis of the profile

Shaft: Shaft the profile about axis of symmetry

Sweep: Pad of a cross section along a path

Blend / Loft: Blending of different cross sections along a path

Editing & Engineering Features in Part Modeling

Round: Modify the sharp edge to curved edge

Chamfer: Modify the sharp edge to flat edge
Shell: Removes a surface or surfaces from the solid then hollows out the inside of the solid,
leaving a shell of a specified wall thickness.
Rib: Special type of protrusion to create a thin fin or web
Cut: Remove the undesirable portion from the basic part
Hole: Remove cylindrical portion from the basic part

Pattern: Create instances of the selected feature by varying some specified dimensions

COORDINATES:

“When a command prompts you for a point, you can use the pointing device to specify a
point, or you can enter a value on the command line. You can enter two-dimensional
coordinates as either Cartesian (X,Y) or polar coordinates.

Cartesian and Polar Coordinates

A Cartesian coordinate system has three axes X, Y, and Z. When you enter coordinate values,
you indicate a point’s distance (in units) and its direction (- or +) along the X, Y and Z axes
relative to the coordinate system origin (0,0,0).

In 2D, you specify points on the XY plane, also called the construction plane. The
construction plane is similar to a flat sheet of grid paper. The X value of the cartesian
coordinate specifies the horizontal distance, and the Y value specifies the vertical distance.
The origin point (0,0) indicates where the two axes intersect.
The origin is marked by an object known as the UCS icon UCS = User Coordinate System.
This icon can be manipulated (moved and rotated) such that the origin point moves. But for
the purposes of learning the basics of coordinates, this post will treat the UCS icon as a static
object in a permanent position. Oddly enough, the UCS icon does have
permanent position that it can always be re-positioned to. This position is called the “World
coordinates.”
Absolute Coordinates let you type in a specific X and Y location on the construction
plane.Use the picture below to work through the use of using absolute coordinates to create
the shape that is shown. Note that the coordinates that are shown in the lower left of the
screen (status bar) displays the coordinates of your cursor.

Note the all of the Drafting Setting toggles are turned off. this is because when DYN
(dynamic input) is turned on it changes how absolute and relative coordinates are entered.

Relative Coordinate
Relative Coordinate entry is simply specifying the next point as it relates to your previously
defined point whether you picked a point with the cursor or you entered a specific coordinate.
Think of this method as the last point you specified being equal to the coordinate 0,0.
The way that you tell AutoCAD that you want to use relative coordinates is that you prefix
the coordinate with the @ symbol. Note that the first point that is specified is an absolute
coordinate since there is not a specified previous point.

Note the all of the Drafting Setting toggles are turned off. this is because when DYN
(dynamic input) is turned on it changes how absolute and relative coordinates are entered.
Relative Polar Coordinate entry is very useful but for some people it is easily forgotten. As
shown above, Relative coordinates use the @ symbol when specifying a point. As shown in
the picture below, relative polar uses the # symbol to specify the LENGTH of the object
followed by the < symbol to specify the angle.
Use the below picture to create the shape that is shown using Relative Polar
Coordinate entry. Turn off all toggles in the drafting settings.

As mentioned before each exercise, Dynamic Input when enabled turns your entry method to
an automatic Relative Polar method. This is confusing because when DYN is turned on and
say that you want to specify the coordinate of 0,0 you will not see anything happen. So in
order to force Dynamic input to use Absolute coordinates use the # sign before the
coordinates.
Experiment.1 2-D DRAWING PRACTICE.

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA
To Draw the given diagram by Using AUTOCAD/CATIA
To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

To Draw the given diagram by Using AUTOCAD/CATIA

Experiment.2 3-D DRAWING PRACTICE

To create a given model by Using AUTOCAD/CATIA

Suggested Steps:
1. Select the XY plane (the plane the profile will be sketched on).
Reference Step 3 for information on selecting planes.
2. Enter the Sketcher Work Bench. Reference Step 4.
3. Sketch the profile of the part.
Hint: use the Profile tool.
4. Anchor the lower left hand corner of the sketch.
5. Constrain the profile to match the dimensions shown above.
Reference Step 18 for constraining a profile.
6. Exit the Sketcher Work Bench, return to the Part Design Work
Bench (the 3D environment). Reference Step 21 for exiting the
Sketcher Work Bench and entering the Part Design Work Bench.
7. Once in the Part Design Work Bench pad the profile to the
dimension shown (2”). Reference Step 22 for pading a profile.
8. Save the part .
 To create a given model by Using AUTOCAD/CATIA

Hint: To help make it easier to sketch this part set the grid Primary Spacing to 1
and the Graduations to 4. This will put the grid lines in the Sketcher screen to a .25 inch
spacing. With that spacing all you have to do is snap to the intersections of the grid to sketch
the part.

To create a given model by Using AUTOCAD/CATIA

Hint: It is not as complicated as it looks. If your grids Graduations are set to 10 just snap to
the intersections for the beginning and ending points of your lines. To set the constraint for
the angles select the angled lines and the angle constraint will appear. Reference Step 19 for
modifying the angle value.
 To create a given model by Using AUTOCAD/CATIA

Hint: This part can be done using the radius option in the profile command.

To create a given model by Using AUTOCAD/CATIA

Hint: Use the Line or Profile icon first to sketch the profile using sharp corners (no radius).
Once it is constrained to the dimensions above, go back and add in the radiuses using the
Corner icon.
To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA

To create a given model by Using AUTOCAD/CATIA
Experiment.3 3-D MODELING PRACTICE BY USING CATIA

To create a given model by Using CATIA

To create a given model by Using CATIA

To create a given model by Using CATIA

To create a given model by Using CATIA

 To develop the given model by Using CATIA

Aim: To develop the I-section as per give dimensions.

Apparatus/ Tools Required: Windows XP, CATIA V5 R20
Procedure:
1) Open > CATIA V5 R20 window.
2) Go to start > Mechanical Design and then to Sketcher and select any plane XY, YZ, or
ZX.
3) Draw a I-section approximately by using profile in profile tool bar.
4) Then constrain it as per given dimension.
5) Now exit the workbench.
6) Pad the drawn profile and give thickness chuck the mirror extent it and click ok.
7) Then select any phase and go to sketcher.
8) Project a 3D element line at base of I-section and reference axis is drawn at center and
draw a square as per given dimension and also offset it as given to center axis.
9) Then delete the 3D element lines.
10) Exit the workbench.
11) Then select pocket option and give dimension as required and click ok.
12) The I-section is completed and save it.
 To develop the given model by Using CATIA

Aim: To develop 3D Gib as per give dimensions.

Apparatus/ Tools Required: Windows XP, CATIA V5 R20
Procedure:
1) Open > CATIA V5 R20 window.
2) Go to start > Mechanical Design and then to Sketcher and select any plane XY, YZ,or ZX.
3) Draw a axis line as reference and draw a circle of radius required by selecting circle tool
in profile tool bar.
4) Then draw two lines parallel to circle and apply a tangency relation.
5) Then trim extra portion using quick trim option.
6) Take profile and draw gib shape approximately.
7) After completing apply constraints as given.
8) Exit workbench.
9) Pad the drawn profile and give thickness chuck the mirror extent it and click ok.
10) Then select hole option and give diameter and go to sketch and select the point and select
the radius and give concentric.
11) Exit workbench.
12) Then click ok hole is created.
13) We get the required shape of 3D Gib and save it.
 To develop the given model by Using CATIA

Aim: To develop plumber block as per give dimensions.

Apparatus/ Tools Required: Windows XP, CATIA V5 R20
Procedure:
1) Open > CATIA V5 R20 window.
2) Go to start > Mechanical Design and then to Sketcher and select any plane XY, YZ, or
ZX.
3) First draw line of the figure by the axis.
4) Then continue by the appropriate dimension by centering and complete the shape as shown
in figure and also apply corners were required by specifying a radius as given.
5) Exit workbench.
6) Then select any phase and go to sketcher.
7) Now draw a circle by creating offset from base as required.
8) Exit workbench.
9) Select a hole option specify dimension.
10) Then creation of Plumber block is completed a select the pad option and give thickness as
needed.
11)Thus Plumber block is completed and save it.
 To develop the given model by Using CATIA

Aim: To develop rectangular block with cut outs as per give dimensions.
Apparatus/ Tools Required: Windows XP, CATIA V5 R20
Procedure:
1) Open > CATIA V5 R20 window.
2) Go to start > Mechanical Design and then to Sketcher and select any plane XY, YZ, or
ZX.
3) Draw a rectangle and give constraints.
4) Exit workbench.
5) Select the pad option and give thickness as needed.
6) Then select phase and go to sketcher.
7) Then select the point in profile tool bar and place points randomly where required on
rectangular surface and draw a circles where point is placed as given dimension.
8) Then constrain the distance between them along with rectangular surface.
9) Exit workbench.
10) Select a hole option and give dimension as given and give depth upto last and click ok.
11) Repeat the step 8 for remaining three holes.
12) Then again select phase and go to sketcher.
13) Draw a axis line at center and select elongated hole and give radius and constrain it.
14) Exit workbench.
15) Then select pocket option and elongated hole > click ok.
16) Thus rectangular block with cut outs is completed and save it.
 To develop the given model by Using CATIA

Aim: To develop IC Engine Valve as per give dimensions.

Apparatus/ Tools Required: Windows XP, CATIA V5 R20
Procedure:
1) Open > CATIA V5 R20 window.
2) Go to start > Mechanical Design and then to Sketcher and select any plane XY, YZ,or ZX.
3) Take a profile tool in profile tool bar and draw a valve into half section as per given
dimension.
4) Exit workbench.
5) Select the shaft tool in sketch based feature and select the reference axis to revolve 360 o .
6) Thus the IC engine valve is completed and save it.
ASSEMBLY DRAWING
Experiment.4 ASSEMBLY OF 3-D DRAWING

COMPONENTS OF UNIVERSAL COUPLING

 ASSEMBLY ON UNIVERSAL COUPLING

Aim:

To model and assemble the universal coupling as per the dimensions given and also covert
the 3D model into the different views with the bill of material.

System Requirements:

Personal computer

Solid modeling software (solid edge).

Bill of materials: Description Material Numbers

Part no

1 Fork Cast steel 2

2 centre Cast iron 1

3 shaft Fe -410 w 2

4 Parallel key Fe - 410 w 2

5 pin Fe - 410 w 2

6 collar Fe - 410 w 2

7 Taper pin Fe – 410 w 2

Description:
An universal or hooke’s coupling is used to connect the two shafts whose axis intersect at a small
angle.
The inclination is transmitted from one shaft to another.
The main application of the universal coupling is found in the transmission from the gear box to the
differential or back axle of the automobiles.
In such a case, we use two universal couplings. One at each end of the propeller shaft connects the
gear box at one end and the differential at other end.
The universal coupling is also used for transmission of power to different spindles of multiple
drilling machine.
It is used to a knee joint in the milling machine.
Command part Menu operation
sketch Draw toolbar
protrusion Feature toolbar sketch, specify direction thickness
Cutout Feature toolbar sketch- specify direction thickness
hole Feature toolbar sketch specified direction
pattern Feature toolbar select radius direction number of feature
round Feature toolbar select chain specified radius
Revolved cutout Feature toolbar sketch, specify radius direction
Assembly Menu operation
Axial align Relationship toolbar pick the object surfaces
Planar align Relationship toolbar, pick object and faces
mate Relationship toolbar. pick object surface and insect.
angle Relationship toolbar. specify the angle
 ASSEMBLY OF UNIVERSAL COUPLING

Procedure:
Model different parts of the universal coupling using extrude, remove features.
Select the assembly in solid works main menu.
Using insert component icon of property manager, insert base component and next component to
the assemble.
Assemble using mate feature.
Continue the inspecting component and mating until the entire components are assembled.
Save assembly.
From the main menu of solid work, select the drawing option.
Select the drawing sheet format size (i.e) A4 size –landscape.
Using the model view manager browse the document to be open.
Click the view orientation from the model view manager and place the drawing view in the proper
place in the sheet as shown above.
Using the placed view as parent view project the other or needed views.
Move cursor to anyone view and right click the muse button.
Select the table BOM.
Place the BOM in the proper place in the drawing sheet.
Save the drawing sheet.

Result:
Thus the given universal coupling is modeled, assembled and different views are taken.
 COMPONENTS OF KNUCKLE JOINT

ASSEMBLY OF KNUCKLE JOINT

Aim:
To create the component of the knuckle joint and to assemble then using to parametric feature based
solid modeling software.
System Requirements:
 Personal computer
 Solid modeling software (solid edge).

Description:
A knuckle joint is used to connect two rods which are under the action of tensile loads.
However if the joint is guided, the rods may support a compressive load.
A knuckle joint may be readily disconnected for adjustment or repairs.
It’s use may be found in the link of a cycle chain, tie rod joint for roof truss, valve rod joint with
eccentric rod, pump joint, tension link in bridge structure and lever and rod connections of the various
types.
In knuckle joint, one end of one of the rods is made into an eye and the end of the other rod is
formed into fork with an eye in each of the fork leg.
The knuckle pin passes through both the eye hole and the fork holes and may be secured by means
of a small stop pin or plug.
In order to get a better quality of joint the series of the fork and eye are machined, the hole is
accurately drilled and pin turned.
The material used for one joint may be steel or wrought iron.
Command part Menu operation
sketch Draw toolbar
protrusion Feature toolbar sketch, specify direction thickness
Cutout Feature toolbar sketch- specify direction and
thickness
hole Feature toolbar sketch specified direction
pattern Feature toolbar select radius direction of feature
round Feature toolbar select chain specified radius
Revolved cutout Feature toolbar sketch, specify radius and direction
Assembly Menu operation
Axial align Relationship toolbar pick the object surfaces
Planar align Relationship toolbar, pick object and faces
mate Relationship toolbar. pick object surface and
insect.
angle Relationship toolbar. specify the angle

Procedure:
Using sketch protrusion, fillet, cutout, revolve cutout, mirror and pattern command as fork end of
the rod is created.
Using sketch protrusion, fillet, cutout, revolve cutout, mirror and pattern command an eye end of
the rod is created.
Using sketch protrusion and revolve cutout command a pin is created.
Using sketch protrusion, the revolve cutout command a collar is created.
Using axial align, planar align and angle command take fork end, eye end of the rod are assembled.
Using mate command, pin, taper pin and collar is positioned and assembled it.

Result: Thus the components of knuckle joint are created and assembled successfully.
 To develop the given model by Using CATIA
(STUFFING BOX)
AIM: To draw the detail view of the Stuffing Box and assemble the parts by using the pro-e
software and obtain its respective views.
COMMANDS USED: Sketch, pad, Shaft, Pattern, Mate, Align, Helical Sweep, Round, Chamfer
etc.,
PROCEDURE: PART DRAWING: CYLINDER:
Using Pad, Cut and Round Commands the cylinder has been drawn.

NUT:
Using Pad, Cut and Round Commands the nut has been drawn.

GLAND BUSH:
Using Pad and Cut Commands the gland bush has been drawn.

PISTON ROD:
Using Pad and Cut Commands the piston rod has been drawn.

PACKING:
Using Shaft command the packing has been drawn.

ASSEMBLY AND DETAILED DRAWING:

Using the Assembly and Drawing mode to make the respective views and bill of materials.

RESULT: Thus the Detail View of the Stuffing Box and then its respective views have been
drawn.
Stuffing box
To develop the given model by Using CATIA
(Screw jack)

Screw jack
Expand CATIAV5?
Computer Aided Three Dimensional Interactive Application.

What is the save pad of sketcher file?

CAT Part

Does CATIA V5 work on UNIX Platform?

Yes

Is it possible to increase the size of plane boundary representation & how?

Yes, go for Tools-Options- Infrastructure-Part structure-Display

Is It Possible to directly enter in to Sketcher Workbench?

No, it is not possible to enter in to sketcher workbench directly. We have to go for any
workbench &form there we can enter the sketcher workbench..

Which is the tool used to exit from sketcher workbench to part design Workbench?
Exit Sketcher.

What is the use of construction elements?

Construction elements assist in sketching the required profile in sketcher.

What are the default units of LMT (Length, Mass and Time)
mm, Kg, Second.

Is it possible to hide specification tree?

Yes, with help of F3 button, but the option in Tools command must be checked to allow this.

What is SHOW/HIDE option?

Show mode enable us to see all the components presently opened and in Hide mode we can
hide the desired elements from the view for time being.

What is the meaning of true dimension?

True dimension is the dimension desired after the machining. In other words, this is the
value that should be attained after the machining.

What are different conic sections?

Ellipse, Hyperbola and Parabola
 AUTOCAD VIVA QUESTIONS
1. The toolbar at the top of the AutoCAD 2014 window is: [c]
(a) The Draw toolbar
(b) The Modify toolbar
(c) The Standard toolbar
(d) The Properties toolbar

2. The Design Center palette can be opened from the: [d]

(a) Layer toolbar
(b) Properties toolbar
(c) Modify toolbar
(d) Standard toolbar

3. Press the F9 key of the keyboard for: [b]

(a) Grid on/off
(b) Snap on/off
(c) Ortho on/off
(d) Osnapon/off

4. In the coordinate system of AutoCAD 2014: [b]

(a) Positive x figures are to the left
(b) Positive x figures are to the right
(c) Positive x figures are in the direction vertically upwards
(d) Positive x figures are in the direction vertically downwards

5. Drawing templates are held in files with the file extension: [a]
(a) *.dwt
(b) -*.dwg
(c) *.bmp
(d) *.dwr

6. A left-click on a name in a drop-down menu showing three dots (...) appearing after the name means
that: [b]
(a) A command name will appear at the command line
(b) A dialog will appear on screen
(c) A sub-menu will appear
(d) A tool will be activated

7. AutoCAD 2008 can be opened with: [a]

(a) A left-click on the AutoCAD 2014 shortcut icon in the Windows desktop
(b) By typing acad at the keyboard
(c) Automatically when the computer is switched on
(d) By selecting from a list which appears on screen when the computer is switched on.
8. The term dragging means: [c]
(a) Left-click on an item and the item can be moved to another position on screen
(b) Double-click on an item. The item can then be moved to another point on screen;
(c) Holding down the left-hand button of the mouse on an item can be moved to another point on
screen
(d) Press the right-hand button of the mouse. This allows an item to be moved anywhere
on screen.

9. An arrow appearing after a name in a drop-down menu means that: [c]

(a) A command name will appear at the command line
(b) A dialog will appear on screen
(c) A sub-menu will appear
(d) A tool will be activated

10. A tool tip is: [a]

(a) The tool name appearing in a rectangle when the cursor is placed on a tool icon
(b) The name given to a tool
(c) The instruction which appears at the left-hand end of the status bar when a tool is
chosen
(d) A tip which can be read from the Help screen for a tool

11. To call the Line tool from the command line, the following abbreviation can be entered:
[c]
(a) lin
(b) li
(c) l
(d) ln

12. When the F6 key of the keyboard is pressed, the following facility is toggled on/off: [ c ]
(a) Snap
(b) Ortho
(c) DUCS
(d) DYN

13. The key F9 toggles on/off: [a]

(a) Snap
(b) Ortho
(c) Grid
(d) DYN

14. When enteringabsolute coordinate numbers at the command line, the coordinates are
preceded by: [d]
(a) The letter a (b) The symbol @ (c) The letters ab
(d) There is no need to enter anything in front of the coordinate numbers
15. The command line abbreviation for the Circle tool is: [b]
(a) cir
(b) c
(c) ci
(d) cl

16. What are the differences between outlines drawn using the Line tool and those drawn
using the Polyline tool? Outlines from the Line tool form separate objects. Those from the
Polyline tool form single objects.

17. The Arc tool can be called by entering the following abbreviation at the command line:
(a) ar [b]
(b) a
(c) ac;
(d) There is no abbreviation. The name arc must be entered in full

18. The set variable PELLIPSE can be set to either 0 or 1 when it allows the following
actions: [b]
(a) When set to 0 the Edit Polyline tool to be used on ellipses
(b) When set to 1 the Edit Polyline tool to be used on ellipses
(c) When set to 0 it allows ellipses to be drawn with the major axis at any angle
(d) When set to 0 ellipses become polylines

19. When saving an AutoCAD 2014 drawing it is filed with the extension: [b]
(a) *.drw
(b) *.dwg
(c) *.dwt
(d) *dg

20. What is the function of entering command line at the keyboard? [b]
(a) It enables the command line to be used for entering command
(b) It brings back the command palette when it has been hidden
(c) It can only be used when DYN is set on to allow Dynamic Input to work
(d) It places the command palette at the bottom of the screen

21. The Polyline Edit tool can only be used when working with polylines: [b]
(a) True
(b) False

22. What is the purpose of the set variable MIRRTEXT: [a]

(a) To enable text to be mirrored with a drawing, when the Mirror tool is in use
(b) To make sure that text is deleted from drawings when acted upon by the Mirror tool
(c) To show text clearly in drawings acted upon by the Mirror tool
(d) None
23. When using the Rotatetool the angle of rotation is in the following direction: [ b ]
(a) Clockwise
(b) Anticlockwise
(c) The direction in which the cursor is moved
(d) There is no fixed rotation direction

24. When using the Stretch tool: [b]

(a) Circles can be stretched into ellipses
(b) The tool has no effect upon circles
(c) Be careful because circles can be erased
(d) Treat circles like any other part of the drawing being stretched

25. When using the Break tool on circles and/or arcs: [c]
(a) Breaks can be made in any direction
(b) Breaks can only be made in a clockwise direction
(c) Breaks can only be made in an anticlockwise direction
(d) Break cannot be made in circles or arcs

CATIA VIVA QUESTIONS AND ANSWERS

1. What is full form of CATIA?

Ans: It’s Computer Aided Three-Dimensional Interactive Application.
2. Who is developer of CATIA software?
Ans: French Company, Dassault Systems developed CATIA.
3. CATIA is written in which language?
Ans: CATIA is written in C++ programming language.
4. What is default units for Length, Mass, Time in CATIA
Ans: Its mm, kg, sec respectively.
5. What are different conic sections available in CATIA?
Ans: Parabola, Ellipse and Hyperbola.
6. What dimensions are necessary to constraint ellipse?
Ans: Major axis, minor axis and distance from origin are required to fully constrain ellipse.
7. What is thickness of surfaces?
Ans: Thickness of surfaced are tends to zero.
8. What is the file extension of a part file?
Ans: File Extension of Part file is dot CATPart (.CATPart)
9. Which are the Neutral file extensions we can use for the part file?
Ans: IGES/igs, STEP/stp, STL, WRL, etc
10.Can you create a Block using a line/ Is it possible to extrude a Line or Open profile using
PAD.
Ans: Yes, you can create a block using line. When you are extruding a line or any open
profile you can check thick option in Pad feature (to avoid Error message). You can Give
limit one, Limit Two and Thickness one and two. You will get Block from line and thin sheet
from any open profile.
Note: Don’t use this option to create a sheet metal part using part design.
11. What is merging ends in Pad?
Ans: Please refer the following figure-1 for merge ends in pad. Create a hollow block. On
inside surface create an open profile. To extrude an open profile select thick option and it will
extrude by taking the length of curve. When you check merge ends option solid will extend
up to the next wall here it will maintain the tangent continuity.
12. Application of Multi-pad.
Ans: Application of multi pad is to extrude profiles to different height we can use it.
13. How do you create a corner chamfer for a bolt/Nut?
Ans: Using Grove option you can create a corner Chamfer for Bolt.
14. What the difference between Merge Rib ends and Merge ends in Rib option.
Ans: Merge rib ends will extend a solid along center curve up to the solid and merge ends
will extend a solid along profile end points to solid.
15. What are the uses of coupling Curves and Guide curves in Loft/ Multi-section Solid?
Ans: Coupling curves are used to get number of edges on the solid and Guide curves are used
to get the shape to a solid.
16. What are the limiting elements in Multi-section Solid?
Ans: If you are selected N number of profiles in Loft or Multi-section and creating a solid
along a spine or through the guide curves. The Limitations are first and last profile.
17. What is Trim Ribbons in fillet?
Ans: If the fillet materials are over lapping each other to remove that overlapped material
trim ribbons are used OR It will remove the overlapped material in fillet.
18. What is Circle fillet?
Ans: Due to concave and convexity the fillet on the edges ll tries to close or it will expand to
avoid and maintain the parallel on the creating fillet Circle fillet is useful.
19. Can you create a hyperbolic fillet in Catia? If yes How?
Ans: Yes we can create a hyperbolic fillet. By defining the parameter value above 0.5 and
less than 1.0 you will get hyperbolic fillet. If the parameter is 0.5 resulting is parabolic fillet.
If parameter is less than 0.5 and greater than 0.0 you will get Elliptical fillet.
20. Can you create a sheet metal parts in Part design? How
Ans: You can create sheet metal parts in part design by using SHELL option. Here the shell
will be your last feature to complete the model.
21. Can you operate a shell command on Spear?
Ans: Yes
22.Is it possible to give a variable distance for a feature in rectangular pattern?
Ans: Yes we can give a variable distance in Rectangular pattern. Select the option Instances
and Unequal spacing.
23. What is use of keep specification in Patterns?
Ans: Keep specification in the pattern is, it will maintain the same specifications what you
have used for the patterned feature to the entire Duplicate.
24. What are the differences between Mirror and symmetry?
Ans: Differences between mirror and Symmetry
Mirror
Reference will be a plane or any planar surface
Reference may be a Plane, Point or a line
It will create a Duplicate
Symmetry
Original element will be translated to other side of the reference
Can be used for a single or multiple Features
It will consider a current solid in a body
25.Can you use symmetry reference as a point or line
Ans: Yes
26. Can you make symmetry of single feature out of 10 features?
Ans: No
27.What Is remove Lump?
Ans: Remove lump is a only option we can use within a inserted body or in a part body to
remove the unwanted lump.
28. Is there any alternate option for remove lump?
Ans: Alternative option for remove lump is remove faces in Dress-up feature.
29. Is it possible to use pad as alternative for stiffener?
Ans: Yes
30.What is power copy?
Ans: Power copy is a feature using this u can copy a single or multiple features and save it
whenever required you can insert (Similar to Block command in AUTOCAD)
31.What is UFC?
Ans: UFC = User Feature Creation. It’s again similar to Power copy
32.What is the difference between PC & UFC?
Ans: The Difference between Power copy and UFC is. When you insert a power copy you
will get a Feature or sketch what you have copied when you are creating an Independent
feature. But when you insert UFC you will get a user feature and you get get an independent
feature.
33. What is the use of Design table? When you use it.
Ans: Design Table is linking parameters of a model to EXCEL. It’s used for standard parts
like Bush, Steel structures (i.e. I, C and L channels) Nut, bolt, washers, O-Rings and Keys
etc.
34.What is the difference between SEW surface and SPLIT.
Ans: SEW and Split is almost same to split the solid we can use. When you are using a sew
surface if there is a air between the solid and surface it fill with Solid material.
35. Can you create Fillet with 12mm radius for a 10 X 10 X10 cube
Ans: YES use Edges to keep creating 12mm Radius fillet for 10 mm Block?
36. What is blend corner? When you use it.
Ans: If the selected three Edges are meeting at the same point then that point is Blend corner.
It’s used in plastic parts to avoid sharp edges on a solid. By giving a setback distance from
the corner you can stop the fillet and get the blend at the corners.
37. What is use of Spline in multi-section solid?
Ans: Spline in multi-section solid is used to follow solid along the Curve.
38. What is the alternate option for Intersect Boolean operation
Ans: Solid Combine is alternative option for Intersection Boolean operation.
39. How do you create a negative Polarity body in Part design?
Ans: After inserting a new body if you use Negative feature as fist feature in a body the
polarity of the body will be negative. Negative features like Pocket, Groove, and Slot Hole
etc.
 Structural Analysis

Experiment.5
SOLVING STRUCTURAL PROBLEM USING ANSYS
TWO DIMENSIONAL STATIC LINEAR ANALYSIS OF A CANTILEVER BEAM

AIM: Todetermine the stresses acting on a cantilever beam with a point load of 750 N
acting at one of its ends and perpendicular to the axis of the beam.
 Young’s modulus = 2e5
 Poisson’s ratio = 0.3
 Length of the beam = 2 m = 2000 mm
 Breadth of the beam = 80 mm
 Height of the beam = 40 mm
PROCEDURE:

PRE PROCESSING
STEP 1: From the Main menu select preferences
Select structural and press OK
STEP 2: From the main menu select Pre-processor
Element type  Add / edit/Delete  Add  BEAM – 2D Elastic 3  Apply 
Close
Material properties  material models  Structural  Linear  Elastic  Isotropic
EX = 2e5; PRXY = 0.3
STEP 3: From the main menu select Pre-processor
Sections Beam  Common Sections  Select subtype as Rectangular section 
Enter B = 100, H = 50  Apply  Preview
Real constants  Add Add Ok  Geometric Properties  Area = 5000,
Izz = 4170000, Height = 40  Ok  Close
STEP 4: From the main menu select Pre-processor Modeling
 Create the key points in the Workspace
Create  Key points  in active CS
X 0 2000
Y 0 0
 Click APPLY to all the points and for the last point click OK
 Create LINES using the Key points
Create  Lines Lines Straight Line  Click on Key points to generate lines
Select Plot controls from menu bar  Capture image  file save as and save your
file

Figure: Model

STEP 4: Meshing the Geometry

From the main menu select Meshing
Meshing  Size controls  Manual size  Lines  All lines – Number of element
divisions = 20  Click OK
Meshing  Mesh  Lines – pick all
 Fig. MESHED MODEL

Figure: Meshed Model with nodes

SOLUTION PHASE: ASSIGNING LOADS AND SOLVING

STEP 5: From the ANSYS main menu open Solution

Solution  Analysis type  new analysis – Static
STEP 6: Defining loads at the Key points
Solution  Define Loads  Apply  Structural  Displacement  On key points
Left end – ALL DOF arrested
Solution  Define loads  Apply  Structural  Force/moment  On key Points
Right end – Apply a load of FY = -750 N
Select Plot controls from menu bar  Capture image  file save as and save your
file
 Figure: Model with boundary conditions
STEP 7: Solving the system
Solution Solve  Current LS

POSTPROCESSING: VIEWING THE RESULTS

1. Deformation
From the main menu select General post processing
General post processing  Plot Results  Deformed Shape
Select 'Def + undef edge' and click 'OK' to view both the deformed and the
undeformed object.

Figure: Deformed and undeformed Model

 Nodal solution
From the Utility menu select PLOT
PLOT Results Contour plot  Nodal solution – DOF solution – Y component of
displacement – OK
 Figure: Y-Component displacement of the Model
RESULT:

DMX =
SMN =
SMX =

VIVA QUESTIONS
1. If a cantilever beam has a uniformly distributed load, will the bending moment diagram
be quadratic or cubic?
2. Name the element type used for beams?
3. Define Analysis and its Purpose?
4. What are the modules in Ansys Programming?
5. What are the Real Constants & Material Properties in Ansys? Explain?
 2-D STATIC LINEAR ANALYSIS OF A TRUSS STRUCTURE
AIM: To determine the nodal deflections, reaction forces, and stress of the indeterminate
truss system when it is subjected to a load of 2000 N.

APPARATUS:Ansys 12.0
GIVEN DATA:
 Young’s modulus = 2e5
 A = 3250mm2
 Poisson’s ratio = 0.3

PROCEDURE:
PREPROCESSING
STEP 1: From the Main menu select preferences
Select structural and press OK
STEP 2: From the main menu select Preprocessor
Element type  Add / edit/Delete  Add  Link – 2D spar 8  ok close
Real constants  Add  Geometric Properties  Area = 3250
Material properties  material models  Structural  Linear  Elastic  Isotropic
EX = 2e5; PRXY = 0.3
STEP 3: From the main menu select Pre-processor  Modeling
 Create the key points in the Workspace
Pre-processor  Modeling  Create  Nodes  In active CS
X Y Z
0 0 0
5 0 0
10 0 0
15 0 0
2.5 2.5 0
7.5 2.5 0
12.5 2.5 0

Click APPLY to all the points and for the last point click OK

FIG: TRUSS (KEY POINTS MODEL)

 Create LINES using the Elements

Pre-processor  Modeling  Create  Elements  Auto numbered  through

nodes  select node 1&2  apply 2&3  apply3&4  apply1&5
 apply5&2 apply 2&6  apply6&3 apply  3&7  apply  7&4 
apply  5&6  apply 6&7 ok  close

FIG: TRUSS (LINE MODEL)

SOLUTION PHASE: ASSIGNING LOADS AND SOLVING
STEP 5: From the ANSYS main menu open Solution
Solution  Analysis type  new analysis – Static
STEP 6: Defining loads at the Key points
Solution  Define Loads  Apply  Structural  Displacement  On nodes 
select node 1&4 ok  select All DOF  ok
Left end – ALL DOF arrested
Solution  Define loads  Apply  Structural  Force/moment  On nodes
Select node 2&3  ok FY direction  Give force value as 2000 N  ok 
close

Figure: Model with boundary conditions

STEP 7: Solving the system
 Solution Solve  Current LS

POSTPROCESSING: VIEWING THE RESULTS

1. Deformation
From the main menu select General post processing
General post processing  Plot Results  Deformed Shape
Select 'Def + undef edge' and click 'OK' to view both the deformed and the undeformed
object.

Figure: Deformed and undeformed Model

Nodal solution
From the Utility menu select PLOT

PLOT Results Contour plot  Nodal solution  DOF solution  Y component

of displacement  OK

RESULT:
DMX =
SMN =
 Figure: Y-Component displacement of the Model

VIVA QUESTIONS
1. Ansys needs the final element model(FEM) for its final solution.(T/F)
2. Element attributes must be set before meshing the solid model. (T/F)
3. In a plane strain, the strain in the direction of thickness is assumed to be zero.(T/F)
4. The ______ elements are used for in-plane bending problems.
5. Which one of the following elements is required to define the thickness as a real
constant?
a. Beam
b. Shell
c. Solid
d. None
To find the displacement, maximum, minimum stresses induced in a given cantilever
beam and draw the shear force and bending moment diagrams by using ANSYS tool,
also list the results according to the given loads.
10N

5m

Procedure:
Preferences:

Main menu > preferences > check structural

Preprocessor:

1. Main menu > preprocessor > element type > add/edit/delete > Add > select Beam -2D
elastic3 > click ok > close.
2. Main menu > preprocessor > Real constraints > Add/Edit/Delete > Add > Click ok >
Enter the following values Area=1, Area moment of Inertia ( IZZ)=1/12, Height=1, >
click ok > close.
3. Main menu > preprocessor > Material properties > Material model > structural >
linear > elastic > isotropic > enter Ex as 2E5 & PRXY as 0.3 > click ok > close.

4. Main menu > preprocessor > modeling > create > nodes > Inactive CS > (Enter
X<Y<Z location values) as shown in the figure starting from node-1 i.e., 0,0,0 and
10,0,0 thus two nodes are created.
5. Main menu > preprocessor > modeling > create > element > auto numbered > through
nodes (select node by node and middle click ) with this elements are created.

Solution:
1. Solution > define loads > Apply > structural > displacement > pick on nodes (Pick the
node which are to be constrained with direction) > middle click > select DOF or UX
or UY or UZ as required > click ok.
Pick node-1 > middle click > select all DOF since to constrain the beam.

2. Solution > define loads > Apply > structural > force/moment > on nodes > select node
> middle click > select FX and FY or MZ depending on the problem > click ok. In the
above problem load acting downwards i.e. in negative Y-direction at node -2 of about
10N.
General post processor:

1) General post processor > element table > define table > add select by sequence
number > enter SMISC , 2,4,6,8,12 one after the other > click ok > close.
2) General post processor > plot results > deformed shape > click ok.
3) General post processor > plot results > contour plot > nodal solution > click ok.
4) General post processor > plot results > contour plot > element solution > click ok.
5) General post processor > plot results > contour plot > line element results > use the
6) Combination 2,8 for shear force diagram and 6,12 for bending moment diagram.
7) General post processor > plot results > vector plot > predefined > click ok.
8) General post processor > list results > nodal solution > click ok.
9) General post processor > list results > element solution > click ok.

Result: Thus the analysis on the given beam is performed using ANSYS tool, Shear force
,bending moment diagrams are captured and values are noted.

Viva Questions:

1. What is ANSYS?
2. Why ANSYS is used?
3. What is Structural Analysis?
4. What is Thermal Analysis?
5. What is the difference between Structural Analysis and Thermal Analysis?
6. What is node?
7. What is element?
8. What is difference between node and element?
9. What are the minimum requirements to develop a drawing ANSYS?
10. What is general post processor?
To find the displacement, maximum, minimum stresses induced in a given cantilever
beam with uniformly distributed load and point loads and draw the shear force and
bending moment diagrams by using ANSYS tool, also list the results according to the
given loads.

3t 10N/m 2.5t

1m 1.5m 2m 1m

Procedure:
Preferences:

Main menu > preferences > check structural

Preprocessor:

1) Main menu > preprocessor > element type > add/edit/delete > Add > select Beam -2D
elastic3 > click ok > close.
2) Main menu > preprocessor > Real constraints > Add/Edit/Delete > Add > Click ok >
Enter the following values Area=1, Area moment of Inertia ( IZZ)=1/12, Height=1, >
click ok > close.
3) Main menu > preprocessor > Material properties > Material model > structural >
linear > elastic > isotropic > enter Ex as 2E5 & PRXY as 0.3 > click ok > close.

4) Main menu > preprocessor > modeling > create > nodes > Inactive CS > (Enter
X<Y<Z location values) as shown in the figure starting from node-1 i.e., 0,0,0 and
1,0,0, 2.5,0,0, 4.5,0,0, 5,0,0 thus five nodes are created.
5) Main menu > preprocessor > modeling > create > element > auto numbered > through
nodes (select node by node and middle click ) with this elements are created.

Solution:
1. Solution > define loads > Apply > structural > displacement > pick on nodes
(Pick the node which are to be constrained with direction) > middle click >
select DOF or UX or UY or UZ as required > click ok.
Pick node-1 > middle click > select all DOF since to constrain the beam.

2. Solution > define loads > Apply > structural > force/moment > on nodes >
select node > middle click > select FX and FY or MZ depending on the
problem > click ok. In the above problem load acting downwards i.e. in
negative Y-direction at node -2 and 5 of about 3tones and 2.5 tones.
3. Solution > define loads > apply > structural > pressure (applied or uniformly
distributed load) > on beams > select beam middle click(Enter pressure value
at the both ends) i.e., at I & J , enter 1 and 1 > click ok
Solution > solve > click ok.
General post processor:

1. General post processor > element table > define table > add select by sequence
number > enter SMISC , 2,4,6,8,12 one after the other > click ok > close.
2. General post processor > plot results > deformed shape > click ok.
3. General post processor > plot results > contour plot > nodal solution > click
ok.
4. General post processor > plot results > contour plot > element solution > click
ok.
5. General post processor > plot results > contour plot > line element results >
use the
6. Combination 2,8 for shear force diagram and 6,12 for bending moment
diagram.
7. General post processor > plot results > vector plot > predefined > click ok.
8. General post processor > list results > nodal solution > click ok.
9. General post processor > list results > element solution > click ok.

Result: Thus the analysis on the given beam is performed using ANSYS tool, Shear force,
bending moment diagrams are captured and values are noted.

Viva Questions:
1. What is nodal solution?
2. What is pre processor?
3. What is post processor?
4. What is modeling?
5. What type of options we use in preferences?
6. ANSYS is it a tool or software?
7. What is the difference between Animation and Modeling?
8. What is DOF?
9. How to create a Node?
10. How to create an Element?
To find the displacement, maximum, minimum stresses induced in a given cantilever
beam with uniformly distributed load and point loads and draw the shear force and
bending moment diagrams by using ANSYS tool, also list the results according to the
given loads.

400kg 300kg 800kg 500kg

2700kgm

0.5 0.5 0.5 0.5

Procedure:
Preferences:

Main menu > preferences > check structural

Preprocessor:

1. Main menu > preprocessor > element type > add/edit/delete > Add > select
Beam -2D elastic3 > click ok > close.
2. Main menu > preprocessor > Real constraints > Add/Edit/Delete > Add >
Click ok > Enter the following values Area=1, Area moment of Inertia
(IZZ)=1/12, Height=1, > click ok > close.
3. Main menu > preprocessor > Material properties > Material model > structural
> linear > elastic > isotropic > enter Ex as 2E5 & PRXY as 0.3 > click ok >
close.

4. Main menu > preprocessor > modeling > create > nodes > Inactive CS >
(Enter X<Y<Z location values) as shown in the figure starting from node-1
i.e., 0,0,0 and 1,0,0, 0.5,0,0, 1,0,0, 1.5,0,0 , 2,0,0 thus six nodes are created.
5. Main menu > preprocessor > modeling > create > element > auto numbered >
through nodes (select node by node and middle click ) with this elements are
created.

Solution:
1. Solution > define loads > Apply > structural > displacement > pick on nodes
(Pick the node which are to be constrained with direction) > middle click >
select DOF or UX or UY or UZ as required > click ok.
Pick node-1 > middle click > select all DOF since to constrain the beam.
 2. Solution > define loads > Apply > structural > force/moment > on nodes >
select node > middle click > select FX and FY or MZ depending on the
problem > click ok. In the above problem load acting downwards i.e. in
negative Y-direction at node -2 ,3,4,5and 5 of about
400kg.300kg.800kg.500kg and at node-1 a force in MZ direction of about
2700 kgm is acting , pick node-1 > middle click > select MZ > enter value as
2700.

General post processor:

1. General post processor > element table > define table > add select by sequence
number > enter SMISC , 2,4,6,8,12 one after the other > click ok > close.
2. General post processor > plot results > deformed shape > click ok.
3. General post processor > plot results > contour plot > nodal solution > click
ok.
4. General post processor > plot results > contour plot > element solution > click
ok.
5. General post processor > plot results > contour plot > line element results >
use the
6. Combination 2,8 for shear force diagram and 6,12 for bending moment
diagram.
7. General post processor > plot results > vector plot > predefined > click ok.
8. General post processor > list results > nodal solution > click ok.
9. General post processor > list results > element solution > click ok.

Result: Thus the analysis on the given beam is performed using ANSYS tool, Shear
force, bending moment diagrams are captured and values are noted.

Viva Questions:

1. What is steady state Analysis?

2. What is unsteady state Analysis?
3. What are the types of Thermal Analysis?
4. What is task in Thermal Analysis?
5. How to apply loads in Thermal Analysis?
6. How to apply loads in Structural Analysis?
7. What is load?
8. What is structure?
9. What is beam?
10. What is Shear force?
To find the displacement, maximum, minimum stresses induced in a given simply
supported beam and draw the shear force and bending moment diagrams by using
ANSYS tool, also list the results according to the given loads.

4000N 10kN 9kN

1.5m 2.5m 2m 2m

Procedure:
Preferences:

Main menu > preferences > check structural

Preprocessor:

1. Main menu > preprocessor > element type > add/edit/delete > Add > select
Beam -2D elastic3 > click ok > close.
2. Main menu > preprocessor > Real constraints > Add/Edit/Delete > Add >
Click ok > Enter the following values Area=1, Area moment of Inertia
( IZZ)=1/12, Height=1, > click ok > close.
3. Main menu > preprocessor > Material properties > Material model > structural
> linear > elastic > isotropic > enter Ex as 2E5 & PRXY as 0.3 > click ok >
close.

4. Main menu > preprocessor > modeling > create > nodes > Inactive CS >
(Enter X<Y<Z location values) as shown in the figure starting from node-1
i.e., 0,0,0 and 1.5,0,0, 3.5,0,0, 5.5,0,0, 7.5,0,0 , 2,0,0 thus five nodes are
created.
5. Main menu > preprocessor > modeling > create > element > auto numbered >
through nodes (select node by node and middle click ) with this elements are
created.

Solution:
1. Solution > define loads > Apply > structural > displacement > pick on nodes (Pick the
node which are to be constrained with direction) > middle click > select DOF or UX
or UY or UZ as required > click ok
Pick node-1 > middle click > select all DOF since to constrain the beam.

2. Solution > define loads > Apply > structural > force/moment > on nodes > select node
> middle click > select FX and FY or MZ depending on the problem > click ok. In the
above problem load acting downwards i.e. in negative Y-direction at node -2, 3,4 of
about 4KN, 10KN, 7KN.
General post processor:

1. General post processor > element table > define table > add select by sequence
number > enter SMISC , 2,4,6,8,12 one after the other > click ok > close.
2. General post processor > plot results > deformed shape > click ok.
3. General post processor > plot results > contour plot > nodal solution > click ok.
4. General post processor > plot results > contour plot > element solution > click ok.
5. General post processor > plot results > contour plot > line element results > use the
6. Combination 2,8 for shear force diagram and 6,12 for bending moment diagram.
7. General post processor > plot results > vector plot > predefined > click ok.
8. General post processor > list results > nodal solution > click ok.
9. General post processor > list results > element solution > click ok.

Result: Thus the analysis on the given beam is performed using ANSYS tool, Shear
force, bending moment diagrams are captured and values are noted

Viva Questions:

1. What is Bending Moment?

2. What is Cantilever Beam?
3. What is Simply Supported Beam?
4. What are the types of Beams?
5. What are the types of Loads?
6. What is overhanging Beam?
7. What is UDL?
8. What is Work?
9. What are the units for Work?
10. What is General post processor?
Experiment.6 SOLVING THERMAL ANALYSIS PROBLEM USING ANSYS

A steel link, with no internal stresses, is pinned between two solid structures at a reference
temperature of 0 C (273 K). One of the solid structures is heated to a temperature of 75 C
(348 K). As heat is transferred from the solid structure into the link, the link will attemp to
expand. However, since it is pinned this cannot occur and as such, stress is created in the link.
A steady-state solution of the resulting stress will be found to simplify the analysis.

Loads will not be applied to the link, only a temperature change of 75 degrees Celsius. The
link is steel with a modulus of elasticity of 200 GPa, a thermal conductivity of 60.5 W/m*K
and a thermal expansion coefficient of 12e-6 /K.

"A sequentially coupled physics analysis is the combination of analyses from different
engineering disciplines which interact to solve a global engineering problem. For
convenience, the solutions and procedures associated with a particular engineering discipline
[will be referred to as] a physics analysis. When the input of one physics analysis depends on
the results from another analysis, the analyses are coupled."

Thus, each different physics environment must be constructed separately so they can be used
to determine the coupled physics solution. However, it is important to note that a single set of
nodes will exist for the entire model. By creating the geometry in the first physical
environment, and using it with any following coupled environments, the geometry is kept
constant. For our case, we will create the geometry in the Thermal Environment, where the
thermal effects will be applied.

Although the geometry must remain constant, the element types can change. For instance,
thermal elements are required for a thermal analysis while structural elements are required to
determine the stress in the link. It is important to note, however that only certain
combinations of elements can be used for a coupled physics analysis. For a listing, see
Chapter 2 of the ANSYS Coupled-Field Guide located in the help file.
The process requires the user to create all the necessary environments, which are basically the
preprocessing portions for each environment, and write them to memory. Then in the solution
phase they can be combined to solve the coupled analysis.

Thermal Environment - Create Geometry and Define Thermal Properties

1. Give example a Title

Utility Menu > File > Change Title ...

/title, Thermal Stress Example

2. Open preprocessor menu

ANSYS Main Menu > Preprocessor

/PREP7

3. Define Keypoints

Preprocessor > Modeling > Create >Keypoints> In Active CS...

K,#,x,y,z

We are going to define 2 keypoints for this link as given in the following
table:

Keypoint Coordinates (x,y,z)

1 (0,0)
2 (1,0)

4. Create Lines

Preprocessor > Modeling > Create > Lines > Lines > In Active Coord
L,1,2

Create a line joining Keypoints 1 and 2, representing a link 1 meter long.

5. Define the Type of Element

Preprocessor > Element Type > Add/Edit/Delete...

For this problem we will use the LINK33 (Thermal Mass Link 3D conduction)
element. This element is a uniaxial element with the ability to conduct heat
between its nodes.

6. Define Real Constants

Preprocessor > Real Constants... > Add...

 In the 'Real Constants for LINK33' window, enter the following geometric
properties:

i. Cross-sectional area AREA: 4e-4

This defines a beam with a cross-sectional area of 2 cm X 2 cm.

7. Define Element Material Properties

Preprocessor > Material Props > Material Models > Thermal > Conductivity >
Isotropic

In the window that appears, enter the following geometric properties for steel:

i. KXX: 60.5
8. Define Mesh Size

Preprocessor > Meshing > Size Cntrls>ManualSize> Lines > All Lines...

For this example we will use an element edge length of 0.1 meters.

9. Mesh the frame

Preprocessor > Meshing > Mesh > Lines > click 'Pick All'

10. Write Environment

The thermal environment (the geometry and thermal properties) is now fully
described and can be written to memory to be used at a later time.
Preprocessor > Physics > Environment > Write

In the window that appears, enter the TITLE Thermal and click OK.

11. Clear Environment

Preprocessor > Physics > Environment > Clear > OK

 Doing this clears all the information prescribed for the geometry, such as the
element type, material properties, etc. It does not clear the geometry however,
so it can be used in the next stage, which is defining the structural
environment.

Structural Environment - Define Physical Properties

Since the geometry of the problem has already been defined in the previous steps, all that is
required is to detail the structural variables.

1. Switch Element Type

Preprocessor > Element Type > Switch Elem Type

Choose Thermal to Struc from the scoll down list.

This will switch to the complimentary structural element automatically. In this

case it is LINK 8. For more information on this element, see the help file. A
warning saying you should modify the new element as necessary will pop up.
In this case, only the material properties need to be modified as the geometry
is staying the same.

2. Define Element Material Properties

Preprocessor > Material Props > Material Models > Structural > Linear >
Elastic > Isotropic

In the window that appears, enter the following geometric properties for steel:

i. Young's Modulus EX: 200e9

ii. Poisson's Ratio PRXY: 0.3

Preprocessor > Material Props > Material Models > Structural > Thermal
Expansion Coef> Isotropic

iii. ALPX: 12e-6

3. Write Environment

The structural environment is now fully described.

Preprocessor > Physics > Environment > Write

In the window that appears, enter the TITLE Struct

Solution Phase: Assigning Loads and Solving

1. Define Analysis Type

Solution > Analysis Type > New Analysis > Static

ANTYPE,0

2. Read in the Thermal Environment

Solution > Physics > Environment > Read

Choose thermal and click OK.

If the Physics option is not available under Solution, click Unabridged Menu at the
bottom of the Solution menu. This should make it visible.

3. Apply Constraints

Solution > Define Loads > Apply > Thermal > Temperature > On Keypoints

Set the temperature of Keypoint 1, the left-most point, to 348 Kelvin.

4. Solve the System

Solution > Solve > Current LS

SOLVE

5. Close the Solution Menu

Main Menu > Finish

 It is very important to click Finish as it closes that environment and allows a
new one to be opened without contamination. If this is not done, you will get
error messages.

The thermal solution has now been obtained. If you plot the steady-state temperature
on the link, you will see it is a uniform 348 K, as expected. This information is saved
in a file labelled Jobname.rth, were .rth is the thermal results file. Since the jobname
wasn't changed at the beginning of the analysis, this data can be found as file.rth. We
will use these results in determing the structural effects.

6. Read in the Structural Environment

Solution > Physics > Environment > Read

Choose struct and click OK.

7. Apply Constraints

Solution > Define Loads > Apply > Structural > Displacement > On
Keypoints

Fix Keypoint 1 for all DOF's and Keypoint 2 in the UX direction.

8. Include Thermal Effects

Solution > Define Loads > Apply > Structural > Temperature > From
ThermAnaly

As shown below, enter the file name File.rth. This couples the results from the
solution of the thermal environment to the information prescribed in the
structural environment and uses it during the analysis.

9. Define Reference Temperature

Preprocessor > Loads > Define Loads > Settings > Reference Temp

For this example set the reference temperature to 273 degrees Kelvin.
 10. Solve the System

Solution > Solve > Current LS

SOLVE

Postprocessing: Viewing the Results

1. Hand Calculations

Hand calculations were performed to verify the solution found using ANSYS:

As shown, the stress in the link should be a uniform 180 MPa in compression.

2. Get Stress Data

Since the element is only a line, the stress can't be listed in the normal way.
Instead, an element table must be created first.

General Postproc> Element Table > Define Table > Add

Fill in the window as shown below. [CompStr> By Sequence Num> LS >

LS,1
ETABLE,CompStress,LS,1
3. List the Stress Data

General Postproc> Element Table > List Elem Table > COMPSTR > OK
PRETAB,CompStr

The following list should appear. Note the stress in each element: -0.180e9 Pa, or 180
MPa in compression as expected.
 PART-B
CAM LAB EXPERIMENTS

1.Simple turning operation using 1

ACE CNC LATHE & CNC Lathe Machine as per part
1 Metrology instruments for drawing
quality control and 2. Step and taper turning operation 2
inspection using CNC Lathe Machine as per
part drawing
CNC DRILL TAP 1. Linear and circular interpolation 1
MACHINING CENTRE & Operation using CNC Drill Tap
2 Metrology instruments for Machine as per part drawing
quality control and 2. Milling circle using CNC Drill 2

inspection Tap Machine as per part drawing

1.Develop a 3-D model-1(Nut & 1
Bolt) by using 3-D Printer
3 3-D Printer
2. Develop a 3-D model-2(Knuckle 2
joint) by using 3-D Printer
INTRODUCTION TO COMPUTER AIDED MANUFACTURING
1. What is computer aided manufacturing?
Most machines need control systems to operate. There are many kinds of control systems,
for example, manual control, automatic control, computer control or remote control. For
the convenience of mass production, machines need to repeat precise, speedy and
automatic actions continuously. These machines may use mechanical, pneumatic and
electrical systems to control. However, some fixed procedures, changing procedures or
tools may need a lot of time to restore the whole system as technology advances,
electronic and computer technologies have been applied to a lot of production machines to
reduce the production time and increase both the quality and efficiency. So, modern
factories usually use numerical control machines, simply called NC machines. And an NC
machine that comes along with a computer is called a computer control numerical
machine, simply CNC machine. A CNC machine uses digital information to control the
movements of tools and parts, for example, the spinning speed, the cutting speed, the
moving direction of tools etc. So, we can change quickly the production procedures simply
by modifying the information or program in the computer The production method that
requires a computer to control the machines is called a computer aided manufacturing,
simply called CAM. CAM is closely related to the computer-aided design (CAD) because
the output information about the products from the CAD can assist the composing of
production program. Tests and productions can start immediately. This simplifies the
procedures from the designing to manufacturing of the product.
2. The merits of computer numerical controlled (CNC) machine
(i) The computer can design the best tool path, spinning and cutting speeds of tools
according to the information of the product. This can help decrease the cost and time.
(ii) CNC machines usually have automatic changing tools function.
(iii) CNC machines can control precisely the tools movement in any axis, so it can cut
some complicated workpiece efficiently.
(iv) With the use of various input devices and the memories of computer, a CNC machine
can download and modify program efficiently, so the production procedures can be made
quickly. (v) In operating the CNC machine, manual adjustment is not needed. Therefore,
the CNC machine can run at a high speed, and it requires less skillful workers to reduce
the labour cost. (vi) CNC machine uses various designs to produce feedback, and so it can
keep its high reliability and quality, this can help decrease the number of disqualified
 product and the cost of inspection.
3. The restrictions of CNC machine:
(i) The cost of the machine is so high that some small factories may not be able to afford.
(ii) Operators need to be trained to compose computer control program.
(iii) The control system is complicated and sophisticated; therefore the maintenance cost is
high.

CNC LATHE MACHINE

Machine Specifications:
1. Height of centers: 70mm
2. Distance between centers: 310mm
3. Swing over bed: 100 mm
4. Swing over cross slide: 60mm
5. Traverse of cross slide: 55mm

Head Stock:
1. Spindle Taper MT 2
2. Hole through work spindle 16mm
3. Spindle range 50-3200 RPM
4. Output power 0.3 KW
Tail Stock:
1. Spindle Diameter 22mm
2. Spindle Taper MT 2
3. Sleeve stroke 35mm
Feed Rate:
1. Rapid traverse 700mm/min
2. Auto feed rate 1-699mm/min
Main Specifications:
1. Table Size: 420x125mm
2. Max. Job weight: 20Kg.
Axes Travel Ranges:
1. Longitudinal (Table): 200mm
2. Cross (Saddle): 125mm
3. Vertical: (Spindle): 200mm
4. Distance from spindle nose To Table top: 25-225mm
5. Distance from spindle centre line to column: 155mm
6. Spindle Centre to table top (Horizontal mode) 114-314mm
Spindle:
1. Spindle nose: ISO 30
2. Spindle motor: 0.44 KW
3. Speed Range: 200-2000 RPM (Infinitely Variable)
4. Tool change: Manual with CNC prompting
5. No. of tools: 8 No.
6. Axis drive: Through stepper motor 1.8 step angles, on all the 3 axes.
7. Machine weight including CNC system: 200 Kg
8. Overall machine dimensions with control system: 1800x1000x800mm
CNC LATHE
PROGRAMS
STUDY OF “G” CODES AND “M” CODES FOR CNC MACHINE

AIM: To study the “G” codes and “M” codes for the CNC milling machine.
PROGRAMMING CODES:

1. Codes are model and do not have to be repeated in every sequence line.
2. All dimensions are entered as decimals.

G –CODES FOR TURNING MACHINE:

G- To define tool movement for preparatory function.

G 00> Rapid movement
G 01> Linear movement with feed rate
G 02 > Circular interpretation clockwise with feed rate
G 03 > Circular interpretation counterclockwise with feed rate
G 04 > Dwell time in seconds
G 17 > XY plane
G 18 > XZ plane
G 19 > YZ plane
G 20 > Inch mode input (in)
G 21 >multi mode input (mm)
G 28 > return to reference point (home position)
G 40 > tool nose radius compensation cancel
G 41 > tool nose radius compensation left
G 42 > tool nose radius compensation right
G 70 > finishing cycle
G 71 > multiple turning cycle
G 72 > multiple facing cycle
G 74 > deck drilling cycle in z axis
G 75 > grooving cycle in z axis
G 76 > thread cutting cycle
G 90 > turning cycle
G 92 > thread cutting cycle
G 94 > facing cycle
G 98 > feed per minute
G 99 > feed per revolution
M- CODES / MISCELLANEOUS CODES:

M 00 > program stop

M 01 > optional stop
M 02 > program end
M 03 > spindle forward (CW)
M 04 > spindle reverse (CCW)
M 05 > spindle stop
M 06 > tool change
M 08 > coolant ON
M 09 > coolant OFF
M 10 > chuck open
M 11 > chuck close
M 30 > program stop and restart
M 98 > sub program call
M 99 > sub program exit
G- CODES FOR MILLING MACHINES

G 00 > point to point rapid positioning

G 01 > linear interpretation
G 02 > Circular interpretation arc clockwise
G 03 > Circular interpretation arc counterclockwise
G 04 > Dwell time in seconds
G 12 > circular pocketing clockwise
G 13 > circular pocketing anticlockwise
G 15 > polar coordinate system OFF
G 16 > polar coordinate system ON
G 17 > XY plane selection for arc movement
G 18 > XZ plane selection for arc movement
G 19 > YZ plane selection for arc movement
G 20 > selecting inch mode input
G 21 > selecting metric mode input
G 40 > cutter compensation/offset,cancel
G 41 > cutter radius compensation / offset-left
G 42 > cutter radius compensation / offset-right
G 43 > tool length compensation -positive
G 44 > tool length compensation -negative
G 49 > tool length compensation -cancel
G 50 > scaling mode cancel (OFF)
G 51 > scaling mode ON
G 54 > shift of coordinate
G 55 > shift of coordinate
G 56 > shift of coordinate
G 57 > shift of coordinate
G 58 > shift of coordinate
G 59 > shift of coordinate
G 68 > coordinate rotation system ON
G 69 > coordinate rotation system ON
G 70 > Inch programming
G 71 > metric programming
G 80 > drilling cycle
G 81 > fixed cycle no 1 drill, spot drill
G 82 > fixed cycle no 2 drill, counter bore
G 83 > fixed cycle no 3 drill, deep hole
G 84 > tapping cycle
G 85 > fixed cycle no 4 drill, bore
G 86 > boring cycle
G 87 > back boring cycle
G 88 > boring cycle
G 89 > boring cycle
G 90 > absolute dimension input
G 91 > incremental dimension input
G 94 > feed rate selection per min
G 95 > feed rate selection per minute
G 98, 99 > tool return position
G 28 > return to reference point (home position)
G 40 > tool nose radius compensation cancel
G 41 > tool nose radius compensation left
G 42 > tool nose radius compensation right
G 70 > finishing cycle
G 71 > multiple turning cycle
G 72 > multiple facing cycle
G 74 > peck drilling cycle in z axis
G 75 > grooving cycle in z axis
G 76 > thread cutting cycle
G 90 > turning cycle
G 92 > thread cutting cycle
G 94 > facing cycle
G 98 > feed per minute
G 99 > feed per revolution
M- CODES / MISCELLANEOUS CODES:

M 00 > program stop

M 01 > optional program stop
M 02 > program end
M 03 > spindle motor ON and forward direction (CW)
M 04 > spindle motor ON and reverse direction (CCW)
M 05 > spindle stop
M 06 > automatic tool change
M 08 > coolant pump motor ON
M 09 > coolant pump motor OFF
M 21 > mirror image along x axis
M 22 > mirror image along y axis
M 23 > mirror image along z axis
M 30 > program stop and restart
M 98 > sub program call
M 99 > sub program exit

RESULT:Thus the “G” codes and “M” codes for the CNC milling machines were studied.
Viva Question:

1. What is CAM?
2. What is CIM?
3. What is P code?
4. What is G code?
5. What are the advantages using Computer Aided Lathe Machine over Conventional
Lathe?
6. What are the advantages of CAD?
7. What is mean by G21?
8. What is mean by G00?
9. What is mean by G71?
10. What is mean by G98?
 Experiment.1
SIMPLE TURNING OPERATION USING CNC LATHE MACHINE AS PER PART
DRAWING

AIM: To write the part programming and simulation them to the given lathe job.

TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC

2. CNC trainer software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G98

G28 U0 W0

M06 T0101

M03 S1500

G00 X26 Z1

G01 X25 F50

G01 Z-30 F50

G01 X26 F50

G01 Z1 F50

G01 X24 F50

G01 Z-30 F50

G01 X26 F50

G01 Z1 F50

G01 X23 F50

G01 Z-30 F50

G01 X26 F50

G01 Z1 F50

G01 X22 F50

G01 Z-30 F50

G01 X26 F50

G01 Z1 F50

G01 X18 Z0 F50

G03 X22Z-2 R2 F40

G28 U0 W0

M05

M30

RESULT

Thus the part program was written and simulated for given job.
Viva Questions:
1. What is mean by M05?
2. What is mean by U00?
3. What is mean by W00?
4. What is mean by M30?
5. What is N series?
6. What is the difference between Manufacturing and Production?
7. What is Counter?
8. What is ASP?
9. What is F30 command?
10. How you fix the tool?
 Experiment.2
STEP TURNING USING CYCLE G90 BILLET SIZE ø25.4, L=70

AIM: To write the part programming and simulation them to the given lathe job.

TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC

2. CNC trainer software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G98

G28 U0 W0

M06 T0101

M03 S1500

G00 X26 Z1

G90 X25 Z-40 F50

X24

X23

X22

G90 X21 Z-28 F50

X20

X19
X18

X17

X16

G90 X15 Z-10 F50

X14

X13

X12

G28 U0 W0

M05

M30

RESULT

Thus the part program was written and simulated for given job.
Viva Questions:

1. What Lathe you are using?

2. What are the different types of lathes?
3. Why we opt for CNC lathe than for conventional?
4. What is T3 command?
5. What thisG00 X0 Z0 command performs?
6. What is difference between Group technology and FMS?
7. What is computer assisted part programming?
8. What is storage system?
9. What is Production flow analysis?
10. How you fix the work piece?
 Experiment.3
PROFILE TURNING USING MULTIPLE TURNING CYCLE (G71) BILLET SIZE

ø25.4, L=70

AIM: To write the part programming and simulation them to the given lathe job.
TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC

2. CNC trainer software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X26 Z1
G71 U0.5 R1.0
G71 P01 Q02 U0.2 W0.2 F50
N01 G01 X8
G01 Z0
G01 X10 Z-2
G01 X10 Z-12
G02 X15 Z-14.5 R2.5
G01 X15 Z-24.5
G03 X20 Z-27 R2.5
G01 X20 Z-32
N02 G01 X25.4 Z-32
G70 P01 Q02 F40
G28 U0 W0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.4
STEP AND TAPER TURNING OPERATION USING CNC LATHE MACHINE AS
PER PART DRAWING
AIM: To write the part programming and simulation them to the given lathe job

TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC

2. CNC trainer software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G98
G28 U0 W0
M06 T0101
M03 S1500
G00 X26 Z1
G90 X25 Z-35 F50
G90 X24 Z-5 F50
X23
X22
X21
X20
G00 X26 Z-5
G90 X25 Z-15 R0 F50
X25 Z-15 R-0.5 F50
X25 Z-15 R-1.0 F50
X25 Z-15 R-1.5 F50
X25 Z-15 R-2.0 F50
X25 Z-15 R-2.5 F50
G00 X26 Z-20
G90 X25 Z-30 R0 F50
X24 Z-30 R0.5 F50
X23 Z-30 R1.0 F50
X22 Z-30 R1.5 F50
X21 Z-30 R2.0 F50
X20 Z-30 R2.5 F50
G00 X26 Z-30
G90 X24 Z-35 F50
X23
X22
X21
X20
G28 U0 W0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.5
THREAD CUTTING USING BOX CYCLE (G92) BILLET SIZE ø25.4, L=70

AIM: To write the part programming and simulation them to the given lathe job.

TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC

2. CNC trainer software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G98
G28 U0 W0
M06 T0101
M03 S1500
G00 X26 Z1
G90 X25 Z-40 F50
X24
X23
X22
G28 U0 W0
M06 T0202
M03 S300
G00 X26 Z1
G92 X22 Z-20 F2
X21.95
X21.90
X21.85
X21.80
X21.75
X21.70
X21.65
X21.60
X21.55
X21.50
X21.45
X21.40
X21.35
X21.30
X21.25
X21.20
X21.15
X21.10
X21.05
X21
X20.95
X20.90
X20.85
X20.80
X20.75
X20.70
X20.65
X20.60
X20.55
X20.50
X20.45
X20.40
X20.35
X20.30
X20.25
X20.20
X20.15
X20.10
X20.05
X20
X19.95
X19.90
X19.85
X19.80
X19.75
X19.70
X19.65
X19.60
X19.54
G28 U0 W0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 CNC MILLING
PROGRAMS

FEATURES:
Compact machine with heavy milling capabilities
LM guideways for all three axes
BT-30 spindle
12 tool ATC
Chip to Chip time of 2.7/3.5 sec
50/50/40 m/min rapid rate for X,Y and Z axes
Ergonomically designed structure for outstanding dynamic rigidity
Effective chip disposal design

SPECIFICATIONS:
Model Unit DART M

CAPACITY
Table longitudinal travel ( X - Axis) mm 500
Table cross travel ( Y - Axis) mm 400
Headstock travel ( Z - Axis) mm 350
Distance from Spindle nose face to table top mm 220-570

TABLE
Table size mm x mm 800 x 400
Max. load on table kgf 350

SPINDLE
Spindle taper 7 / 24 No. 30
Spindle speed - Std. rpm 80 - 8000
Opt.. rpm 100 -
10000 Spindle power kW 5.5

FEED
Feed rate mm / min 1 - 10000
Rapid traverse - X / Y / Z - Std. Opt m / min 50 / 50 / 40
Guideways Type LM
AUTOMATIC TOOL CHANGER
Tool change system Disc Armless
Tool storage capacity - Std. / Opt. Nos. 12 / 16
Max. tool dia with all pockets full mm 80
Max. tool dia with adjacent pocket empty mm
Max. tool length mm 200
Max. tool weight kgf 2.5
Chip to chip time sec. 2.7 / 3.5
Tool shank type BT - 30 / BBT -
30
CNC System Std/Opt FANUC 0iMate MD / Siemens
828 D
Power supply (Basic Machine) kVA 15
MACHINE WEIGHT - NET Kgf 4200
 Experiment.1
CNC-MILLING RECTANGULAR POCKETING

AIM:To perform a rectangular milling operation by using CNC milling programming codes.

TOOLS AND EQUIPMENTS

1. CNC machine
2. Personal computer
3. CNC software

PROGRAM:

M 03 S 1500
G21 G98
G00 X0 Y0 Z5
G00 X10 Y10 Z5 F120
G01 X60 Y10 Z-3 F120
G01 X60 Y60 Z-3 F120
G01 X10 Y60 Z-3 F120
G01 X10 Y10 Z-3 F120
G00 X0 Y0 Z5
M05 M30

RESULT:

Thus the rectangular milling operations by using CNC milling programming codes
were performed
 Experiment.2
LINEAR AND CIRCULAR INTERPOLATION OPERATION USING CNC DRILL
TAP MACHINE AS PER PART DRAWING

LINEAR AND CIRCULAR INTERPOLATION BILLET SIZE (100X100X10, Z=-10)

AIM: To write the part programming and simulation them to the given milling job.

TOOLS AND EQUIPMENTS

1. CNC simulation software
2. CNC milling software
3. Software Pentium IV

PROCEDURE
1. To write the program for given job.
2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G94
G91
G28 Z0
G28 X0 Y0
M06 T1
M03 S1500
G90
G00 X30 Y20
G00 Z5
G01 Z-0.5 F30
G01 X70 Y20 F50
G03 X80 Y30 R10 F50
G01 X80 Y70 F50
G01 X70 Y80 F50
G01 X30 Y80 F50
G02 X20 Y70 R10
G01 X20 Y30 F50
G01 X30 Y20 F50
G01 Z5 F50
G91
G28 Z0
G28 X0 Y0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.3
CIRCULAR INTERPOLATION CCW

AIM: To write the part programming and simulation them to the given milling job.

TOOLS AND EQUIPMENTS

1. CNC simulation software

2. CNC milling software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G94
G91
G28 Z0
G28 X0 Y0
M06 T1
M03 S1500
G90
G00 X30 Y20
G00 Z5
G01 Z-0.5 F30
G01 X70 Y20 F50
G03 X80 Y30 R10 F50
G01 X80 Y70 F50
G03 X70 Y80 R10 F50
G01 X30 Y80 F50
G03 X20 Y70 R10 F50
G01 X20 Y30 F50
G03 X30 Y20 R10 F50
G91
G28 Z0
G28 X0 Y0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.4
CIRCULAR INTERPOLATION-CW

AIM:To write the part programming and simulation them to the given milling job.

TOOLS AND EQUIPMENTS

1. CNC simulation software

2. CNC milling software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G94
G91
G28 Z0
G28 X0 Y0
M06 T1
M03 S1500
G90
G00 X30 Y20
G00 Z5
G01 Z-0.5 F30
G01 X70 Y20 F50
G02 X80 Y30 R10 F50
G01 X80 Y70 F50
G02 X70 Y80 R10 F50
G01 X30 Y80 F50
G02 X20 Y70 R10 F50
G01 X20 Y30 F50
G02 X30 Y20 R10 F50
G91
G28 Z0
G28 X0 Y0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.5
LINEAR INTERPOLATION
BILLET SIZE (100X100X10, Z= -10)

AIM: To write the part programming and simulation them to the given milling job.

TOOLS AND EQUIPMENTS

1. CNC simulation software

2. CNC milling software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.
PROGRAM
G21 G94
G91
G28 Z0
G28 X0 Y0
M06 T1
M03 S1500
G90
G00 X20 Y20
G00 Z5
G01 Z-0.5 F30
G01 X80 Y20 F50
G01 X80 Y80 F50
G01 X20 Y80 F50
G01 X20 Y20 F50
G91
G28 Z0
G28 X0 Y0
M05
M30
RESULT

Thus the part program was written and simulated for given job.
 Experiment.6
MILLING CIRCLE USING CNC DRILL TAP MACHINE AS PER PART DRAWING

MILLING CIRCLE
BILLET SIZE (100X100X10, Z=-10)
AIM: To write the part programming and simulation them to the given milling job.

TOOLS AND EQUIPMENTS

1. CNC simulation software

2. CNC milling software
3. Software Pentium IV

PROCEDURE

1. To write the program for given job.

2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM

G21 G94
G91
G28 Z0
G28 Y0 X0
M06 T1
M03 S1500
G90
G00 X25 Y50 Z5
G01 Z-1 F100
G02 X25 I25
G00 Z5
G91
G28 Z0 Y0 X0
M05
M30

RESULT

Thus the part program was written and simulated for given job.
 Experiment.7
Develop a 3-D model-1(Nut &Bolt) by using 3-D Printer

As per the given parameters the models have to develop by using 3-D Printer.

Develop the bolt and nut as per given dimensions by using AUTO CAD/CATIA.
Save the model in stl file or format.
Import the file from stl to qura 3 D software.
Generate the G-Code for the imported model.
To copy the G-Code program in memory card
Switch on the 3-D printer machine.
Set the build plates in 3-D Printing machine.
Print the G-Code program.

Result: The given model has been developed in 3-D printer build plates.
 Experiment.8

DEVELOP A 3-D MODEL-2(KNUCKLE JOINT) BY USING 3-D PRINTER

As per the given parameters the models have to develop by using 3-D Printer.

Develop the bolt and nut as per given dimensions by using AUTO CAD/CATIA.
Save the model in stl file or format.
Import the file from stl to qura 3 D software.
Generate the G-Code for the imported model.
To copy the G-Code program in memory card
Switch on the 3-D printer machine.
Set the build plates in 3-D Printing machine.
Print the G-Code program.

Result: The given model has been developed in 3-D printer build plates.
 PROGRAM OUTCOMES (POs):
Engineering Graduates will be able to:
PO1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
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 design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
PO4. Conduct 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 societal, 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 and receive
clear instructions.
PO11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management 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 preparation and ability to
engage in independent and life-long learning in the broadest context of technological change.
The following are the program Specific outcomes:
PROGRAM SPECIFIC OUTCOMES (PSOs):
PSO1. To solve complex mechanical engineering problems which enables students
employable in reputed industries or self-entrepreneurs.

PSO2. To develop the new products/systems in collaboration with research & development
centres and to continue higher education.