MT8711 COMPUTER AIDED

DESIGN AND COMPUTER AIDED

MANUFACTURING LABORATORY

Name of the Student :……………………………….

Register Number :……………………………….

Year /Semester /Section :………………………………

Branch :……………………………….

DEPARTMENT OF MECHATRONICS ENGINEERING

Register No

BONAFIDECERTIFICATE

Certified that this is the bonafide record of work done by

Mr./Ms.………………………………………………………of……semester
B.E.…………………………Engineering in the
……………………………………………
Laboratory during the academic year …………………………

Staff in-Charge Head of the Department

Submitted for the University Practical Examination held on…………………………

Internal Examiner External Examiner

Date: ……………. Date: ……………...

CONTENT:

SIGNATURE
EXP. DATE OF THE DATE OF
TITLE OF THE
NUMBER EXPERIMENT COMPLETION
FACULTY
1. Modelling of a part

2. Modelling of a component.
Modelling and assembling of
3.
Screw jack
Modelling and assembling of
4.
stuffing box assembly.
Modelling and assembling of
5.
knuckle joint
Force and stress analysis using
6. link elements in trusses and
cables
Force and stress analysis using
7. link elements in trusses and
cables
Stress and deflection analysis in
8.
cantilever beam

9. Stress analysis of flat plates

10. Thermal analysis

11. Vibration or modal analysis

Modelling and tool path

12.
simulation.

Modelling and tool path

13.
simulation

14. NC code generation for milling

15. NC code generation for turning

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CONTENT BEYOND THE SYLLABUS

EXP. DATE OF THE DATE OF SIGNATURE OF

TITLE
NUMBER EXPERIMENT COMPLETION THE FACULTY
1. Study of Tool and materials

2. Study of Tool holders

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 `

4
EX NO : 1
MODELLING OF A PART

AIM:
To draw the detail view of the part model using CATIA V5 R20.0.
COMMANDS USED:
Sketch, Pad,Shaft,Pattern, Mate,Align, Helical sweep,Round,Chamfer etc.

PROCEDURE :

PART DRAWING:
1. To open the new part file in CATIA V5 R 20.
2. To draw the sketch for the base feature by using profile tool and operation tools.
3. To convert the base sketch into base feature by the use of required sketch base features tools.
4. To create Boolean features by using the required sketch tools (Profile, Operation and Constraint
tool) and Part modeling tool ( Sketch based features, Dress-up features, transformation features).
5. To save the part file in separate file name.
DETAILED VIEW:
1. To create the new drafting file.
2. To create the drawing view of the above model using view tool.
3. To insert the dimensions of the view using dimension tool.
4. To insert the annotations of the view by using the annotation tool.
5. To Save the drawing file.
6. To print the output file as per the required view and scale using printer/plotter.

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INFERENCE :

RESULT :

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 EX NO : 2
MODELLING OF A COMPONENT

AIM:
To draw the detail view of the Component using CATIA V5 R20.0.
COMMANDS USED :
Sketch, pad, shaft, pattern, mate, align, helical sweep, round, chamfer etc.

PROCEDURE :
PART DRAWING:
1. To open the new part file in CATIA V5 R 20.
2. To draw the sketch for the base feature by using profile tool and operation tools.
3. To convert the base sketch into base feature by the use of required sketch base features tools.
4. To create Boolean features by using the required sketch tools (Profile, Operation and Constraint
tool) and Part modeling tool ( Sketch based features, Dress-up features, transformation
features).
5. To save the part file in separate file name.
DETAILED VIEW:
6. To create the new drafting file.
7. To create the drawing view of the above model using view tool.
8. To insert the dimensions of the view using dimension tool.
9. To insert the annotations of the view by using the annotation tool.
10. To save the drawing file.
11. To print the output file as per the required view and scale using printer/plotter.

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INFERENCE :

RESULT :

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EX NO : 3
MODELLING AND ASSEMBLING OF THE SCREW JACK

AIM:
To draw the detail of the screw jack and assemble the parts by using the CATIA V5 R 20.0

COMMANDS USED:
Sketch,pad,shaft,pattern,mate,align,helical sweep,round,chamfer,etc.

PROCEDURE:
PART DRAWING:
SCREW JACK BODY:
1. Draw the sectional view of the screw gauge in sketcher mode.
2. Draw the middle axis line for the purpose of using shaft command and make the screw gauge.
3. Make the keyway and holes by using pad material remove command.
4. Round the sharp edges of the screw gauge by using round tool command.
SHAFT AND KEY:
1. Use the pad command to make the shaft and the keyway.
2. Use pad command to make the key.
BOLT AND NUT:
1. Use the pad command makes the bolt head and shank of the bolt.
2. Use the helical sweep command makes the thread in bolt shank .
3. Use the pad and helical sweep command make the nut with thread.
ASSEMBLY:
1. Use the mate, align , insert, and pattern commands to assemble the screw gauge coupling .

DETAILED DRAWING:
1. Use the drawing mode makes the respective views and bill of materials.

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INFERENCE :

RESULT:

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 EX NO : 4
MODELLING AND ASSEMBLING OF THE STUFFING BOX

AIM:
To draw the detail view of the stuffing box and assemble the parts by using the Catia software and
obtain its respective views.

COMMANDS USED:
sketch, pad, shaft,mate,align, helical sweep,round,chamfer etc.

PROCEDURE:

PART DRAWING:
CYLINDER:
Using pad, cut, round commands the cylinder has been drawn.
NUT:
Using pad, cut, 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 DETAILING DRAWING:

Using the assembly and drawing mode to make the respective views and bill of materials.

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INFERENCE :

RESULT:

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 EX NO :5 MODELLING AND ASSEMBLING OF THE KNUCKLE
JOINT

AIM:
1.To draw the detail view of the knuckle joint and assemble the parts by using the CATIA V5
R20.0 software and obtain its respective views.
2. To find the mass properties of the final assembly.
COMMANDS USED:
Sketch, pad ,shaft, pattern ,mate, align ,helical sweep,round,chamfer etc.
PROCEDURE:
PART DRAWING:
KNUCKLE JOINT.
1. Draw the sectional view of the knuckle joint in the sketcher mode.
2. Draw the middle axis line for the purpose of using shaft command and make the screw gauge.
3. Make the keyway and holes by using pad material remove command.
4. Round the sharp edges of the screw knuckle joint by round tool command.
SHAFT AND KEY:
1. Use pad command to make the shaft and the keyway.
2. Use pad command to make the key.
BOLT AND NUT:
1. Use the pad command makes the bolt head and shank of the bolt.
2. Use the helical sweep command makes the thread in bolt shank.
3. Use the pad and helical sweep command make the nut with thread.
ASSEMBLY:
1. Use the mate,align,insert,and pattern commands to assemble the knuckle joint coupling .
DETAILED DRAWING:
2. Use the drawing mode makes the respective views and bill of materials.

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INFERENCE :

RESULT:

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 TRUSS
2
E = 210 GPa, A = 0.1 m

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EX.NO: 6 FORCE AND STRESS ANALYSIS USING LINK ELEMENTS
IN TRUSSES AND CABLES

AIM :
To conduct the force and stress analysis using link elements in trusses and cables using ANSYS
software.

SYSTEM CONFIGURATION
Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)

PROCEDURE:
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.

PREPROCESSING

1. File – clear and start new – do not read file – ok – yes.

2. Ansys Main Menu – Preferences select – STRUCTURAL - ok
3. Element type – Add/Edit/Delete – Add – Link – 2D spar 1 – ok – close.
4. Real constants – Add – ok – real constant set no – 1 – c/s area – 0.1 – ok – close.
5. Material Properties – material models – Structural – Linear – Elastic – Isotropic – EX –
210e9 – ok – close.
6. Modeling – Create – Nodes – In Active CS – Apply (first node is created) – x,y,z location
in CS– 4 (x value w.r.t first node) – apply (second node is created) – x,y,z location in CS – 4, 3
(x, y value w.r.t first node) – apply (third node is created) – 0, 3 (x, y value w.r.t first node) – ok
(forth node is created).
7. Create – Elements – Elem Attributes – Material number – 1 – Real constant set number – 1
– ok Auto numbered – Thru Nodes – pick 1 & 2 – apply – pick 2 & 3 – apply – pick 3 & 1 –
apply – pick 3 & 4 – ok (elements are created through nodes).
8. Loads – Define loads – apply – Structural – Displacement – on Nodes – pick node 1 & 4 –
apply– DOFs to be constrained – All DOF – ok – on Nodes – pick node 2 – apply – DOFs to be
constrained – UY – ok.
9. Loads – Define loads – apply – Structural – Force/Moment – on Nodes- pick node 2 – apply
– direction of For/Mom – FX – Force/Moment value – 2000 (+ve value) – ok – Structural –
Force/Moment – on Nodes- pick node 3 – apply – direction of For/Mom – FY – Force/Moment
value – -2500 (-ve value) – ok.

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SOLUTION

11. Solve – current LS – ok (Solution is done is displayed) – close.

GENERAL POST PROCESSOR
12. Element table – Define table – Add – ‘Results data item’ – By Sequence num – LS – LS1 –
ok.
13. Plot Results – Deformed Shape – def+undeformed – ok. Plot results – contour plot – Line
Element Results – Elem table item at node I – LS1 – Elem table item at node J – LS1 – ok (Line
Stress diagram will be displayed).
14. Plot results – contour plot – Nodal solution – DOF solution – displacement vector sum – ok.
List Results – reaction solution – items to be listed – All items – ok (reaction forces will be
displayed with the node numbers). List Results – Nodal loads – items to be listed – All items –
ok (Nodal loads will be displayed with the node numbers)
15. PlotCtrls – Animate – Deformed shape – def+undeformed-ok

INFERENCE :

RESULT

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Rectangular c/s area of 0.2 m * 0.3 m, Young’s modulus of 210 GPa, Poisson’s ratio 0.27.

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EX.NO: 7 STRESS AND DEFLECTION ANALYSIS IN SIMPLY
SUPPORTED BEAM

AIM :
To conduct the stress and deflection analysis in Simply supported beam using ANSYS software.

SYSTEM CONFIGURATION
Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)

PROCEDURE:
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.
PREPROCESSING
1. Preference - Structural- h-Method - Ok.
2. Element type – Add/Edit/Delete – Add – BEAM – 2D elastic 3 – ok- close
3. Real constants – Add – ok – real constant set no – 1 – c/s area – 0.2*0.3 moment of inertia
0.2*0.3**3/12 – total beam height – 0.3 – ok
4. Material Properties – material models – Structural – Linear – Elastic – Isotropic – EX –
210e9 – PRXY – 0.27 – ok – close.
5. Modeling – Create – Nodes – In Active CS – Apply (first node is created) – x,y,z location
in CS – 2 (x value w.r.t first node) – apply (second node is created) – 4 (x value w.r.t first node)
– ok (third node is created). Create – Elements – Auto numbered – Thru Nodes – pick 1 & 2
apply – pick 2 & 3 – ok (elements are created through nodes).
6. Loads – Define loads – apply – Structural – Displacement – on Nodes- pick node 1 & 3 –
apply – DOFs to be constrained – UY – ok. Loads – Define loads – apply – Structural –
Force/Moment – on Nodes- pick node 2 – apply – direction of For/Mom – FY – Force/Moment
value – -20000 (-ve value) – ok.

Rectangular c/s area of 100 mm * 100mm, Young’s modulus of210 MPa, Poisson’s ratio 0.27.

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SOLUTION

1. Solve – Current LS – Ok – Solution is done – Close.

GENERAL POST PROCESSOR

2. Plot Results – Deformed Shape – def+undeformed – ok.

3. Plot Results – Contour plot – Nodal solu – DOF solution – displacement vector sum – ok.
Element table – Define table – Add – ‘Results data item’ – By Sequence num – SMISC –
SMISC, 2 – apply, By Sequence num – SMISC – SMISC, 8 – apply, By Sequence num –
SMISC – SMISC, 6 – apply, By Sequence num – SMISC – SMISC, 12 – ok – close.

4. List Results – reaction solution – items to be listed – All items – ok (reaction forces will be
displayed with the node numbers). List Results – Nodal loads – items to be listed – All items –
ok (Nodal loads will be displayed with the node numbers).

5. PlotCtrls – Animate – Deformed results – DOF solution – USUM – ok.

INFERENCE :

RESULT

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Rectangular c/s area of 0.2 m * 0.3 m, Young’s modulus of 210 GPa, Poisson’s ratio 0.27.

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EX.NO: 8 STRESS AND DEFLECTION ANALYSIS IN CANTILEVER
BEAM

AIM :
To conduct the stress and deflection analysis in cantilever beam using ANSYS software.

SYSTEM CONFIGURATION
Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)

PROCEDURE:
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.

PREPROCESSING
1. Preference - Structural- h-Method - Ok.
2. Element type – Add/Edit/Delete – Add – BEAM – 2D elastic 3 – ok- close.
3. Real constants – Add – ok – real constant set no – 1 – c/s area – 0.2*0.3 moment of inertia
–0.2*0.3**3/12 – total beam height – 0.3 – ok.
4. Material Properties – material models – Structural – Linear – Elastic – Isotropic – EX –
210e9 – PRXY – 0.27 –ok – close.
5. Modeling – Create – Nodes – In Active CS – Apply (first node is created) – x,y,z location
in CS – 5 (x value w.r.t first node) – ok (second node is created). Create – Elements – Auto
numbered – Thru Nodes – pick 1 & 2 – ok (elements are created through nodes).
6. Loads – Define loads – apply – Structural – Displacement – on Nodes- pick node 1 – apply
– DOFs to be constrained – ALL DOF – ok Loads – Define loads – apply – Structural –
Force/Moment – on Nodes- pick node 2 – apply – direction of For/Mom – FY – Force/Moment
value - -10000 (-ve value) – ok.

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SOLUTION

7. Solve – Current LS – Ok – Solution is done – Close.

GENERAL POST PROCESSING

8. Plot Results – Deformed Shape – def+undeformed – ok. Plot Results – Contour plot – Nodal
solu – DOF solution – displacement vector sum – ok. Element table – Define table – Add –
‘Results data item’ – By Sequence num – SMISC – SMISC, 2 – apply, By Sequence num –
SMISC – SMISC, 8 – apply, By Sequence num – SMISC – SMISC, 6 – apply, By Sequence
num – SMISC – SMISC, 12 – ok – close.

9. Plot results – contour plot – Line Element Results – Elem table item at node I – SMIS2 – Elem
table item at node J – SMIS8 – ok (Shear force diagram will be displayed). Plot results –
contour plot – Line Element Results – Elem table item at node I – SMIS6 – Elem table item at
node J – SMIS12 – ok (bending moment diagram will be displayed).

10. List Results – reaction solution – items to be listed – All items – ok (reaction forces will be
displayed with the node numbers) List Results – Nodal loads – items to be listed – All items –
ok (Nodal loads will be displayed with the node numbers).

11. PlotCtrls – Animate – Deformed results – DOF solution – USUM – ok.

INFERENCE :

RESULT:

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Young’s Modulus = 200 GPa
Poisson’s Ratio = 0.3

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EX.NO:9
STRESS ANALYSIS OF FLAT PLATES

AIM :
To conduct the stress analysis in a plate with a circular hole using ANSYS software.
SYSTEM CONFIGURATION
Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)

PROCEDURE:
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing

Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.

PREPROCESSING

1. Preference - Structural- h-Method - Ok.

2. Preprocessor - Element type - Add/Edit/Delete – Add – Solid, 8 node 82 – Ok – Option –
Choose Plane stress w/thk - Close.
3. Real constants - Add/Edit/Delete – Add – Ok – THK 0.5 – Ok - Close.
4. Material props - Material Models – Structural – Linear – Elastic – Isotropic - EX 2e5,
PRXY 0.3 - Ok.
5. Modeling – Create – Areas – Rectangle - by 2 corner - X=0, Y=0, Width=100, Height=50 -
Ok. Circle - Solid circle - X=50, Y=25, Radius=10 - Ok. Operate – Booleans – Subtract – Areas
- Select the larger area (rectangle) – Ok – Ok - Select Circle – Next –Ok - Ok.
6. Meshing - Mesh Tool – Area – Set - Select the object – Ok - Element edge length 2/3/4/5 –
Ok - Mesh Tool -Select TRI or QUAD - Free/Mapped – Mesh - Select the object - Ok.

SOLUTION

1. Solution – Define Loads – Apply – Structural – Displacement - On lines - Select the boundary
where is going to be arrested – Ok - All DOF - Ok. Pressure - On lines - Select the load
applying area – Ok - Load PRES valve = 1 N/mm2- Ok.

2. Solve – Current LS – Ok – Solution is done – Close.

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POST PROCESSING

1. General post proc – Read results – First set - Plot results – Deformed shape – Choose
Def+undeformed – Ok.Read results – Next set - Plot results – Deformed shape – Choose
Def+undeformed – Ok and so on.

FOR REPORT GENERATION

File – Report Generator – Choose Append – OK – Image Capture – Ok - Close. (Capture all
images)

INFERENCE :

RESULT:

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EX.NO: 10
THERMAL STRESS AND HEAT TRANSFER ANALYSIS OF
PLATES

AIM :

To conduct the Thermal stress and heat transfer analysis of plates by using ANSYS software.

SYSTEM CONFIGURATION

Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)

PROCEDURE:
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.

PREPROCESSING

1. Preference – Thermal - h-Method - Ok.

2. Preprocessor - Element type - Add/Edit/Delete – Add – Solid, Quad 4 node 55 – Ok – Close –
Options – plane thickness – Ok.
3. Real constants - Add/Edit/Delete – Add – Ok – THK 0.5 – Ok – Close.
4. Material props - Material Models –Thermal – Conductivity – Isotropic – KXX 10 – Ok.
5. Modeling – Create – Areas - Rectangle – by 2 corners – Enter the coordinate values, width -
Ok.
6. Meshing – Mesh tool – Areas, set – select the object – Ok – Element edge length 0.05 - Ok –
Mesh tool- Tri, free - mesh – Select the object –Ok.
SOLUTION

7. Solution – Define Loads – Apply – Thermal – Temperature - On lines – Select the right
and left side of the object –Ok – Temp. Value 100 – On lines – select the top and bottom of the
object – Ok –Temp 500 – Ok.
8. Solve – Current LS – Ok – Solution is done – Close.

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POST PROCESSING

1. General post proc – Plot results – Contour plot – Nodal solution – DOF solution – Nodal
Temperature – Ok.

FOR REPORT GENERATION

File – Report Generator – Choose Append – OK – Image Capture – Ok - Close.

INFERENCE :

RESULT:

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 3
Modulus of elasticity = 200GPa, Density = 7800 Kg/m

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EX.NO: 11
MODAL ANALYSIS OF BEAMS

AIM :

To conduct the Modal Analysis of beams by using ANSYS software.

SYSTEM CONFIGURATION

Ram : 2 GB
Processor : Core 2 Quad / Core 2 Duo
Operating system: Window XP Service Pack 3
Software : ANSYS (Version12.0/12.1)
`
PROCEDURE:

The three main steps to be involved are

1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 12.0/12.1 - Mechanical APDL Product Launcher – Set the Working
Directory as E Drive, User - Job Name as Roll No., Ex. No. – Click Run.

PREPROCESSING

1. Preference – structural - h-Method - Ok.

2. Element type – Add/Edit/Delete – Add – BEAM – 2D elastic 3 – ok- close.
3. Real constants – Add – ok – real constant set no – 1 – c/s area – 0.01*0.01 moment of inertia –
0.01*0.01**3/12 – total beam height – 0.01 – ok.
4. Material Properties – material models – Structural – Linear – Elastic – Isotropic – EX –
200e9– PRXY – 0.27 – Density – 7800 – ok – close.
5. Modeling – Create – Keypoints – in Active CS – x,y,z locations – 0,0 – apply – x,y,z locations
– 1,0 – ok (Keypoints created). Create – Lines – lines – in Active Coord – pick keypoints 1 and
2 – ok.
6. Meshing – Size Cntrls – ManualSize – Lines – All Lines – element edge length – 0.1 – ok.
Mesh – Lines – Pick All – ok.

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SOLUTION

7. Solution – Analysis Type – New Analysis – Modal – ok.

8. Solution – Analysis Type – Subspace – Analysis options – no of modes to extract – 5 – no of

modes to expand – 5 – ok – (use default values) – ok.

9. Solution – Define Loads – Apply – Structural – Displacement – On Keypoints – Pick first

keypoint – apply – DOFs to be constrained – ALL DOF – ok. Solve – current LS – ok (Solution
is done is displayed) – close.

10 Solve – Current LS – Ok – solution is done – Close.

GENERAL POST PROCESSOR:

11. Read Results – First Set. Plot Results – Deformed Shape – def+undeformed – ok.
PlotCtrls – Animate – Deformed shape – def+undeformed-ok.

12. Read Results – Next Set. Plot Results – Deformed Shape – def+undeformed – ok. PlotCtrls –
Animate – Deformed shape – def+undeformed-ok.

INFERENCE :

RESULT:

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EX.NO: 12 MODELLING AND TOOL PATH SIMULATION USING
MASTER CAM (MILLING) OR ANY CAM PACKAGE

AIM:
To determine the modeling and tool path simulation for milling operation using cad/cam software.
TOOL REQUIRED:
Processor i5
RAM 8GB
Operating system 64 bit
Windows service pack 1
SOFTWARES REQUIRED:
NX CAD/CAM
PROCEDURE :
Modelling :
1. File → new → manufacturing → milling → ok.
2. Sketch → click → XY plane → click OK → Orientation view →by right click on mouse
(long press) → profile →draw the sketch as per the dimension for step milling.
3. Revolve → specify vector →choose X axis → ok
4. Sketch → choose bottom face of the component → ok → orientation view → draw circle
on the face → extrude the circle → reverse direction →Boolean none → ok ctrl
+J → part → ok → increase translucency to 50 → ok.
Manufacturing :
1 File →New → manufacturing → milling → ok.
2 Right click on the operation navigator → select geometric view → click(+)symbol on
→ mcs spindle → double click work piece →specify part which is to turned → click
ok
3 Specify blank → select the outer cylinder → select ok
4 Again click (+) symbol in work piece → select milling work piece select milling work piece
→ Ok

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 5. Create tool → type (milling exp) → choose od 80 → ok → bring tool to the centreplane
→ click ok.

6. Create operation → milling exp → operation subtype → rough turn od

program(nc program ) → tool (od 80 l ) → geometry (milling work piece) →method
(lathe finish) → ok
7. Generate → tool path → last loop position → ok.
8. Verify → choose (3d dynamics) → reduce the animation speed → play.

INFERENCE :

Result :

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EX.NO: 13 MODELLING AND TOOL PATH SIMULATION USING
MASTER CAM (TURING) OR NX CAM PACKAGE

AIM:
To determine the modelling and toolpath simulation for milling operation using cad/cam software.

TOOL REQUIRED:
Processor i5
RAM 8GB
Operating system 64 bit
Windows service pack 1

SOFTWARES REQUIRED:
NX CAD/CAM

PROCEDURE :
Modelling :
1. File →New → Manufacturing → turning → ok.
Sketch → click → XY plane → click OK → Orientation view → by right click on mouse
(long press) → profile → draw the sketch as per the dimension for step turning.
2. Revolve → specify vector → choose X axis → ok
3. Sketch → choose bottom face of the component → ok → orientation view →
draw circle on the face → extrude the circle → reverse direction → Boolean → none
→ ok → ctrl +J → part → ok → increase translucency to 50 → ok.
Manufacturing :
1 File →New → Manufacturing → turning → ok.
2 Right click on the operation navigator → select geometric view → click(+)symbol on
mcs spindle → double click work piece → specify part which is to turned → click ok
3 Specify blank → select the outer cylinder → select ok
4 Again click(+) symbol in work piece → select turning work piece select turning work piece
→ Double click turning work piece → Ok.
4. Create tool → type (turning exp) → choose( od 80 l)→ ok → bring tool to the centreplane
→ click ok.

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 5. Create operation → turning exp → operation subtype →rough turn od → program(nc
program ) → tool (od 80 l ) → geometry (turning work piece) → method (lathe finish)
→ ok
6. Generate → tool path → last loop position → ok.
7. Verify → choose (3d dynamics) → reduce the animation speed → play.

INFERENCE :

Result :

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EX.NO: 14
NC CODE GENERATION FOR MILLING

AIM:
To determine the modelling and toolpath simulation for milling operation using cad/cam software.
TOOL REQUIRED:
Processor i5
RAM 8GB
Operating system 64 bit
Windows service pack 1
SOFTWARES REQUIRED:
NX CAD/CAM
Procedure :
Modelling :
1. File → new → manufacturing → milling → ok.
2. Sketch → click → XY plane → click OK → Orientation view →by right click on mouse
(long press) → profile →draw the sketch as per the dimension for step milling.
3. Revolve → specify vector →choose X axis → ok
4. Sketch → choose bottom face of the component → ok → orientation view → draw circle
on the face → extrude the circle → reverse direction →Boolean none → ok ctrl
+J → part → ok → increase translucency to 50 → ok.
Manufacturing :
1. File →New → manufacturing → milling → ok.
2. Right click on the operation navigator → select geometric view →
click(+)symbol on → mcs spindle → double click work piece →specify part
which is to turned → click ok
3. Specify blank → select the outer cylinder → select ok
4. Again click (+) symbol in work piece → select milling work piece select milling work
piece → Ok
5. Create tool → type (milling exp) → choose od 80 → ok → bring tool to the
centreplane → click ok.

6. Create operation → milling exp → operation subtype → rough turn od

program(nc program ) → tool (od 80 l ) → geometry (milling work piece) →method
(lathe finish) → ok
7. Generate → tool path → last loop position → ok.
8. Verify → choose (3d dynamics) → reduce the animation speed → play.

59
% N0510 X-1.4176 Y-1.563
N0010 G40 G17 G90 G70 N0520 Z.4724
N0020 G91 G28 Z0.0 N0530 G01 Z.3543
N0030 T00 M06 N0540 Y-1.4893
N0040 G00 G90 X1.9182 Y1.563 S0 M03 N0550 X-1.5129 Y-1.4646
N0050 G43 Z.7874 H00 N0560 X-1.9199 Y-1.3591
N0060 Z.4724 N0570 G02 X-2.0551 Y-1.3055 I.1482 J.5717
N0070 G01 Z.3543 F9.8 M08 N0580 G01 X-2.1535 Y-1.2516
N0080 X1.9767 Y1.4642 N0590 Z.4724
N0090 G02 X2.0396 Y1.331 I-.6775 J-.4012 N0600 G00 Z.7874
N0100 X2.0551 Y1.3252 I-.268 J-.7404 N0610 X-1.0254 Y-1.563
N0110 G01 X2.1535 Y1.2872 N0620 Z.4724
N0120 Z.4724 N0630 G01 Z.3543
N0130 G00 Z.7874 N0640 Y-1.4893
N0140 X1.7885 Y1.563 N0650 X-1.1207 Y-1.4646
N0150 Z.4724 N0660 X-1.8952 Y-1.2638
N0160 G01 Z.3543 N0670 G02 X-2.0551 Y-1.1897 I.1235 J.4764
N0170 X1.8591 Y1.4646 N0680 G01 X-2.1535 Y-1.1203
N0180 G02 X1.9615 Y1.2529 I-.5598 J-.4016 N0690 Z.4724
N0190 X2.0551 Y1.2185 I-.1899 J-.6623 N0700 G00 Z.7874
N0200 G01 X2.1535 Y1.1741 N0710 X2.1535 Y-1.2341
N0210 Z.4724 N0720 Z.4724
N0220 G00 Z.7874 N0730 G01 Z.3543
N0230 X1.6409 Y1.563 N0740 X2.0551 Y-1.3362
N0240 Z.4724 N0750 G02 X1.7717 Y-1.4567 I-.2835 J.2732
N0250 G01 Z.3543 N0760 G01 X-.7087
N0260 X1.7322 Y1.4646 N0770 G02 X-.8075 Y-1.4441 I0.0 J.3937
N0270 G02 X1.8798 Y1.1711 I-.433 J-.4016 N0780 G01 X-1.8705 Y-1.1685
N0280 X2.0551 Y1.1086 I-.1081 J-.5806 N0790 G02 X-2.0551 Y-1.0606 I.0988 J.3811
N0290 G01 X2.1535 Y1.0548 N0800 G01 X-2.1535 Y-.9585
N0300 Z.4724 N0810 Z.4724
N0310 G00 Z.7874 N0820 G00 Z.7874
N0320 X1.4447 Y1.563 N0830 X2.1535 Y-1.0512
N0330 Z.4724 N0840 Z.4724
N0340 G01 Z.3543 N0850 G01 Z.3543
N0350 X1.5837 Y1.4646 N0860 X2.0827
N0360 G02 X1.791 Y1.0823 I-.2845 J-.4016 N0870 X2.0551 Y-1.1457
N0370 X2.0551 Y.9928 I-.0193 J-.4917 N0880 G02 X1.7717 Y-1.3583 I-.2835 J.0827
N0380 G01 X2.1535 Y.9235 N0890 G01 X-.7087
N0390 Z.4724 N0900 G02 X-.7828 Y-1.3488 I0.0 J.2953
N0400 G00 Z.7874 N0910 G01 X-1.8458 Y-1.0732
N0410 X-1.8098 Y-1.563 N0920 G02 X-2.0551 Y-.8701 I.0741 J.2858
N0420 Z.4724 N0930 G01 X-2.0827 Y-.7756
N0430 G01 Z.3543 N0940 X-2.1535
N0440 Y-1.4893 N0950 Z.4724
N0450 X-1.9051 Y-1.4646 N0960 X2.1535
N0460 X-1.9446 Y-1.4543 N0970 Z.315
N0470 G02 X-2.0441 Y-1.4202 I.1729 J.6669 N0980 G00 Z.7874
N0480 G01 X-2.1535 Y-1.3731 N0990 M02
N0490 Z.4724 %
N0500 G00 Z.7874

60
INFERENCE :

RESULT :

61
62
EX.NO: 15
NC CODE GENERATION FOR TURNING

AIM:
To determine the modelling and toolpath simulation for milling operation using cad/cam software.
TOOL REQUIRED:
Processor i5
RAM 8GB
Operating system 64 bit
Windows service pack 1

SOFTWARES REQUIRED:
NX CAD/CAM
PROCEDURE :
Modelling :
1. File →New → Manufacturing → turning → ok.
Sketch → click → XY plane → click OK → Orientation view → by right click on mouse
(long press) → profile → draw the sketch as per the dimension for step turning.
2. Revolve → specify vector → choose X axis → ok
3. Sketch → choose bottom face of the component → ok → orientation view →
draw circle on the face → extrude the circle → reverse direction → Boolean →
none → ok → ctrl +J → part → ok → increase translucency to 50 →
ok.
Manufacturing :
1. File →New → Manufacturing → turning → ok.
2. Right click on the operation navigator → select geometric view → click(+)symbol on
mcs spindle → double click work piece → specify part which is to turned → click ok
3. Specify blank → select the outer cylinder → select ok
4. Again click (+) symbol in work piece → select turning work piece select turning work
piece → Double click turning work piece → Ok.
5. Create tool → type (turning exp) → choose( od 80 l)→ ok → bring tool to the
centreplane → click ok.
6. Create operation → turning exp → operation subtype →rough turn od → program(nc
program ) → tool (od 80 l ) → geometry (turning work piece) → method (lathe
finish) → ok
7. Generate → tool path → last loop position → ok.
8. Verify → choose (3d dynamics) → reduce the animation speed → play.

63
% N0510 X-1.4176 Y-1.563
N0010 G40 G17 G90 G70 N0520 Z.4724
N0020 G91 G28 Z0.0 N0530 G01 Z.3543
N0030 T00 M06 N0540 Y-1.4893
N0040 G00 G90 X1.9182 Y1.563 S0 M03 N0550 X-1.5129 Y-1.4646
N0050 G43 Z.7874 H00 N0560 X-1.9199 Y-1.3591
N0060 Z.4724 N0570 G02 X-2.0551 Y-1.3055 I.1482 J.5717
N0070 G01 Z.3543 F9.8 M08 N0580 G01 X-2.1535 Y-1.2516
N0080 X1.9767 Y1.4642 N0590 Z.4724
N0090 G02 X2.0396 Y1.331 I-.6775 J-.4012 N0600 G00 Z.7874
N0100 X2.0551 Y1.3252 I-.268 J-.7404 N0610 X-1.0254 Y-1.563
N0110 G01 X2.1535 Y1.2872 N0620 Z.4724
N0120 Z.4724 N0630 G01 Z.3543
N0130 G00 Z.7874 N0640 Y-1.4893
N0140 X1.7885 Y1.563 N0650 X-1.1207 Y-1.4646
N0150 Z.4724 N0660 X-1.8952 Y-1.2638
N0160 G01 Z.3543 N0670 G02 X-2.0551 Y-1.1897 I.1235 J.4764
N0170 X1.8591 Y1.4646 N0680 G01 X-2.1535 Y-1.1203
N0180 G02 X1.9615 Y1.2529 I-.5598 J-.4016 N0690 Z.4724
N0190 X2.0551 Y1.2185 I-.1899 J-.6623 N0700 G00 Z.7874
N0200 G01 X2.1535 Y1.1741 N0710 X2.1535 Y-1.2341
N0210 Z.4724 N0720 Z.4724
N0220 G00 Z.7874 N0730 G01 Z.3543
N0230 X1.6409 Y1.563 N0740 X2.0551 Y-1.3362
N0240 Z.4724 N0750 G02 X1.7717 Y-1.4567 I-.2835 J.2732
N0250 G01 Z.3543 N0760 G01 X-.7087
N0260 X1.7322 Y1.4646 N0770 G02 X-.8075 Y-1.4441 I0.0 J.3937
N0270 G02 X1.8798 Y1.1711 I-.433 J-.4016 N0780 G01 X-1.8705 Y-1.1685
N0280 X2.0551 Y1.1086 I-.1081 J-.5806 N0790 G02 X-2.0551 Y-1.0606 I.0988 J.3811
N0290 G01 X2.1535 Y1.0548 N0800 G01 X-2.1535 Y-.9585
N0300 Z.4724 N0810 Z.4724
N0310 G00 Z.7874 N0820 G00 Z.7874
N0320 X1.4447 Y1.563 N0830 X2.1535 Y-1.0512
N0330 Z.4724 N0840 Z.4724
N0340 G01 Z.3543 N0850 G01 Z.3543
N0350 X1.5837 Y1.4646 N0860 X2.0827
N0360 G02 X1.791 Y1.0823 I-.2845 J-.4016 N0870 X2.0551 Y-1.1457
N0370 X2.0551 Y.9928 I-.0193 J-.4917 N0880 G02 X1.7717 Y-1.3583 I-.2835 J.0827
N0380 G01 X2.1535 Y.9235 N0890 G01 X-.7087
N0390 Z.4724 N0900 G02 X-.7828 Y-1.3488 I0.0 J.2953
N0400 G00 Z.7874 N0910 G01 X-1.8458 Y-1.0732
N0410 X-1.8098 Y-1.563 N0920 G02 X-2.0551 Y-.8701 I.0741 J.2858
N0420 Z.4724 N0930 G01 X-2.0827 Y-.7756
N0430 G01 Z.3543 N0940 X-2.1535
N0440 Y-1.4893 N0950 G00 Z.7874
N0450 X-1.9051 Y-1.4646 N0960 Y1.2903
N0460 X-1.9446 Y-1.4543 N0970 Z.315
N0470 G02 X-2.0441 Y-1.4202 I.1729 J.6669 N0980 G00 Z.7874
N0480 G01 X-2.1535 Y-1.3731 N0990 M02
N0490 Z.4724 %
N0500 G00 Z.7874

64
INFERENCE :

RESULT :

65
66
CONTENT BEYOND THE SYLLABUS

67
68
EX.NO: 1
STUDY OF TOOLS AND MATERIALS

Aim:
To study about the tools and materials which are used for different machining process.

Theory:
The variety of cutting tools available for modern CNC milling centers makes it imperative for
machine operators to be familiar with different types of milling cutters and how they are
applied to everyday milling processes.

This course curriculum contains 16-hours of material for instructors to get their students
ready to identify different types of milling cutters and their uses.
Introduction

Milling produces 3-dimensional shapes with a rotating multi-edge cutting tool. The cutting
tool can be programmed to move against a fixed workpiece in almost any direction. Milling
tools remove material by their movement in the machine and from their shape.

Audience
This class is intended for entry-level milling operators and students in a milling operator
training program who have a basic understanding of milling machines and their operation. This
lesson is also useful to anyone interested in the metalworking industry who wants to gain
knowledge about material removal in CNC machining.

Purpose
Learn how to visually identify the types of cutting tools most commonly used in CNC milling
operations and how those tools are used in everyday milling processes. Students are introduced
to tools for milling and hole making operations, and common tool holder configurations.
Students finish with an introduction to the concepts of spindle speeds and feed rates.

Lesson Objectives
At the end of this lesson, you will know how to:
Identify common types of tools for milling
Identify common types of tools for drilling and
threading Identify basic tool holders for milling
Identify the main groups of cutting tool materials and
coatings Understand the applications for common milling
tools
Understand the difference between cut speed and feed rate
Understand the difference between Revolutions Per Minute (RPM) and Surface
69
 Feet per Minute (SPM)
Understand the difference between Inches per Minute (IPM) and Inches per Tooth
(IPT)
Anatomy of a Milling Tool

Milling is done using a cylindrical milling tool mounted in a milling tool holder that is
then mounted in the tool spindle on the machine.

End Mills
End mills are the most common milling cutters. End mills are available in a wide variety
of lengths, diameters, and types.

A square end mill is used for most general milling applications. It produces a sharp edge at the
bottom of pockets and slots.

70
End mills can be center cutting and non-center cutting. As their name implies, center cutting
end mills have cutting edges on both the end face of the cutter and the sides. Center cutting
end mills are essential for plunge milling.

Non-center cutting end mills have cutting edges only on the sides and are used only for side
milling. These tools are identified by a small hole at the center.

Roughing end mills have serrations in the teeth to quickly remove large amounts of material
without creating vibration. The serrations produce many small chips and a rough finish.

71
Ball end mills produce a radius at the bottom of pockets and slots. Ball end mills are used for
contour milling, shallow slotting, contour milling and pocketing applications.

Flutes
Spiral-shaped cutting edges are cut into the side of the end mill to provide a path for chips to
escape when an end mill is down in a slot or a pocket.

The most common options are 2, 3, or 4 flutes. The more flutes, the more cutting edges but the
narrower the channel for chip evacuation.

An important consideration when choosing the number of flutes is called “chip load”.

“Chip load” is a measurement of the thickness of material removed by each cutting edge during
a cut.

The number of flutes you choose depends on the material you want to cut and the capabilities
of your machine.

72
A material like aluminum produces large chips compared to other materials. For that reason, 4
flute end mills are rarely used with aluminum because the flutes can get jammed with chips and
break the cutter.

For harder materials, you want to use more flutes. Having more flutes reduces chip load and
improves surface finish.

While the number, direction and type of flutes that a cutting tool has can vary widely, the tools
most commonly used have two flutes and are up-cut spirals to move the chips up out of the cut.

Two Flute: Has the greatest amount of flute space, allowing for more chip carrying
capacity in softer materials. Used primarily in slotting and pocketing of non-ferrous
materials like aluminum where chip removal is a concern.
Three Flute: Allows for better part finish in harder materials. The three flutes
provide for greater strength and the ability to pocket and slot both ferrous and non-
ferrous materials.
Four Flute/Multiple Flute: Ideal for finish milling. The extra flutes allow for faster
feed rates to produce a much finer finish than two or three flute tools. However, the
reduced flute space may cause problems with chip removal.

The most common flute numbers for general milling operations are two (better space for chip
ejection) and four (better surface finish).
Applications for End Mills
End Mill Materials
End mills are made out of either cobalt steel alloys (known as high speed steel, or HSS), or from
tungsten carbide in a cobalt lattice (shortened to "carbide").

High Speed Steel (HSS): Provides good wear resistance and costs less than cobalt or
carbide end mills. HSS is used for general purpose milling of both ferrous and non-
ferrous materials. While usually inexpensive, HSS does not offer the tool life or speed
advantages of cobalt and carbide end mills.
Cobalt: Cobalt is an M42 tool steel with an 8% cobalt content. Cobalt is more expensive
but provides better wear resistance and toughness than HSS (M7). Because the tool can
run 10% faster than HSS, metal removal rates and finish are better than HSS.
Solid Carbide: Carbide is considerably harder, more rigid, and more wear resistant than
HSS. However, carbide is brittle and tends to chip instead of wear. Carbide is used
primarily in finishing applications. Carbide tools are best suited for shops operating
newer milling machines or machines with minimal spindle wear. Rigidity is critical
when using carbide tools. Carbide end mills may require a premium price over the
cobalt end mills, but they can also be run at speeds 2 1/2 times faster than HSS end
mills.

The choice of tool material depends on the material to be cut as well as on the maximum spindle
speed of the machine. Smaller milling machines may not be capable of reaching

73
the spindle speeds recommended for carbide end mills.

End Mill Coatings

The use of coatings will increase the surface hardness of the tool. This will allow for greater tool
life and faster cutting speed.

Standard coatings include Titanium Nitride (TiN), Titanium Carbonitride (TiCN), and
Aluminum Titanium Nitride (AlTiN).

Long-life TiN (titanium nitride) coating is good for use on alloy steel, aluminum, and
plastic. Color is gold.

Extra-life TiCN (titanium carbonitride) coating has better wear resistance than TiN coating,
making it a good choice for tough-to-machine materials such as ductile cast iron, stainless steel,
aluminum, and plastic. Color is blue-gray.

Super-life AlTiN (aluminum titanium nitride) coating is the best for very high feeds/speeds and
high-temperature applications. Use to mill cast iron, stainless steel, nickel-based alloys, and
titanium. Not for use on aluminum. Color is purple-gray.

The choice to use coated end mills is a cost versus benefit choice. If your machining benefits
enough from the extra performance of a premium coating, purchase end mills with a coating.

Face Mills and Indexable End Mills

Face mills are tools with a large diameter that are used to cut a wide shallow path for facing
operations. Facing is used for machining a large flat area, typically the top of the part in
preparation for other milling operations.

A face mill is a solid body that holds multiple carbide inserts that can be replaced as they wear
out. The more inserts, the faster the metal removal rate.
Cutters with a 45 lead angle are used most frequently.

74
Square shoulder (90 ) and round insert cutters are also used for certain conditions.

Indexable end mills also use replaceable carbide inserts. Indexable end mills are convenient for
efficient roughing and to save costs on the larger sizes of solid end mills. Indexable end mills
are typically used to rough the part, which is then finished with a solid end mill.

Drills, Taps and Reamers

High Speed Steel (HSS) tools such as drills, taps and reamers are commonly used on CNC
machining centers for hole making operations.
Twist Drills
Holes are by far the most common feature in CNC machining. The material removal rate of twist
drills is outstanding, and usually better than equivalent sized end mills. Twist drills come in
many more diameters and sizes than end mills. It often makes sense to drill the ends of a slot and
then machine out the web between the holes with an end mill.

Twist drills have a conical cutting point at the tip of a cylindrical shaft that has one or more
helical flutes. The flutes are designed to evacuate chips out of the hole being drilled. Twist drills
are available in a variety of sizes, lengths, materials and coatings, but the most common are
High Speed Steel (HSS) and solid carbide.

75
Tool coatings have an influence on the cutting process by increasing cutting speed and tool life.
Coatings such as titanium nitride (TiN) increase the initial cost but reduce wear and increase tool
life. Applied as a thin coating, TiN is used to harden and protect cutting surfaces.

Twist drills coated with titanium nitride (TiN) are easily identified by a gold like color.
This coating increases the hardness of the bit and adds a self-lubricating property.

Indexable Drills
Considering how often holes are made and the advantages of indexable tooling for end and
face milling, indexable drills are also available. These are generally best used for larger holes.

Spot Drills and Center Drills

These two are special purpose drills with very short flutes.
Spot drills are designed to be extremely rigid so that they can precisely spot a hole for a twist
drill. The goal is use the spot drill to make a little dimple in the workpiece that keeps the twist
drill from walking so that the hole winds up in the right place.

Center drills are intended to be used to create a 60 center in the end of lathe stock. They have a
2-part tip that has a small pilot as well as the larger countersinking area of the bit. In theory,
there is no reason to use a Center Drill on a mill. Their secondary "pilot" tip makes them more
delicate than spot drills. However, many machinists will grab one anyway if it is handy and use
it as they would a spot drill.

76
If you use a carbide drill, spotting is typically not needed. The carbide itself is so rigid compared
to HSS that the drill will go where it is pointed.

Reamers
Reamers are used to enlarge an existing hole to a precise tolerance and to add a high quality
surface finish. Reamers require a hole be drilled first that is fairly close to the final size so that
the reamer actually removes relatively little material. Reamers ensure a hole has an accurate
diameter, roundness, and good surface finish.

Taps
Taps are used to cut internal threads of a specific size and pitch. Like reamers, a tap requires a
hole be drilled first to the size of the minor diameter.

Not all threads are made by cutting the material. There are two major categories of taps: Roll
Form and Cut Taps. Unlike thread cutting, a Roll Form tap does not produce any chips. Instead
of cutting, the tap is forced into the hole and the material is deformed into the required thread
form. This process creates stronger threads and reduces manufacturing time.

Forming taps must be applied in materials that cold form well. This includes steels, stainless
steels, light metals, and light metal alloys. Generally, materials that produce a continuous chip
when drilling are good candidates for thread forming.

Result:

77
78
EX.NO: 2
STUDY OF TOOL HOLDERS

Aim:
To Study about the tool holders,Chucks,Drill chucks, collet,feed and speed parameters
during machining.

Theory:
Tool Holders
Tool holders are used to adapt tools of different shapes and sizes accurately and securely to a
milling machine spindle. Shanks are shaped to fit various standard machine tapers such as R8,
NT 40, CAT 40, and BT 40.

Pull studs (retention knobs) are threaded into the tapered end of the tool holder so the holder
can seat securely in the CNC machine.

The successful application of milling depends on how well the tool is supported by the tool
holder. To achieve best results an end mill must be mounted concentric in a tool holder.
End Mill Holders
A solid end mill holder consists of a precision bored hole and a set screw. An end mill that has a

79
shank with a Weldon flat is slid into the holder and then secured by the set screw from the side.
The set screw clamps down on the Weldon flat, providing a strong grip with a slight loss in
concentricity.

Solid end mill holders are often preferred for roughing and heavy duty milling because of their
secure holding ability.

ER Collet Chuck
An ER collet chuck consists of a collet nut, a collet, and a tapered socket. Collet chucks have
high accuracy and a wide range of gripping sizes, allowing the chuck to hold many different
sizes and types of tools.

Collet chucks are often preferred for finishing because of their accuracy and versatility. Collet
chucks have less holding security than solid end mill holders.

Milling Chuck
Milling chucks have a greater gripping power than traditional collet chucks and are more rigid
and accurate. Milling chucks are preferred for larger milling tools and high-speed applications

80
Drill Chuck
Drill chucks are convenient and versatile for general hole drilling. ER collet chucks can also be
used to hold drills that do not need to be switched out often.

Hydraulic Holders and Shrink Fit Holders

These two are specialty holders for high-speed applications.

Hydraulic holders use fluid to center and compress the tool with uniform pressure, allowing for
outstanding concentricity and rigidity of the tool during machining.

Shrink fit holders use thermal expansion to center the tool. The diameter of the bored hole is
intentionally undersized so that it can expand sufficiently to accommodate the tool after it is
heated in an induction heater. Cooling of the holder then creates the clamp when the metal
contracts.

Feeds and Speeds

Feeds and speeds refer to two separate velocities for machine tools: feed rate and cutting
speed. They are used together because of their combined effect on the cutting process.
Cut speed is the speed at the outside edge of the milling cutter as it is rotating
Feed rate is the velocity at which the cutter is advanced along the workpiece; its vector is
perpendicular to the vector of cutting speed
Cutting Speed
Cutting speed is a velocity unit expressed in terms of revolutions per minute or surface feet per
minute. This is the speed that the cutting edge moves past the material.
81
Revolutions Per Minute (RPM) relates directly to the speed, or velocity, of the tool spindle. It
annotates the number of turns completed in one minute around a fixed axis. RPM maintains
the same revolutions per minute throughout the entire operation.

Surface Feet Per Minute (SFM) is a combination of the tool diameter and RPM. The faster the
spindle turns, and/or the larger the tool diameter, the higher the SFM. If two cutters of different
sizes are rotating at the same revolutions per minute, the cutter with the larger diameter results
in a greater cutting speed because it has a larger circumference and has more surface area.

Materials will run better at specific SFMs. SFM is a constant, with RPM as a variable based
upon tool diameter.

When the SFM constant is known for a specific material, the formulas below can be used to
determine spindle speed for milling various materials.

RPM = SFM x (12/Pi) / Tool Diameter

So, for an SFM of 400 and a tool diameter of 1/2", RPM can be found:
RPM = 400 x 3.82 / 0.5 = 3056 RPM
The calculation of SFM is the opposite:
SFM = RPM x Tool Diameter x Pi/12
For example, if you have a 1/2” tool and a spindle speed of 3056 RPM, then:
SFM = 3056 x 0.5 x .262 = 400

Feed Rate
Feed rate is the velocity at which the cutter is advanced along the workpiece. Feed rate is
expressed as units of distance per minute or distance per tooth (chip load).

Feed rate can be defined as Inches Per Minute (IPM) or Inches Per Tooth (IPT). IPT, or chip
load, is more commonly used.
Values for IPM and IPT are easily converted with the following formulas:
IPM = RPM x IPT x Number of Flutes
IPT = IPM / RPM / Number of Flutes

So, for a spindle speed of 3056 RPM and a feed rate of .005 IPT with a 2 flute cutter, the
IPM can be calculated as follows:
IPM = 3056 x .005 x 2 = 30 IPM
Selection of Tools, Feeds, and Speeds
Cutting tool selection has a direct impact on the proper programming of feeds and speeds at
the machine.
82
However, many other variables that affect feeds and speeds are:
Workpiece material class and condition
Workpiece diameter
Cutter material
Cutter geometry
Type of cut
Depth of cut

Condition of the machine

Cutting tool manufacturers publish the general feeds and speeds and recommended usage for
the application. Cutting tool manufacturers are often a good place to start for recommendations
on tool selection and feeds/speeds since they rely on customer loyalty. The customer (or
potential) should select a cutter and cutter material based on the vendor’s recommendation.

Result:

83