CAD CAM CIM Lab Manual

Swami Vivekanand College of Engineering, Indore
Department of Mechanical Engineering
Session: July- Dec 2021
LAB MANUAL
VII SEMESTER
CAD/CAM/CIM & ME-704
Submitted to Submitted by
Name:
Roll No:
65
Department’s Vision and Mission -
Vision: To develop technically sound human resources of high quality in Mechanical Engineering who
can contribute to the technological and socioeconomic development of the nation constructively.
Mission:
M1. Quality Education: to prepare liable graduates having sound technical knowledge and problem
solving ability, by continuously improving educational methods in academic programme.
M2. Innovation: prepare graduates to fulfil the desired needs of industry by inculcating creative thinking
and competitive spirit in all activities.
M3. Research: develop collaborative environment with the industries to promote research.
M4. Entrepreneurship: to develop the spirit of taking calculated risk for generating self-employment
among graduates.
M5. Value: prepare graduates having moral values for the growth of the society.
Program Outcomes:
PO1.(a) Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering problems.
PO2.(b) Problem analysis: Identify, formulate, research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and
engineering sciences.
PO3.(c)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.(d) 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.(e) 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.(f) 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.(g) 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.
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PO8.(h) Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
PO9.(i) Individual and team work: Function effectively as an individual, and as a member or leader in
diverse teams, and in multidisciplinary settings.
PO10.(j) 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.(k) 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.(l) 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.
Course Learning Objectives (CLO)

The Learning Objectives of Basic Mechanical Engineering are such that the student will
CLO1: Understand 2D and 3D modeling and CAD software.
CLO2: Understand the CAM software for writing CNC programs.
CLO3: Study and understand Production & layout for GT for group of jobs to be manufactured
CLO4: Understand basic concepts of CAPP
CLO5: Understand basics of Robotics.
Course Outcomes (CO)
At the end of the course, student would be able to
CO1: Know the 2D and 3D modeling and CAD software.
CO2: Practical exposure to CNC programming.
CO3: Know how to use CAM software..
CO4: Know different types of plant layout and Group Technology..
CO5: Know the basics of CAPP.
CO6: Know the basics of Robotics.
Program Specific Outcome
PSO – 1: Ability to Develop and implement new ideas on product design and development with the help
of modern computer aided tools, while ensuring best manufacturing practices.
PSO – 2: Ability to apply engineering knowledge and design & analysis tools to solve problems in the
domains of structural, thermal and fluid mechanics.
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PSO - 3:Engage professionally in industries or as an entrepreneur by applying manufacturing and
management practices.
Swami Vivekanand College of Engineering
INDEX
Student Practical Evaluation Sheet
Marks
Date of Date of Signature
S. Obtained Signature
Name of Experiment Experime Submissi of
No. nt on LW(10 PQ (10 of Faculty
Student
marks) marks)
1. Introduction of CAD
Study of CNC Machine.
2
Writing part program
for given lathe
machine
3 operation using
M and G codes.
Study of different
4 types of plant layout.
Study of computer aided

5 process planning
system.
Study of basic robotic
co-ordinate
6 configurations, types of
grippers and sensors.
Total marks obtained
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Experiment No. 1
AIM: Introduction of CAD
COMPUTER AIDED DESIGN (CAD)-It is also known as computer aided design and drafting .it is
used computer technology for the process of design and design documentation CAD describes the
process of drafting with computer software environment provide the uses of with input tool for the
purpose of stream design process drafting documentation and manufacturing process environment after
in value more than fast shapes in manual drafting of technical arousing the output of cad must convey
information such as material process dimension and tolerance.
Geometric Modeling: Geometric Modeling is branch of applied mathematics and computational

geometry that studies methods and algorithms for the mathematical description of the shapes of
geometries modeling are mostly two dimensional and three dimensional,2D models are important in
typography and technical drawing and 3 D models
1.2D =Two dimensional representation is use for a flat objects.
2.21/2 D=It is better than tow dimensional capabilities by presenting a 3 D object to be represented as
long as is has no side wall details thus allows for full 3 D modeling of a mash complex geometry.
3. 3 D= It is the 3 D picture of real objects.
There are 3 types of modeling
(1).Wire frame modeling.
(2).Surface modeling.
(3).Solid modeling.
(1).Wire frame modeling:It is the simplest type of three modes these are generated by continuous
segment the point and line generated and then translation,rotation and scaling is carried out. The wire
frame models define the edge and surface of3 D object.
 Stores positions of lines (in 2D or 3D)

 Helpful for drafting (easy multiple views and easy editing)
 Ambiguous surfaces limit the automation possibilities(e.g. no volume calculation, no NC tool
path generation)
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(2).Surface modelingIn the surface technique the arc created by use of surface attached to wire frame
construction. The surface are useful for prevent mass flow and allows storage of quantities because of
hollow use of object.
 Stores equations of surfaces

 Most 3D graphics libraries use surface modeling
 Good for visualizing complex surfaces and automated NC path generation of complex surfaces
 Material volume information is ambiguous or hard to determine (therefore can’t calculate
volume)
(3).Solid modelingIn solid modeling the cube is represented by the volume is easy to represent object it
is the process of creating.Object which is similar to actual solid object
 Various mathematical representations exist that each allow point-set classification:

 Solid models can be used for: volume calculations, Automatic FE mesh generation, Collision
determination
Different ways that a user can create solid shapes:

 Primitive creation
 Boolean operations
 Sweep operations
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 Surface operations
 Engineering Feature-Based modeling
 Parametric modeling
Primitive creation
 Primitives are simple solid shapes with simple mathematical surfaces

 Can be controlled by a small number of parameters and positioned using a transformation matrix
Boolean operations
 Boolean operations are used to make more complicated shapes by combining simpler shapes
 3 types of operations are possible:
1. union (‘∪’) or “join”
2. intersection (‘∩’)
3. difference (‘-’) or “subtract”
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Sweep operations
 Use 2D wireframe section(s) to generate a 3D solid.

 This includes operations such as:
a. extrude
b. revolve
c. sweep
d. loft
Surface operations
 These operate directly on the solid model surfaces, edges and vertices to create a desired
modification.
 Examples:
a. chamfering
b. rounding/filleting
c. drafting
d. shelling
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Feature-Based Modeling
 Features are shapes having engineering significance. They usuallyare the geometric embodiment
of machining operations or the function of a component.
 Examples:
a. hole - pocket
b. slot - boss
• Many people use the term “Feature” to refer to any kind of solid modeling operation.
• Many systems provide for userdefined features.
Parametric Modeling
• Parameters come from:

a. dimensions in 2D sketches
b. dimensions on 3D geometry (advanced systems only)
c. modeling operation parameters
d. variables in user-equations
• Entire part geometry can be controlled by asmall number of key parameters!
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CAD System Hardware
Hardware Description
Design workstations This has the following functions: (1) communication with the computer’s
central processing unit; (2) continuously generate a graphic image; (3)
provide digital descriptions of the image; (4) translate user commands into
operating functions; and (5) facilitate interaction between the user and the
system.
CAD workstation design has an important influence on the convenience,

productivity, and quality of user’s output. The workstation consists of a
display terminal and a set of user input devices, with which the user
interacts with geometric model via: entering alphanumeric data; entering
system commands to perform various graphics operations; and by
controlling cursor position on the display screen.
Digital computer This uses a high-speed central processing unit to process CAD operations.
There are several CAD system configurations, such as host and terminal;
engineering workstation; and a CAD system based upon a personal
computer. These are discussed in the paragraphs below.
Output devices These include plotters and printers, which generate the output from the
CAD system. Plotters include: pen plotters, which are x-y plotters of various
type, used to produce high accuracy line drawings; and electrostatic
plotters, which are based upon the same principal as photocopying, and
produce lower quality drawings. Printers used include inkjet printers, where
drawings are produced by high-speed jets of ink impacting the paper.
Secondary Storage This includes various storage devices attached to the CAD system to store
programmes and data files. The storage mediums used can include:
magnetic discs, magnetic tape, floppy discs, external hard-drives etc.
Configuration of a typical CAD system

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CAD software
The software is a which allows the user to perform specific types of application to CAD
Softwares used
1. Auto CAD
2. PRO E
3. ANSYS
4. SOLID Works
5. SOLID edge
6. Master CAM
7. STAD – PRO
8. Microstation
EXPERIMENT NO. 2
Aim :
Study of CNC Machine.
Introduction :
Computer Numerical Control (CNC) is a specialized and versatile form of soft automation and its
application cover many kinds, although it was initially developed to control the motion and operations of
machine tools.
Computer Numerical Control may be considered to be a means of operating a machine through the use
of discrete numerical values feed into the machine, where the required ‘input’ technical information is
stored on a kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive, or Ram
card etc. The machine follows a predetermined sequence of machining operations at the predetermined
speeds necessary to produce a work piece of right shape and size and thus according to completely
predictable results. A different product can be produced through reprogramming and a low – quantity
production run of different products is justified.
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CNC Machine
Classification of CNC Machine :
 Based on the motion type

 Based on the control loops
 Based on the number of axes
 Based on the power supply
Based on the motion type :
There are two main types of machine tools and the control systems required for use with them differ
because of the basic differences in the functions of the machines to be controlled. They are known as
point-to-point and contouring controls.
Point-to-point systems
Some machine tools for example drilling, boring and tapping machines etc, require the cutter and the
work piece to be placed at a certain fixed relative positions at which they must remain while the cutter
does its work. These machines are known as point-to-point machines as shown in figure and the control
equipment for use with them are known as point-to-point control equipment. Feed rates need not to be
programmed. In theses machine tools, each axis is driven separately. In a point-to-point control system,
the dimensional information that must be given to the machine tool will be a series of required position
of the two slides. Servo systems can be used to move the slides and no attempt is made to move the slide
until the cutter has been retracted back.
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Point-to-point systems
Contouring systems
Other type of machine tools involves motion of work piece with respect to the cutter while cutting
operation is taking place. These machine tools include milling, routing machines etc. and are known as
contouring machines as shown in figure and the controls required for their control are known as
contouring control.
Contouring machines can also be used as point-to-point machines, but it will be uneconomical to use
them unless the work piece also requires having a contouring operation to be performed on it. These
machines require simultaneous control of axes. In contouring machines, relative positions of the work
piece and the tool should be continuously controlled. The control system must be able to accept
information regarding velocities and positions of the machines slides. Feed rates should be programmed.
Contouring systems
Based on the control loops
Open Loop Control System :
Open loop systems have no access to real time data about the performance of the system and therefore no
immediate corrective action can be taken in case of system disturbance. This system is normally applied
only on the case where the output is almost constant and predictable. Therefore, an open loop system is
unlike to used to control machine tool since the cutting force and loading of a machine for which some
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machine tool builders still prefer to use an open loop system because there is virtually no cutting force in
wire cut machining.
Block diagram for Open Loop Control System
Close Loop Control System :
In a close loop system, feedback devices closely monitor the output and any disturbance will be
corrected in first instance. Therefore high system accuracy is achievable. This system is more powerful
than the open loop system and can be applied to the case where the output is subjected to frequent
changes. Nowadays, almost all CNC machines use this control system
Block diagram for Close Loop Control System
Based on the number of axes
2& 3 axes CNC machines:
CNC lathes will be coming under 2 axes machines. There will be two axes along which motion takes
place. The saddle will be moving longitudinally on the bed (Z-axis) and the cross slide moves
transversely on the saddle (along X-axis). In 3-axes machines, there will be one more axis, perpendicular
to the above two axes. By the simultaneous control of all the 3 axes, complex surfaces can be machined.
4 & 5 axes CNC machines:
4 and 5 axes CNC machines provide multi-axis machining capabilities beyond the standard 3-axis CNC
tool path movements. A 5-axis milling centre includes the three X, Y, Z axes, the A axis which is rotary
tilting of the spindle and the B-axis, which can be a rotary index table.
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Importance of higher axes machining :
Reduced cycle time by machining complex components using a single setup. In addition to time savings,
improved accuracy can also be achieved as positioning errors between setups are eliminated.
 Improved surface finish and tool life by tilting the tool to maintain optimum tool to part contact
all the times.
 Improved access to under cuts and deep pockets. By tilting the tool, the tool can be made normal
to the work surface and the errors may be reduced as the major component of cutting force will
be along the tool axis.
 Higher axes machining has been widely used for machining sculptures surfaces in aerospace and
automobile industry.
Based on the power supply
Mechanical power unit refers to a device which transforms some form of energy to mechanical power
which may be used for driving slides, saddles or gantries forming a part of machine tool. The input
power may be of electrical, hydraulic or pneumatic.
CNC System Elements :

Any CNC system consists of following elements:
 Part program
 Program input device
 Machine control unit
 Drive system
 Machine tool
 Feedback system
Part Program
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A part program is series of coded instruction that are required to the movement of the machine tools and
the ON/OFF controls of auxiliary functions such as spindle rotation and coolant for producing a part.
The basic commands of coded instructions are G-codes, M-codes, T-function, and F-function. Any part
program, simple or complicated, is coded from these instructions. A word is the basic building unit of the
part program. It always starts with an address followed by a numeric value, e.g.
G01 Linear interpolation mode
X5.0 X-dimension (5.0 in +X direction)
F15.0 Feed rate at 15 inches per minute
The coded instructions are composed of letters, numbers, and symbol and are arranged in the format of
functional words and blocks, e.g.
N5 G00 X2.0 Y3.0 S1000 M3
Where N5= sequence number
G00= rapid traverse mode
X2.0= X-coordinate (2.0”)
Y3.0= Y-coordinate (3.0”)
S1000= spindle rate (1000 rpm)
M3= spindle on (Clockwise direction)
There are four methods of generating CNC part programs, namely: manual programming method,
computer-assisted programming method, conversational programming method, and CAD/CAM
programming method. In the manual programming method, standard G-codes, M-codes, T-function, and
F-function are used to create the part program block-by-block. A computer program allows the
programmer to pre-define part-geometry, tool-path movements and auxiliary functions, in computer-
assisted programming method. Most modern CNC controls provide conversational programming
function to allow part-programmers to interact with the control for generating part programs. CAD/CAM
programming method mainly consists of three components CAD, CAM, and post processor. CAD
creates part geometry; CAM uses that part geometry to generate tool paths. Finally, the post-processors
convert the toolpaths to CNC part programs for particular CNC machine.
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Working Principle of CNC Machine
Program Input Device
The program input device is the mechanism used to enter the part program into the CNC control. The
main components of program input devices are:
 Punch tape recorder

 Magnetic tape recorder
 Computer via RS-232-C communication
 NIC card for network communication
Machine Control Unit
The machine control unit (MCU) is the backbone of CNC systems. Following six functions are being
done by MCU:
 Read coded instructions

 Decode coded instructions
 Implement interpolations to generate axis motion commands
 Feed axis motion commands to amplifier circuits to drive axis mechanisms
 Receive the feed back signals of position and speed for each drive axis
 Implement auxiliary control functions such as coolant ON/OFF, spindle ON/OFF, and tool
change
Drive System
Amplifier circuits, drive motors, and ball lead screws are main component of a drive systems. Control
signals i.e. position and speed of each axis is fed to amplifier circuits from MCU. The control signals are
augmented to actuate drive motors that in turn rotate ball lead-screws to position the machine table.
Machine Tool
CNC controls are used to control various types of machine tools. Irrespective of type of machine tool is
to be controlled, a machine consists of one or two motion axes (X and/or Y) perpendicular to the work
head and one motion axis (Z) parallel to the work head. Some machines are equipped with index tables
that allow rotary motions (A, B, or C) around the linear axes (X, Y, or Z).
Feedback System
A feed back system is also referred to as a measuring system. It uses position and speed transducers to
continuously monitor the position of the cutting tool at any particular time. The MCU uses the difference
between reference signals and feedback signals for correcting position and speed errors.
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EXPERIMENT NO. 3
Aim: Writing part program for given lathe machine operation using M and G codes.
Part No 1
(All dimensions are in mm).
Turning Operation
% 1000; (Main programme)
N01 G54 G90 G71 G94 M03 S800; (Parameters Setting)
N05 G01 X-12.5 Z0 F2; (Facing the job)
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N10 G00 Z1; (Retrieval of tool)
N15 G00 X00; (Tool clearance)
N20 G01 Z-100; (Starting cut)
N25 G00 X1 Z1; (Clearance position)
N30 G00 X-2; (Position of cut)
N35 G01 Z-60; (Cutting length)
N40 G00 X-1 Z1; (Retrieval of tool)

N75 G00 X-4.5; (Position of cut)
N85 G00 X5 Z5; (Final position of tool)
N90 M02; (End of programme)
Part No 2
(All dimensions are in mm).
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Taper Turning
N01 G54 G91 G71 G94 M03 S800; (Parameters Setting)
N05 G01 X-15 Z0 F2; (Facing the job)
N10 G00 Z1; (Tool clearance)
N15 G00 X10; (Tool clearance from the centre)
N20 G01 Z-36; (Turning operation)
N25 G01 X5 –Z30; (Taper turning operation)
N30 G00 X1 Z66; (Final position of tool)
Aim:Writing part program for Machining centres (Milling)
Part No 1
Straight Line
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N5 G17 G71 G90 G94 G54; (Parameters Setting)
N10 T2 L90; (Home position)
N15 G00 D2 Z50 M3 S700 X10 Y-25; (Position of tool)
N20 G01 Z-1.5; (Position of cut)
N25 G01 X4 F100 M8; (Cutting slat)
N30 G00 Z100 M9; (Final position of tool)
N35 M30; (Main programme end)
Part No 2
Circular Interpolation
%101; (Main programme)
N2 G17 G71 G90 G94 G54; (Parameters Setting)
N4 T1 L90; (Home position)
N6 G00 Z5 D5 M3 S500 X20 Y90; (Position of tool)
N8 G01 Z-2 F50; ( (Position of cut)
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N10 G02 X60 Y50 I0 J-40; (Circular interpolation clockwise-CW)
N12 G03 X80 Y50 I20 J0; (Circular interpolation clockwise-CCW)
N14 G00 Z100; (Final position of tool)
Aim :Writing part program for Drilling, Deep Drilling and Tapping.
Part No 1
Drilling Cycle
01 (G81 Drilling Cycle) (All dimensions are in mm).
R00 – Dwell time at the starting point for chip removal.
R02 – Reference plane absolute with sign.
R03 – Final depth of hole absolute with sign.

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R04 – Dwell time at the bottom of drilled hole for chip breaking.
R10 – Retract plane without sign.
R11 – Drilling axis number 1 to 3.
% 400;
N5 G17 G71 G90 G94 G55;
N10 T1 L90;
N15 G00 D5 Z5 M3 S600 X27 Y27;

N20 G81 R02=5, R03=-33, R11=3, F50 M7;
N25 X97;
N30Y97;
N35 X27;
N40 G00 G80 Z100 M9;
Part No 2
Deep Drilling Cycle

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02 (G83 Deep Drilling Cycle) (All dimensions are in mm).
R00 – Dwell time at the starting point for chip removal.
R01 – First drilling depth (incremental) without sign.
R05 – Amount of digression is without sign.
R10 – Retract plane without sign.
% 401;
N5 T1 L90;
N15 G00 D5 Z5 M3 S600 X62 Y62;
N20 G83 R00=30, R01=15, R02=5, R03=-60, R04=1, R05=15, R10=80, R11=3, F50 M7;
N25 G00 G80 Z100 M9;

N30 M02
G17 G71 G90 G94 G55;
N10 T1 L90;
N15 G00 D5 Z5 M3 S600 X62 Y62;
N20 G83 R00=30, R01=15, R02=5, R03=-60, R04=1, R05=15, R10=80, R11=3, F50 M7;
N25 G00 G80 Z100 M9;
Part No 3
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Tapping Cycle
03 (G84 Tapping Cycle) (All dimensions are in mm).
R06 – Reverse direction of spindle rotation.
R07 – Return to the original direction of spindle rotation.
R08 – Machine data setting.
R09 – Thread pitch.
% 403;
N5 G17 G71 G90 G94 G55;
N10 T1 L90;
N15 G00 D5 Z5 M3 S600 X27 Y27;
N20 G81 R02=5, R03=-32, R11=3, F50 M7;
N25 X97;
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N30 Y97;
N35 X27;
N40 G00 G80 Z100 M9;
N45 T2 L90;
N43 G00 D10 Z5 M3 S60 X27 Y27;
N50 G84 R02=5, R03=-29, R04=1, R06=4, R07=3, R08=0, R09=1, R11=3 F60 M7;
N55 X97;
N60 Y97;
N65 X27;
N70 G00 G80 Z100 M9;
EXPERIMENT NO. 4
AIM :
Study of different types of plant layout.
Plant Location:
Plant location refers to the choice of region and the selection of a particular site for setting up a
business or factory.
But the choice is made only after considering cost and benefits of different alternative sites. It is a
strategic decision that cannot be changed once taken. If at all changed only at considerable loss, the
location should be selected as per its own requirements and circumstances. Each individual plant is a
case in itself. Businessman should try to make an attempt for optimum or ideal location.
Ideal location An ideal location is one where the cost of the product is kept to minimum, with a large
market share, the least risk and the maximum social gain. It is the place of maximum net advantage or
which gives lowest unit cost of production and distribution. For achieving this objective, small-scale
entrepreneur can make use of location analysis for this purpose.
Location Analysis :
Locational analysis is a dynamic process where entrepreneur analyses and compares the
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appropriateness or otherwise of alternative sites with the aim of selecting the best site for a given
enterprise. It consists the following:
(a) Demographic Analysis: It involves study of population in the area in terms of total population (in
no.), age composition, per capita income, educational level, occupational structureetc.
(b) Trade Area Analysis: It is an analysis of the geographic area that provides continued clientele to
the firm. He would also see the feasibility of accessing the trade area from alternativesites.
(c) Competitive Analysis: It helps to judge the nature, location, size and quality of competition in a
given tradearea.
(d) Traffic analysis: To have a rough idea about the number of potential customers passing by the
proposed site during the working hours of the shop, the traffic analysis aims at judging the
alternativesitesintermsofpedestrianandvehiculartrafficpassingasite.
(e) Site economics: Alternative sites are evaluated in terms of establishment costs and operational
costs under this. Costs of establishment is basically cost incurred for permanent physical facilities but
operational costs are incurred for running business on day to day basis, they are also called as running
costs.
Selection Criteria :
a) Natural or climaticconditions.
b) Availability and nearness to the sources of rawmaterial.
c) Transport costs-in obtaining raw material and also distribution or marketing finished products to the
ultimateusers.
d) Access to market: small businesses in retail or wholesale or services should be located within the
vicinity of densely populatedareas.
e) Availability of Infrastructural facilities such as developed industrial sheds or sites, link roads,
nearness to railway stations, airports or sea ports, availability of electricity, water, public utilities, civil
amenities and means of communication are important, especially for small scalebusinesses.
f) Availability of skilled and non-skilled labour and technically qualified and trainedmanagers.
g) Banking and financial institutions are locatednearby.
h) Locations with links: to develop industrial areas or business centers result in savings and cost
reductions in transport overheads, miscellaneousexpenses.
i) Strategic considerations of safety and security should be given dueimportance.
j) Government influences: Both positive and negative incentives to motivate an entrepreneur to choose
a particular location are made available. Positive includes cheap overhead facilities like electricity,
banking transport, tax relief, subsidies and liberalization. Negative incentives are in form of
restrictions for setting up industries in urban areas for reasons of pollution control and decentralization
ofindustries.
k) Residence of small business entrepreneurs want to set up nearby theirhomelands
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Plant Layout :The efficiency of production depends on how well the various machines;
production facilities and employee’s amenities are located in a plant. Only the properly laid
out plant can ensure the smooth and rapid movement of material, from the raw material
stage to the end product stage. Plant layout encompasses new layout as well as
improvement in the existinglayout.
It may be defined as a technique of locating machines, processes and plant services within the factory
so as to achieve the right quantity and quality of output at the lowest possible cost of manufacturing. It
involves a judicious arrangement of production facilities so that workflow is direct.
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Essentials:An efficient plant layout is one that can be instrumental in achieving the
following objectives:
a) Proper and efficient utilization of available floorspace

b) To ensure that work proceeds from one point to another point without anydelay
c) Provide enough productioncapacity.
d) Reduce material handlingcosts
e) Reduce hazards topersonnel
f) Utiliselabourefficiently
g) Increase employeemorale
h) Reduceaccidents
i) Provide for volume and productflexibility
j) Provide ease of supervision andcontrol
k) Provide for employee safety andhealth
l) Allow ease ofmaintenance
m) Allow high machine or equipmentutilization
n) Improveproductivity
As discussed so far the plant layout facilitates the arrangement of machines, equipment and other
physical facilities in a planned manner within the factory premises. An entrepreneur must possess an
expertise to lay down a proper layout for new or existing plants. It differs from plant to plant, from
location to location and from industry to industry. But the basic principles governing plant layout are
more or less same.
As far as small business is concerned, it requires a smaller area or space and can be located in any kind
of building as long as the space is available and it is convenient. Plant layout for Small Scale business
is closely linked with the factory building and built up area.
From the point of view of plant layout, we can classify small business or unit into three categories:
1. Manufacturingunits
2. Traders
3. ServiceEstablishments
1. Manufacturing units
In case of manufacturing unit, plant layout may be of four types:

(a) Product or linelayout
(b) Process or functionallayout
(c) Fixed position or locationlayout
(d) Combined or grouplayout
66
Swami Vivekanand College of Engineering and Technology, Indore
(a) Product or linelayout:
Under this, machines and equipments are arranged in one line depending upon the sequence of
operations required for the product. The materials move from one workstation to another sequentially
without any backtracking or deviation. Under this, machines are grouped in one sequence. Therefore
materials are fed into the first machine and finished goods travel automatically from machine to
machine, the output of one machine becoming input of the next, e.g. in a paper mill, bamboos are fed
into the machine at one end and paper comes out at the other end. The raw material moves very fast
from one workstation to other stations with a minimum work in progress storage and material
handling. The grouping of machines should be done keeping in mind the following generalprinciples.
a) All the machine tools or other items of equipments must be placed at the point demanded by the
sequence ofoperations
b) There should no points where one line crossed anotherline.
c) Materials may be fed where they are required for assembly but not necessarily at onepoint.
d) All the operations including assembly, testing packing must be included in
theline A line layout for two products is givenbelow.
Advantages: Product layout provides the following benefits:
Advantages: Product layout provides the following benefits:
a) Low cost of material handling, due to straight and short route and absence ofbacktracking
b) Smooth and uninterruptedoperations
c) Continuous flow ofwork
d) Lesser investment in inventory and work inprogress
e) Optimum use of floorspace
f) Shorter processing time or quickeroutput
g) Less congestion of work in theprocess
h) Simple and effective inspection of work and simplified productioncontrol
i) Lower cost of manufacturing perunit
Disadvantages: Product layout suffers from following drawbacks:
a. High initial capital investment in special purposemachine

b. Heavy overheadcharges
c. Breakdown of one machine will hamper the whole productionprocess
d. Lesser flexibility as specially laid out for particularproduct.
Mechanical Engineering Department 67

Suitability: Product layout is useful under following conditions:

1) Mass production of standardizedproducts
2) Simple and repetitive manufacturingprocess
3) Operation time for different process is more or lessequal
4) Reasonably stable demand for theproduct
5) Continuous supply ofmaterials
Therefore, the manufacturing units involving continuous manufacturing process, producing few
standardized products continuously on the firm’s own specifications and in anticipation of sales
would prefer product layout e.g. chemicals, sugar, paper, rubber, refineries, cement, automobiles,
food processing and electronics etc.
(b) Processlayout:
In this type of layout machines of a similar type are arranged together at one place. e.g. Machines
performing drilling operations are arranged in the drilling department, machines performing casting
operations be grouped in the casting department. Therefore the machines are installed in the plants,
which follow the process layout.
Hence, such layouts typically have drilling department, milling department, welding department,
heating department and painting department etc. The process or functional layout is followed from
historical period. It evolved from the handicraft method of production. The work has to be allocated
to each department in such a way that no machines are chosen to do as many different job as possible
i.e. the emphasis is on general purpose machine.
The work, which has to be done, is allocated to the machines according to loading schedules with the
object of ensuring that each machine is fully loaded. Process layout is shown in the following
diagram.
Process layout showing movement of two products The grouping of machines according to the
process has to be done keeping in mind the following principles
a) The distance between departments should be as short as possible for avoiding long distance

movement ofmaterials
b) The departments should be in sequence ofoperations
c) The arrangement should be convenient for inspection andsupervision
Advantages: Process layout provides the following benefits
a) Lower initial capital investment in machines and equipments. There is high degree of machine
utilization, as a machine is not blocked for a singleproduct
b) The overhead costs are relativelylow
c) Change in output design and volume can be more easily adapted to
theoutput of variety ofproducts
d) Breakdown of one machine does not result in complete workstoppage
e) Supervision can be more effective andspecialized
f) There is a greater flexibility of scope forexpansion.
Disadvantages: Product layout suffers from following drawbacks
a. Material handling costs are high due tobacktracking

b. More skilled labour is required resulting in highercost.
c. Time gap or lag in production ishigher
d. Work in progress inventory is high needing greater storagespace
e. More frequent inspection is needed which results in costly supervision
Suitability: Process layout is adoptedwhen
1. Products are notstandardized
2. Quantity produced issmall
3. There are frequent changes in design and style ofproduct
4. Job shop type of work isdone
5. Machines are veryexpensive
Thus, process layout or functional layout is suitable for job order production involving non repetitive
processes and customer specifications and nonstandardized products, e.g.
tailoring,lightandheavyengineeringproducts,madetoorderfurnitureindustries,jewelry.
(c) Fixed Position or LocationLayout
In this type of layout, the major product being produced is fixed at one location. Equipment labour
and components are moved to that location. All facilities are brought and arranged around one work
center. This type of layout is not relevant for small scale entrepreneur. The following figure shows a
fixed position layout regarding shipbuilding.
Advantages: Fixed position layout provides the following benefits

a) It saves time and cost involved on the movement of work from one workstation toanother.
b) The layout is flexible as change in job design and operation sequence can be easilyincorporated.
c) It is more economical when several orders in different stages of progress are being executed
simultaneously.
d) Adjustments can be made to meet shortage of materials or absence of workers by changing the
sequence ofoperations.
Disadvantages: Fixed position layout has the following drawbacks
a. Production period being very long, capital investment is veryheavy

b. Very large space is required for storage of material and equipment near theproduct.
c. As several operations are often carried out simultaneously, there is possibility of confusion and
conflicts among differentworkgroups.
Suitability: The fixed position layout is followed in following conditions
1. Manufacture of bulky and heavy products such as locomotives, ships, boilers, generators, wagon
building, aircraft manufacturing,etc.
2. Construction of building, flyovers,dams.
3. Hospital, the medicines, doctors and nurses are taken to the patient(product).
(d) Combinedlayout
Certain manufacturing units may require all three processes namely intermittent process (job shops),
the continuous process (mass production shops) and the representative process combined process [i.e.
miscellaneous shops]. In most of industries, only a product layout or process layout or fixed location
layout does not exist. Thus, in manufacturing concerns where several products are produced in
repeated numbers with no likelihood of continuous production, combined layout is followed.
Generally, a combination of the product and process layout or other combination are found, in
practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to
employ the process layout, while the assembly areas often employ the product layout. In soap,
manufacturing plant, the machinery manufacturing soap is arranged on the product line principle, but
ancillary services such as heating, the manufacturing of glycerin, the power house, the water
treatment plant etc. are arranged on a functionalbasis.

EXPERIMENT NO. 5
Aim: Study of computer aided process planning system.
Theory:
Process planning translates design information into the process steps and instructions to efficiently and
effectively manufacture products. As the design process is supported by many computer-aided tools,
computer-aided process planning (CAPP) has evolved to simplify and improve process planning and
achieve more effective use of manufacturing resources.
Definition:
the primary purpose of process planning is to translate the design requirements into manufacturing
process details. This suggests a system in which design information is processed by the process
planning system to generate manufacturing process details. CAPP integrates and optimizes system
performance into the inter-organizational flow. For example, when one changes the design, it must be
able to fall back on CAPP module to generate manufacturing process and cost estimates for these
design changes. Similarly, in case of machine breakdown on the shop floor, CAPP must generate the
alternative actions so that most economical solution can be adopted in the given situation. A typical
CAPP frame-work is shown in figure 39.1.
A Computer Aided Process Planning (CAPP) frame-work
CAPP is the application of computer to assist the human process planer in the process planning
function. In its lowest form it will reduce the time and effort required to prepare process plans and
provide more consistent process plan. In its most advanced state, it will provide the automated interface
between CAD and CAM and in the process achieve the complete integration with in CAD/CAM.

STEPS INVOLVED IN CAPP
Now-a-days, rapid progress is being made in the automation of actual production process and also the
product design element. However, the interface between design and production presents the greatest
difficulty in accomplishing integration. CAPP has the potential to achieve this integration. In general, a
complete CAPP system has following steps :
(i) Design input

(ii) Material selection
(iii) Process selection
(iv) Process sequencing
(v) Machine and tool selection
(vi) Intermediate surface determination
(vii) Fixture selection
(viii) Machining parameter selection
(ix) Cost/time estimation
(x) Plan preparation
(xi) Mc tape image generation.
APPROACHES TO COMPUTER-AIDED PROCESS PLANNING
In recent days, several computer-aided process planning systems are available for use for a variety of
manufacturing operation.
These systems can broadly be clarified into two categories :
(i) Variant computer aided process planning method.
(ii) Generative computer aided process planning method.
1. Variant Process Planning:
Variant process planning approach is sometimes referred as a data retrieval method. In this approach,
process plan for a new part is generated by recalling, identifying and retrieving an existing plan for a
similar part and making necessary modifications for new part. As name suggests a set of standard plans
is established and maintained for each part family in a preparatory stage. Such parts are called master
part. The similarity in design attributes and manufacturing methods are exploited for the purpose of
formation of part families. Using coding and classification schemes of group technology (GT), a
number of methods such as coefficient based algorithm and mathematical programming models have
been developed for part family formation and plan retrieval. After identifying a new part with a family,

the task of developing process plan is simple. It involves retrieving and modifying the process plan of
master part of the family.
The general steps for data retrieval modification are as follows :
1. Establishing the Coding Scheme
A variant system usually begins with building a classification and coding scheme. Because,
classification and coding provide a relatively easy way to identify similarity among existing and new
parts. Today, several classification and coding systems are commercially available. In some extreme
cases, a new coding scheme may be developed. If variant CAPP is preferred than it is useful for a
company to look into several commercially available coding and classification systems (e.g. DCLASS,
JD-CAPP etc.). Now, it is compared with companies before developing their own coding and
classification system. Because using an existing system can save tremendous development time and
manpower.
2. Form the Part Families by Grouping Parts
The whole idea of GT lies into group numerous parts into a manageable number of part families. One
of the key issues in forming part families is that all parts in the same family should have common and
easily identifiable machined features. As a standard process plan are attached with each part family,
thereby reducing the total number of standard process plans.
3. Develop Standard Process Plans
After formation of part families, standard process plan is developed for each part families based on
common part features. The standard plan should be as simple as possible but detailed enough to
distinguish it from other.

4. Retrieve and Modify the Standard Plans for New Parts
Step1 to step 3 are often referred as preparatory work. Each time when a new part enters the systems, it
is designed and coded based on its feature, using the coding and classification scheme, and than
assigned to a part family. The part should be similar to its fellow parts in the same family. Also,
family’s standard plan should represent the basic set of processes that the part has to go through. In
order to generate detailed process routes and operation sheets to this part, the standard plan is retrieved
from the data base and modified. Modification is done by human process planar. After this stage parts
are ready for release to the shop.
The success of aforementioned process planning system is dependent on selection of coding scheme,
the standard process plan and the modification process, because the system is generally application
oriented. It may be possible that one coding scheme is preferable for one company and same is not for
other company.
Due to use and advancement of computers, the information management capability of variant process
planning is much superior. Otherwise it is quite similar to manual experience-based planning.
Advantages of Variant CAPP
Following advantages are associated with variant process planning approach:
(i) Processing and evaluation of complicated activities and managerial issues are done in an efficient
manner. Hence lead to the reduction of time and labour requirement.
(ii) Structuring manufacturing knowledge of the process plans to company’s needs through
standardized procedures.
(iii) Reduced development and hardware cost and shorter development time. This is an essential issue
for small and medium scale companies, where product variety is not so high and process planner
are interested in establishing their own process planning research activities.
Disadvantages of Variant Process Planning Approach
Following disadvantages are associated with variant process planning approach
(i) It is difficult to maintain consistency during editing.
(ii) Proper accommodation of various combinations of attributes such as material, geometry, size,
precision, quality, alternate processing sequence and machine loading among many other factors are
difficult.
(iii) The quality of the final process plan largely depends on the knowledge and experience of process
planner. The dependency on process planner is one of the major shortcomings of variant process
planning.
Some of the most widely used process planning method developed by various company are
mentioned as follows :

(i) Mc Donnell-Douglas automation company under the direction and sponsorship of Computer Aided
Manufacturing International (CAM-I) developed a system where CAPP can be used to generate process
plan for rotational, prismatic and sheet metal part.
(ii) Organization for Industrial Research (OIR) and General Electric Company have developed and
another process plan named as MIPLAN. It accommodates both rotational and prismatic part, and is
based on MICLASS coding.
Generative Process Planning:
In generative process planning, process plans are generated by means of decision logic, formulas,
technology algorithms, and geometry based data to perform uniquely processing decisions. Main aim is
to convert a part form raw material to finished state. Hence, generative process plan may be defined as
a system that synthesizes process information in order to create a process plan for a new component
automatically.
Generative process plan mainly consists of two major components :
(i) Geometry based coding scheme.
(ii) Proportional knowledge in the form of decision logic and data.
1. Geometry-based Coding Scheme
All the geometric features for all process such as related surfaces, feature dimension, locations, on the
features are defined by geometry based coding scheme. The level of detail is much greater in generative
system than a variant system.
For example, various details such as rough and finished state of the part are provided to transform into
desired state.
2. Proportional Knowledge in the Form of Decision Logic and Data

Process knowledge in the form of decision logic and data are used for matching of part geometry
requirement with the manufacturing capabilities. All the methods mentioned above is performed
automatically.
Operation instruction sets are automatically generated to help the operators to run the machines in case
of manual operation. NC codes are automatically generated, when numerically controlled machines are
used.
Manufacturing knowledge plays a vital role in process planning. The process of acquisition and
documentation of manufacturing knowledge is a recurring dynamic phenomenon. In addition, there are
various sources of manufacturing knowledge such experience of manufacturing personnel, handbooks,
supplier of machine tools, tools, jigs and fixtures materials, inspection equipment and customers etc.
Hence, in order to understand manufacturing information, ensuring its clarity and providing a
framework for future modification, it is not only necessary but also inevitable to develop a good
knowledge structure from wide spectrum of knowledge. Flowchart, decision trees, decision tables,
algorithms, concepts of unit machined surfaces, pattern recognition techniques, and artificial intelligent
based tools are used to serve the purpose.
A brief discussion on decision table is given below.
The basic elements of decision tables are condition, action and rules. They are represented in the form
of allocation matrix. Figure 9.4 is one such representation where condition states the goal that we want
to achieve and action states the operation that we have to perform. On the basis of experience the expert
rules are formed by entry values to establish the relationship between condition and action.
Table 9.1 is one such representation where entry are of Boolean-types (true, false, don’t care).
Similarly, in Table 9.2, continuous value type entries are shown.
Table 1: Boolean Value-Type Entries
Length of bar 8 in. T* F
Diameter of bar 1 in.
Diameter of bar 1 in.

T T
- - - -
T
Extra Support
* T :True; F : False; blank : don’t care
Table 2 : Continuous Value-type Entries
Length of bar

(in) 4 4 16 16
Diameter of bar 0.2 > 0.2 0.2 > 0.2 1>diameter>0.2 1

(in.)
Extra support T T T
* T: true; blank: do not care
The decision making process works as follow.
For a particular set of condition entries, look for its corresponding rule from that rule determine the
action.
Advantages of Generative Process Plan
Generative process plans have a number of advantages. Among the major ones are the following :
(i) They rely less on group technology code numbers since the process, usually uses decision tree to
categorize parts into families.
(ii) Maintenance and updating of stored process plans are largely unnecessary. Since, any plan may be
quickly regenerated by processing through the tree. Indeed, many argue that with generable systems,
process plans should not be stored since if the process is changed, and out-of-dated process plan might
find its way back into the system.
(iii) The process logic rules however must be maintained up to dated and ready for use. This provides
the process planner with an assurance that the processes generated will reflect state-of-the-art
technology.

EXPERIMENT NO. 6
Aim: Study of basic robotic co-ordinate configurations, types of grippers and sensors.
Introduction:
Industrial Robots Definition
A robot is a programmable arm simulator.
“A robot is a re-programmable, multifunction manipulator designed to move material, parts, tools, or

special devices through variable programmed motions for the performance of a variety of tasks”
Cartesian Co-Ordinate Robot:
The Cartesian co-ordinate robot is one that consists of a column and an arm. It is sometimes called an
x-y-z robot, indicating the axes of motion. The x axis is lateral motion, the y-axis is longitudinal
motion, and the z-axis is vertical motion. Thus, the arm can move up and down on the z-axis; the arm
can slide along its base on the x-axis; and then it can telescope to move to and from the work area on
the y-axis. The Cartesian co-ordinate robot was developed mainly for arc welding, but it is also suited
for many other assembly operations. Robots with Cartesian configurations consists of links connected
by linear joints (L). Gantry robots are Cartesian robots (LLL). A robot with 3 prismatic joints – the axes
consistent with a Cartesian coordinate system.
Commonly used for:
 Pick and place work

 Assembly operations
 Handling machine tools
 Arc welding

Cartesian robot with its rectangular workspace
Advantages:
 Ability to do straight line insertions into furnaces.

 Easy computation and programming.
 Most rigid structure for given length.
Disadvantages:
 Requires large operating volume.

 Exposed guiding surfaces require covering in corrosive or dusty environments.
 Can only reach front of itself
 Axes hard to seal
Cylindrical Co-Ordinate Robot.
The cylindrical co-ordinate robot is a variation of the Cartesian robot. This robot consists of a base and
a column, but the column is able to rotate. It also carries an extending arm that can move up and down
on the column to provide more freedom of movement. The cylindrical co-ordinate robot is designed for
handling machine tools and assembly.
Robots with cylindrical configuration have one rotary ( R) joint at the base and linear (L) joints
succeeded to connect the links. A robot with 2 prismatic joints and a rotary joint – the axes consistent
with a cylindrical coordinate system.
Commonly used for:
 Handling at die-casting machines

 Assembly operations
 Spot welding

Cylindrical robot with its cylindrical workspace
Advantages:
 Can reach all around itself

 Rotational axis easy to seal
 Relatively easy programming
 Rigid enough to handle heavy loads through large working space
 Good access into cavities and machine openings
Disadvantages:
 Can't reach above itself

 Linear axes is hard to seal
 Won’t reach around obstacles
 Exposed drives are difficult to cover from dust and liquids
Spherical Co-Ordinate Robot.
The polar co-ordinate, or spherical co-ordinate robot consists of a rotary base, an elevation pivot, and a
telescoping extend-and-retract boom axis. These robots operate according to spherical co-ordinates and
offer greater flexibility. They are used particularly in spot welding. Polar robots have a work space of
spherical shape. Generally, the arm is connected to the base with a twisting (T) joint and rotatory (R)
and linear (L) joints follow. A robot with 1 prismatic joint and 2 rotary joints – the axes consistent with
a polar coordinate system.

Commonly used for:
 Handling at die casting or fettling machines

 Arc/spot welding
Spherical robot with its Spherical/Polar workspace
Advantages:
 Large working envelope.

 Two rotary drives are easily sealed against liquids/dust.
Disadvantages:
 Complex coordinates more difficult to visualize, control, and program.

 Exposed linear drive.
 Low accuracy.

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Swami Vivekanand College of Engineering, Indore

Department of Mechanical Engineering

Session: July- Dec 2021

PO3.(c)Design/development of solutions: Design solutions for complex engineering problems and

PO10.(j) Communication: Communicate effectively on complex engineering activities with the

Course Learning Objectives (CLO)

Swami Vivekanand College of Engineering

Student Practical Evaluation Sheet

Study of computer aided

Total marks obtained

AIM: Introduction of CAD

Geometric Modeling: Geometric Modeling is branch of applied mathematics and computational

1.2D =Two dimensional representation is use for a flat objects.

3. 3 D= It is the 3 D picture of real objects.

There are 3 types of modeling

(1).Wire frame modeling.

 Stores positions of lines (in 2D or 3D)

 Stores equations of surfaces

 Various mathematical representations exist that each allow point-set classification:

Different ways that a user can create solid shapes:

 Primitives are simple solid shapes with simple mathematical surfaces

 Use 2D wireframe section(s) to generate a 3D solid.

• Parameters come from:

CAD workstation design has an important influence on the convenience,

Configuration of a typical CAD system

Study of CNC Machine.

Classification of CNC Machine :

 Based on the motion type

Based on the motion type :

Based on the control loops

Open Loop Control System :

Block diagram for Open Loop Control System

Close Loop Control System :

Block diagram for Close Loop Control System

Based on the number of axes

2& 3 axes CNC machines:

4 & 5 axes CNC machines:

Based on the power supply

CNC System Elements :

Program Input Device

 Punch tape recorder

Machine Control Unit

 Read coded instructions

(All dimensions are in mm).

% 1000; (Main programme)

N01 G54 G90 G71 G94 M03 S800; (Parameters Setting)

N05 G01 X-12.5 Z0 F2; (Facing the job)

N15 G00 X00; (Tool clearance)

N20 G01 Z-100; (Starting cut)

N25 G00 X1 Z1; (Clearance position)

N30 G00 X-2; (Position of cut)

N35 G01 Z-60; (Cutting length)

N40 G00 X-1 Z1; (Retrieval of tool)

N45 G00 X-3; (Position of cut)

N50 G01 Z-60; (Cutting length)

N55 G00 X-2 Z1; (Retrieval of tool)

N60 G00 X-4; (Position of cut)

N70 G00 X-3 Z1; (Retrieval of tool)

N75 G00 X-4.5; (Position of cut)

N80 G01 Z-60; (Cutting length)

N85 G00 X5 Z5; (Final position of tool)

N90 M02; (End of programme)

(All dimensions are in mm).