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    THE KAVERY ENGINEERING COLLEGE, MECHERI

    DEPARTMENT OF MECHANICAL ENGINEERING

    A Observation Manual

    On

    Computer Aided Manufacturing Lab

    VI SEMESTER

    R 2008 SYLLABUS

    PREPARED BY

    E.JAMUNA AP/MECH

    DEPARTMENT OF MECHANICAL ENGINEERING

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    SYLLABUS

    COMPUTER AIDED MANUFACTURING (CAM) LABORATORY

    LIST OF EXPERIMENTS

    1 Manual part programming (Using G and M Codes) in CNC lathe

    i. Part programming for Linear and Circular interpolation, Chamfering and

    Grooving

    ii. Part programming using standard canned cycles for Turning, Facing, Taper

    turning and Thread cutting.

    2 Manual part programming (using G and M codes) in CNC milling

    2.1 Part programming for Linear and Circular interpolation and Contour

    motions.

    2.2 Part programming involving canned cycles for Drilling, Peck drilling,

    and Boring.

    3 Exposure to Component Modeling and CL data generation using CAD/CAM

    Software like Unigraphics, Pro/E, Edge CAM etc., NC code generation using

    CAD/CAM software-Post processing for standard CNC control like FANUC,

    SINUMERIC etc.,

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    EXPT. NO: 1 STUDY OF CNC MACHINES

    DATE :

    AIM:

    To study the basic components and details of CNC machine.

    BASIC COMPONENTS:

    An operational CNC machine consist of

    i) Program of instruction ii) Machine control unit iii) Machine tool.

    PROGRAM OF INSTRUCTION:

    It is the detailed step by step instruction which tell the machine tool

    what to do. The program can input to the system either by manual data input or

    by a punched t ape.

    MACHINE CONTROL UNIT:

    It is also called as the controller unit. It is considered as the brain of the

    machine. It reads the part program and controls the machine tool operation. It

    consists of two units. (1) Data processing unit (2) Control loop unit.

    CONTROL LOOP UNIT:

    The control loop unit receives the data from data processing unit and

    converts it into control signals. The data usually provides the control

    information such as the new required position of each axis, its direction of

    motion and velocity and auxiliary control signals to relays.

    MACHINE TOOL:

    The machine which performs the machining operation is called

    machine tool. The machine tool consists of workable and spindle as well as

    the motor. It also includes the cutting tool work fixture and other auxiliary

    equipment needed in the operation.

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    MACHINE TYPES

    Lathe

    The engine lathe, one of the most productive machine tools, has always

    been an efficient means of producing round parts. Most lathes are programmed on

    two axes.

    The X axis controls the cross motion of the cutting tool.Negative X (X-)

    moves the tool towards the spindle centerline; positive X moves the tool

    away from the spindle centerline.

    The Z axis controls the carriage travel toward or away from

    the headstock.

    Fig. 1.The main axes of a lathe or turning center.

    Milling Machine

    The milling machine has always been one of the most versatile machine

    tools used in industry (Fig. 2). Operations such asmilling, contouring, gear cutting,

    drilling, boring, and reaming areonly a few of the many operations which can be

    performed on a milling machine. The milling machine can be programmed on

    Three axes:

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    The X axis controls the table movement left or right.

    The Y axis controls the table movement toward or away from the column.

    The Z axis controls the vertical (up or down) movement ofthe knee or spindle.

    .

    Fig. 2The main axes of a vertical machining center

    RESULT:

    Thus the basic components of CNC machine have been studied

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    EXPT. NO: 2 PART PROGRAMMING FUNDAMENTALS

    DATE :

    AIM:

    To know about part programming fundamentals for CNC turning.

    1. CO-ORDINATE SYSTEM FOR A CNC LATHE:

    Machining of the work piece by an NC programming requires a co-

    ordinate system to be applied to the machine tool. As all machine tool have more

    than one slide, it is important that each slide is identified individually.

    There are three planes in which movements can take place:

    (1.) Longitudinal

    (2.) Transverse

    (3.) Vertical.

    Each plane is assigned a letter and is referred t o an axis (i.e.)

    (1.) Axis-x

    (2.) Axis-y

    (3.) Axis-z

    The three axis are identified by the upper case x, y and z and the

    direction of movement along each axis specified as either (+) or (-). The

    three axes are always at right angles and parallel to work holding surface. The z-

    axis is at right angles to both x and y axis.

    2. MACHINE ZERO POINT:

    The manufacturers of the machine specify machine zero point. This is zero

    point for the co-ordinate system and reference point in the machine on

    turning the lathe. The machine zero point is generally at the center of the

    spindle nose face. The main spindle axis represents the z-axis, and the face

    determines x-axis.

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    3. WORK PIECE ZERO POINT:

    The point determines the work piece co-ordinate system in relation to the

    machine zero point. The work piece zero point is chosen by the programmer and

    the input to the system.

    4. NC PROGRAM BUILT UP:

    In an NC program, the machining system operations for producing a

    part on the machine tool are laid down in a form that the control system can

    understand. A program is composed of several block s. A block is a collection of

    NC works. An NC word is collection of address, letter and sequence of number.

    BASIC COMPONENTS:

    An operational CNC machine consists of (i) Program of instruction (ii) Machine

    control unit (iii) Machine tool.

    PROGRAM OF INSTRUCTION:

    It is the detailed step by step instruction which tell the machine tool

    what to do. The program can input to the system either by manual data input or

    by a punched t ape.

    MACHINE CONTROL UNIT:

    It is also called as the controller unit. It is considered as the brain of the

    machine. It reads the part program and controls the machine tool operation. It

    consists of two units. (1) Data processing unit (2) Control loop unit.

    CONTROL LOOP UNIT:

    The control loop unit receives the data from data processing unit and

    converts it into control signals. The data usually provides the control information

    such as the new required position of each axis, its direction of motion and

    velocity and auxiliary control signals to relays.

    MACHINE TOOL:

    The machine which performs the machining operation is called machine

    tool. The machine tool consists of workable and spindle as well as the motor. It

    also includes the cutting tool work fixture and other auxiliary equipment needed in

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    the operation.

    CNC Systems:

    Point-to-point control is the positioning of the tool from one y point to

    another within a coordinate system. Most often used for positioning to a

    point where a manual machining operation such as drilling or boring would

    occur.

    Straight-cut control has the ability move a tool, while engaged, y

    straight in all axes of the machine and has the ability to do angles of

    45 degrees.

    Contouring control systems generate a continuously controlled y tool

    path by interpolating intermediate points or coordinates. Interpolating

    means the ability to generate the points that make up a path.

    Fig.3 point-to-point positionin andContouring, or continuous path machining,

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    Cutting Data and Formulae:

    Here are some of the most common terms used for expressing cutting data:

    Spindle speed - Spindle speed is the rotational speed of the spindle and

    tooling. This value is usually expressed in RPM. (Revolutions per

    Minute).

    Feed rate value - The feed rate value is the numerical value at

    which a tool will traverse a work piece. It is usually expressed in

    either IPM (Inches per Minute) or IPR (Inches per Revolution).

    Cutting speed - Cutting speed is the rotational speed of the cutting tool

    or work piece. It can be stated as either RPM or SFM. (Surface Fee Per

    Minute).

    Depth of Cut - Depth of cut is the distance the tool tip is engaged

    into the wor piece. It is incorporated into the X, Y, and Z values

    in a CNC program. Separate from the program, it can be expressed in

    inches or mm

    Tooling Requirements:

    Tooling requirements and selection are based on part restrictions and

    industry manufacturing practices. Most of these ideas are common sense thoughts.

    Good CNC programmers and operators should be aware of them.

    Know the material to be machined and its characteristics.

    Use industry standard catalog tooling to cut costs.

    Make use of technical services offered by tooling manufacturers.

    Quality of the fixture should be based on the number of pieces that

    will eventually be produced.

    Always use the right tool for the right machining operation.

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    Keep spares or backups of tooling in the event resharpening is needed or tool

    breakage occurs.

    Keep an assortment of tooling in case one type does not perform the

    job as desired.

    Use high speed steel tools on easily machined materials.

    Use carbide tools on difficult to cut materials.

    Use cobalt or oxide coated tools for exotic alloys.

    Use inserts type tooling where possible t o cut costs.

    Consider using reamers, instead of boring bars, on lathe applications where

    chatter and chip control may be a problem

    Be aware of the flexing that occurs with long length tools. Extra passes may

    be required to eliminate tapering and chattering.

    Unit Systems and Input Modes:

    Unit Systems are the units of measurement to be used for the CNC

    program. All machines understand both English and Metric standards. When

    programming in English units you are using inches. And in metric its themillimeter (mm.). The CNC machine needs to be told which units are being

    used. Some machines are automatically set-up at the factory for inches or mm.

    Normally at the beginning of a CNC program you will see either; G70 to

    specify inches or G71 to specify mm..

    Input modes refer to the type of coordinate information that is input into

    the program for the CNC machine. There are two types.

    Absolute input , designated by the G90 c ode, specifies distances from the

    origin or program zero point. Absolute is the most common mode.

    Incremental input , designated by the G91 code, specifies distances and

    directions based on the previous point as an origin. Incremental input is

    sometime called point-to-point. All CNC systems can be switched from absolute

    to incremental mode and back unlimited times within a program.

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    Other input modes such as Helical also exist

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    PREPARATORY FUNCTIONS (G codes)

    The G-codes are the codes that position the tool and do the actual work, as

    opposed to M-codes, that manages the machine; T for tool-related codes. S and F

    are tool-Speed and tool-Feed, and finally D-codes for tool compensation. The

    programming language of Numerical Control (NC) is sometimes informally called

    G-code. But in actuality, G-codes are only a part of the NC-programming

    language that controls NC and CNC machine tools.

    1. G00 - Rapid move (not cutting)

    2. G01 - Linear move

    3. G02 - Clockwise circular motion

    4. G03 - Counterclockwise circular motion

    5. G04 - Dwell

    6. G05 - Pause (for operator intervention)

    7. G08 - Acceleration

    8. G09 - Deceleration

    9. G17 - x-y plane for circular interpolation

    10. G18 - z-x plane for circular interpolation

    11. G19 - y-z plane for circular interpolation

    12. G20 - turning cycle or inch data specification

    13. G21 - thread cutting cycle or metric data specification

    14. G24 - face turning cycle

    15. G25 - wait for input #1 to go low (Prolight Mill)

    16. G26 - wait for input #1 to go high (Prolight Mill)

    17. G28 - return to reference point

    18. G29 - return from reference point

    19. G31 - Stop on input (INROB1 is high) (Prolight Mill)

    20. G33-35 - thread cutting functions (Emco Lathe)

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    21. G35 - wait for input #2 to go low (Prolight Mill)

    22. G36 - wait for input #2 to go high (Prolight Mill)

    23. G40 - cutter compensation cancel

    24. G41 - cutter compensation to the left

    25. G42 - cutter compensation to the right

    26. G43 - tool length compensation, positive

    27. G44 - tool length compensation, negative

    28. G50 - Preset position

    29. G70 - set inch based units or finishing cycle

    30. G71 - set metric units or stock removal

    31. G72 - indicate finishing cycle (EMCO Lathe)

    32. G72 - 3D circular interpolation clockwise (Prolight Mill)

    33. G73 - turning cycle contour (EMCO Lathe)

    34. G73 - 3D circular interpolation counter clockwise (Prolight

    Mill)

    35. G74 - facing cycle contour (Emco Lathe)

    36. G74.1 - disable 360 deg arcs (Prolight Mill)

    37. G75 - pattern repeating (Emco Lathe)

    38. G75.1 - enable 360 degree arcs (Prolight Mill)

    39. G76 - deep hole drilling, cut cycle in z-axis

    40. G77 - cut-in cycle in x-axis

    41. G78 - multiple threading cycle

    42. G80 - fixed cycle cancel

    43. G81-89 - fixed cycles specified by machine tool manufacturers

    44. G81 - drilling cycle (Prolight Mill)

    45. G82 - straight drilling cycle with dwell (Prolight Mill)

    46. G83 - drilling cycle (EMCO Lathe)

    47. G83 - peck drilling cycle (Prolight Mill)

    48. G84 - taping cycle (EMCO Lathe)

    49. G85 - reaming cycle (EMCO Lathe)

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    50. G85 - boring cycle (Prolight mill)

    51. G86 - boring with spindle off and dwell cycle (Prolight Mill)

    52. G89 - boring cycle with dwell (Prolight Mill)

    53. G90 - absolute dimension program

    54. G91 - incremental dimensions

    55. G92 - Spindle speed limit

    56. G93 - Coordinate system setting

    57. G94 - Feed rate in ipm (EMCO Lathe)

    58. G95 - Feed rate in ipr (EMCO Lathe)

    59. G96 - Surface cutting speed (EMCO Lathe)

    60. G97 - Rotational speed rpm (EMCO Lathe)

    61. G98 - withdraw the tool to the starting point or feed per minute

    62. G99 - withdraw the tool to a safe plane or feed per revolution

    63. G101 - Spline interpolation (Prolight Mill)

    MISCELLANIOUS FUNCTION (M CODES):

    M codes are instructions describing miscellaneous functions like calling the

    tool, spindle rotation, coolant supply etc.

    1. M00 - program stop

    2. M01 - optional stop using stop button

    3. M02 - end of program

    4. M03 - spindle on CW

    5. M04 - spindle on CCW

    6. M05 - spindle off

    7. M06 - tool change

    8. M07 - flood with coolant

    9. M08 - mist with coolant

    10. M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill)

    11. M09 - coolant off

    12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)

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    13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill)

    14. M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or

    tool change

    15. M17 - subroutine end

    16. M20 - tailstock back (EMCO Lathe)

    17. M20 - Chain to next program (Prolight Mill)

    18. M21 - tailstock forward (EMCO Lathe)

    19. M22 - Write current position to data file (Prolight Mill)

    20. M25 - open chuck (EMCO Lathe)

    21. M25 - set output #1 off (Prolight Mill)

    22. M26 - close chuck (EMCO Lathe)

    23. M26 - set output #1 on (Prolight Mill)

    24. M30 - end of tape (rewind)

    25. M35 - set output #2 off (Prolight Mill)

    26. M36 - set output #2 on (Prolight Mill)

    27. M38 - put stepper motors on low power standby (Prolight Mill)

    28. M47 - restart a program continuously, or a fixed number of

    times (Prolight Mill)

    29. M71 - puff blowing on (EMCO Lathe)

    30. M72 - puff blowing off (EMCO Lathe)

    31. M96 - compensate for rounded external curves

    32. M97 - compensate for sharp external curves

    33. M98 - subprogram call

    34. M99 - return from subprogram, jump instruction

    35. M101 - move x-axis home (Prolight Mill)

    36. M102 - move y-axis home (Prolight Mill)

    37. M103 - move z-axis home (Prolight Mill)

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    SPECIAL CYCLES

    Special Cycles or Canned Cycles are a preprogrammed sequences of

    repetitive tool motion that are built into the control system f or common

    operations such as drilling, tapping, boring, and pocketing. Its purpose is to

    reduce the amount of program code that would normally have to be written.

    Canned cycles are G codes that are options purchased with a CNC, but some

    are standard equipment depending on the manufacturer.

    Drilling cycle (G81, G82 or G83) are used to drill multiple holes

    without programming each move separately. Using this cycle reduces

    the amount of code that would normally have to be written.

    Facing cycle (G77) is used to clean up rough stock material

    (normally on top of the part) which can be located within a

    rectangular area. Using this cycle reduces the amount of code that would

    normally have to be written.

    Rectangular pocket cycle (G78) is used to clear out material which is

    located within a rectangular area. Using this cycle reduces the amount

    of code that would normally have to be written.

    Circular pocket cycle (G79) is used to clear out material which is located

    within a circular area. Using this cycle reduces the amount of code that

    would normally have to be written.

    INTERPOLATATION

    Linear Interpolation

    Linear Interpolation consists of any programmed points linked together by

    straight lines, whether the points are close together or far apart (Fig. 11). Curves

    can be produced with linear interpolationby breaking them into short, straight-line

    segments. This method has limitations, because a very large number of points

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    would have to be programmed to describe the curve in order to produce a contour

    shape.

    Fig. 3 Two-dimensional linear interpolation

    Circular Interpolation

    The development of MCUs capable of circular interpolation has greatly

    simplified the process of programming arcs and circles. To program an arc (Fig.

    12), the MCU requires only the coordinate positions (the XY axes) of the circle

    center, the radius of the circle, the start point and end point of the arc being cut,

    and the direction in which the arc is to be cut (clockwise or counterclockwise) See

    Fig. 12. The information required may vary with different MCUs.

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    Fig. 4 Two-dimensional circular interpolation

    The functions of a few common G-codes

    RESULT:

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    Thus the part programming fundamentals of CNC Machining is studied

    EXPT. NO: 3 STUDY OF CAM PACKAGES

    DATE :

    Computer-aided manufacturing (CAM):

    The computer-aided manufacturing is the use of computer software to

    control machine tools and related mac hinery in the manufacturing of work

    pieces. This is not the only definition for CAM, but it is the most common

    CAM may also refer to the use of a computer to assist in all operations of a

    manufacturing plant, including planning, management, transportation and

    storage. Its primary purpose is to create a faster production process and

    components and t ooling with more precise dimensions and material consist

    ency, which in some cases, uses only the required amount of raw material

    (thus minimizing waste), while simultaneously reducing energy consumption.

    CAM is a subsequent computer-aided process after computer-aided design (CAD)

    and sometimes computer-aided engineering (CAE), as the model generated in

    CAD and verified in CAE can be input into CAM software, whic h then

    controls the machine tool Over time, the historical shortcomings of CAM

    are being attenuated, both by providers of niche solutions and by providers

    of high-end solutions. This is occurring primarily in three arenas:

    1. Ease of use

    2. Manufacturing complexity

    3. Integration with PLM and the extended enterpriseEase in use:

    For the user who is just getting started as a CAM user, out-of-

    the-box capabilities providing Process Wizards, templates, libraries, machine

    tool k its, automat ed f eature based mac hining and job function specific tailor

    able user interfaces build user confidence and speed the learning curve.

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    User confidence is further built on 3D visualization through a closer

    integration with the 3D CAD environment, including error-avoiding simulations

    and optimizations.

    Manufacturing complexity:

    The manufacturing environment is increasingly complex. The need for

    CAM and PLM tools by the manufacturing engineer, NC programmer or

    machinist is similar to the need for c omput er assistance by the pilot of modern

    aircraft systems. The modern machinery cannot be properly used without this

    assistance. Today's CAM systems support the full range of machine tools

    including: turning, 5 axis machining and wire EDM. Todays CAM user can

    easily generate streamlined tool paths, optimized tool axis tilt for higher feed

    rates and optimized Z axis depth cuts as well as driving non-cutting operations

    such as the Specification of probing motions.

    Integration with PLM and the extended enterprise:

    Todays competitive and successful companies have used PLM to integrate

    manufacturing with ent erprise operations from concept through field support of

    the finished product. To ensure ease of use appropriate to user objectives,

    modern CAM solutions are scalable from a st and-alone CAM system to a fully

    integrated multi-CAD 3D solution-set. These solutions are c reated to meet the

    full needs of manufacturing personnel including part planning, shop

    documentation, resource management and data management and exchange.

    According to the latest analysis of the CAM software market produced

    by CIM data, Inc., Mas ter CAM from CNC Software Inc. with more than

    135,000 installations, is more than twice as popular as its nearest competitor.

    Master cam is a Windows based CAD/CAM package for 2-axis through 5-

    axis milling and turning, 2-axis and 4-axis wire EDM, 2D and 3D design,

    surface and solid modeling, and 2D and 3D routing. The CAD functions are more

    advanced than what is needed to do simple editing of part files for use with the

    CAM f unction. Some users say that it is more than they need and that the

    CAD function is more design-oriented than machinist orient ed. Other users

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    say that the extended design-oriented functionality of the CAD package gives

    them the ability to create complex designs without having to buy a stand-

    alone CAD pack age.

    ABOUT EDGECAM

    EdgeCAM is a complete manufacturing solution to meet all your

    programming needs, including Surface, Rotary and Multiplane Machining, 2 and 4

    Axis Wire EDM, 2, 4 and C & Y Axis Turning. With its standard Microsoft

    Windows interface, EdgeCAM frees you from learning about and maintaining

    several different systems, maximising your efficiency in producing CNC code.

    Before you use the EdgeCAM system and related documentation, you should be

    familiar with CAD/CAM systems, equipment, methods and terminology. You also

    need to have some experience of the MS-DOS operating system and the

    appropriate Microsoft Windows graphical user environment. The complete

    EdgeCAM system provides:

    2D/3D Design and Modelling

    2 to 3 Axis Machining

    5 Axis Trimming and Deflashing

    2 to 4 Axis (C and Y) Multi-Axis Turning

    2 to 4 Axis Wire Erosion

    Tools, PCIs and PDIs

    Editor

    Code Wizard

    Edge Communications

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    EdgeCAM Solid Machinist provides the ability to directly load and

    machine solid files without the need for translation. Solid Machinist

    supports both prismatic and surface milling including multi-plane.

    RESULT:

    Thus, the various features of CAM packages were studied and understood.

    EXPT. NO: 4 PLAIN TURNING & FACING

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G98

    N20 G28 U0 W0

    N30 M06 T01

    N40 M03 S1200

    N50 G00 Z2

    N60 G00 X28

    N70 G94 X-0.5 Z-0.5

    Z-1

    Z-1.5

    Z-2

    N80 G71 U.5 R1N90 G71 P100 Q130 U.1 W.1 F80

    N100 G01 X22 Z0

    N110 G01 X22 Z-50

    N120 G01 X28 Z-50

    N130 G01 X28 Z2

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    N140 G28 U0 W0

    N150 M05

    N160 M30

    RESULT:

    Thus, the plain facing and turning operations were simulated on the given

    work piece according to the dimensions.

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    All dimensions are in mm

    EXPT. NO: 5 STEP TURNING & FACING

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G98

    N20 G28 U0 W0

    N30 M06 T01

    N40 M03 S1200

    N50 G00 X28 Z2

    N60 G71 U.5 R1

    N70 G71 P80 Q130 U.1 W.1 F50

    N80 G01 X15 Z-15N90 G01 X20 Z-15

    N100 G01 X20 Z-30

    N110 G01 X25 Z-30

    N120 G01 X25 Z-45

    N130 G01 X28 Z-45

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    N140 G28 U0 W0

    N150 M05

    N160 M30

    RESULT:

    Thus, the step turning and facing operations were simulated on the given

    work piece according to the dimensions.

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    All dimensions are in mm

    TAPER TURNING AND CIRCULAR INTERPOLATIONEXPT. NO: 6

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

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    dimensions.

    PROGRAM:

    N10 G21 G98

    N20 G28 U0 W0

    N30 M06 T1

    N40 M03 S1500

    N50 G00 Z2

    N60 G00 X28

    N70 G94 X-1 Z-.5 F1.2

    Z-1

    Z-1.5

    Z-2

    N80 G71 U0.5 R1

    N90 G71 P100 Q120 U0.1 W0.1 F80

    N100 G01 X20 Z0

    N110 G01 X20 Z-25

    N120 G01 X28 Z-25

    N140 G71 U0.5 R1

    N150 G71 P160 Q180 U0.1 W0.1 F100

    N160 G01 X20 Z0

    N170 G01 X20 Z-25

    N180 G01 X28 Z-50

    N190 G01 X17.5 Z0

    N200 G01 X17.5 Z-22.5

    N210 G02 X20 Z-25 R2.5

    N220 G28 U0 W0

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    N230 M05

    N240 M30

    RESULT:

    Thus, the Taper Turning and Circular Interpolationoperations weresimulated on the given work piece according to the dimensions.

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    All dimensions are in mm

    THREAD CUTTING OPERATIONS

    EXPT. NO: 7

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G 21 G98

    N20 G 28 U0 W0

    N30 M06 T01

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    N40 M03 S1200

    N50 G 00 X28 Z2

    N60 G 71 U.5 R1

    N70 G 71 P80 Q130 U.1 W.1 F50

    N80 G 00 X15 Z0

    N90 G 01 X15 Z-15

    N100 G01 X20 Z-15

    N110 G01 X20 Z-30

    N120 G01 X25 Z-30

    N130 G01 X28 Z-30

    N140 G01 F30

    N150 S1500

    N160 G70 P1 Q2

    N170 G28 U0 W0

    N180 M06 T03

    N190 M03 S600

    N200 G00 X15.5 Z2

    N210 G76 P021560 Q050 R.02

    N220 G76 X13.774 Z-13 P613 Q100 F1

    N230 G28 U0 W0

    N240 M05

    N250 M30

    RESULT:

    Thus, the Thread Cutting Operations were simulated on the given work

    piece according to the dimensions.

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    All dimensions are in mm

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    DRILLING AND GROOVING

    EXPT. NO: 8

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G98

    N20 G28 U0 W0

    N30 M06 T01

    N40 M03 S1200

    N50 G00 X0 Z1

    N60 G01 Z-3 F0.2N70 G00 Z1

    N80 G01 Z-6

    N90 G00 Z1

    N100 G01 Z-9

    N110 G00 Z1

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    N120 G01 Z-12

    N130 G01 Z1

    N140 G01 Z-15

    N150 G00 Z1

    N160 G01 Z-18

    N170 G00 Z1

    N180 G01 Z-21

    N190 G00 Z1

    N200 G28 U0 W0

    N210 M06 T02

    N220 M03 S1200

    N230 G00 X40 Z-15

    N240 G01 X33

    N250 G00 X40 Z-15

    N260 G00 X-27

    N270 G01 X33

    N280 G00 X40

    N290 G28 U0 W0

    N300 M05

    N310 M30

    RESULT:

    Thus, the Drilling and Grooving Operations were simulated on the given

    work piece according to the dimensions

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    All dimensions are in mm

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    CONTOUR MILLING

    EXPT. NO: 9

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G94

    N20 G91 G28 Z0

    N30 G28 X0 Y0

    N40 M06 T01

    N50 M03 S1500

    N60 G90 G00 X-25 Y-25 Z5

    N70 G01 Z-1 F30

    N80 G01 X25 Y-25

    N90 G01 X25 Y15

    N100 G03 X15 Y25 R10

    N110 G01 X-15 Y25

    N120 G02 X-25 Y15 R10

    N130 G01 X-25 Y-25

    N140 G00 Z5

    N150 G91 G28 Z0

    N160 G28 X0 Y0

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    N170 M05

    N180 M30

    RESULT:

    Thus, the Contour Milling Operations were simulated on the given work

    piece according to the dimensions.

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    All dimensions are in mm

    CIRCULAR POCKETING

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    EXPT. NO: 10

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G94

    N20 G28 Z0N30 G28 X0 Y0

    N40 M06 T01

    N50 M03 S1500

    N60 G90 G00 X0 Y0 Z10

    N70 G01 Z0 F50

    N80 G170 R0 P0 Q3 X0 Y0 Z6 I0 J0 K20

    N90 G171 P75 Z1500 R75 F250 B1800 J130

    N100 G01 Z5

    N110 G28 X0 Y0

    N120 M05

    N130 M30

    RESULT:

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    Thus, the Circular PocketingOperations were simulated on the given

    work piece according to the dimensions.

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    All dimensions are in mm

    RECTANGULAR POCKETING

    EXPT. NO: 11

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

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    N10 G21 G94

    N20 G91 G28 Z0

    N30 M06 T01

    N40 G28 X0 Y0

    N50 M03 S1200

    N60 G90 G00 X0 Y0 Z10

    N70 G01 Z0 F50

    N80 G172 P0 Q2 R5 X-25 Y-20 Z-4 I 50 J50 K0

    N90 G173 P50 S1500 R80 F90 B1200 J60 Z5 T1 I 0 K0

    N100 G00 Z10

    N110 G91 G28 Z0

    N120 G28 X0 Y0

    N130 M05

    N140 M30

    RESULT:

    Thus, the Rectangular Pocketing Operations were simulated on the given

    work piece according to the dimensions.

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    All dimensions are in mm

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    PECK DRILLING

    EXPT. NO: 12

    DATE :

    AIM:

    To simulate the cnc program for given work piece according to the

    dimensions.

    PROGRAM:

    N10 G21 G94

    N20 G28 X0 Y0

    N30 G00 Z5

    N40 M06 T01N50 M03 S1500

    N60 G83 X25 Y25 Z-10 R9 Q3 F120

    X-25 Y25

    X-25 Y-25

    X25 Y-25

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    N70 G00 G80 G90 Z15

    N80 M05

    N90 M30

    RESULT:

    Thus, the Peck DrillingOperations were simulated on the given work

    piece according to the dimensions.

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    All dimensions are in mm

    LINEAR AND CIRCULAR SLOTTING

    EXPT. NO: 13

    DATE :

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    RESULT:

    `Thus, the Linear and Circular Slotting Operations were simulated on the

    given work piece according to the dimensions.

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    All dimensions are in mm

    STUDY ABOUT CNC CODE GENERATION FOR MACHNING

    EXPT. NO: 14

    DATE :

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    AIM:

    To Study about CNC Code Generation for Machning

    SEQUENCE OF CODE GENENERATION

    Open solid model parts generated in CAD packages.

    Change view - select Isometric and zoom.

    Create stock representing the raw billet.

    Specify the stock material.

    Find 'Features' in the model: holes, pockets and bosses.

    Save your work.

    Specify a ToolStore database.

    Create machining for the features, using operations.

    Use Simulator to provide a visual confidence check of your machining.

    Edit operations.

    Generate the CNC code

    Loading the Cad Model

    1) In the Standard toolbar (orFile menu) click the Openbutton.

    2) .In the Open dialog that appears, navigate to the folder: installation

    folder\Cam\Examples\tutorial\Solid Machinist\Parasolid

    i. For example:

    ii. C:\Program Files\EdgeCAM\Cam\Examples\tutorial\Solid

    Machinist\Parasolid

    3) From this folder open prismatic milling.x_t

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    Selecting the Isometric View

    Right-click on the View Caption and in the menu that opens click

    Isometric.

    Zooming In And Out

    Enlarge or reduce the size of the part on the screen:

    Roll the top of the mouse wheel away from you to zoom in.

    Roll the top of the mouse wheel towards you to zoom out.

    Creating the Stock

    Stock represents the billet of material from which the part is to be

    machined.

    To create the stock:

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    2. Click the Solids menu and clickFeature Finder.

    3. In the Feature Finder dialog that opens, make these settings and click the OK

    button to find the features.

    4. Note how the Features Window is automatically displayed, showing a 'tree'

    view of the newlyfound.

    Specifying the Material

    Speeds and feeds are automatically calculated.

    These are based on the material being machined, so you need to specify this:

    1. Click the Options menu and clickModel.

    2. In the Model dialog that opens clickBrowse.

    3. In the dialog that opens scroll down the list in the All tab, then clickSteel

    150HB to select it, then clickSelect.

    4. ClickOKto close the Model

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    Specifying the Tool Store Database

    selecting pre-defined tools from the ToolStore. Using the ToolStore you can

    access tools from different databases, and need to ensure you are using the correct

    one, which is the example database that is installed with EdgeCAM:1. Click the Options menu and clickPreferences.

    2. In the Preferences dialog that opens click the Tool Libraries tab.

    3. The Name entry should be installation folder\Cam\tstore\tstore.mdb for

    example:

    c:\program files\EdgeCAM\Cam\tstore\tstore.mdb

    If this is not the entry, click the Browsebutton and use the browser to

    navigate to this file and open it.

    4. ClickOKto close the dialog.

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    Drilling the Hole

    Drill the hole through the centre of the part:

    1. In the Operations toolbar click the Hole Operationbutton.

    2. The Status Bar now prompts you to 'Select Points'. Click on the Features

    window tab and in the Features window rest the cursor on the 1: Through

    hole feature. The hole feature in the centre of the part changes colour to

    confirm where this is.

    3. Click on the feature to select it (the hole feature in the part changes

    colour again to show this).

    4. Move the cursor (now a cross) back into the Graphics area and right-click

    to terminate the points selection.

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    5. Now the Hole dialog opens. Leave all the settings unchanged, apart from

    setting Clearance to 20. ClickOK.

    6. The Hole operation is now created. Click the Sequence window tab, then

    click the '+' symbol for the Hole operation to see the instructions within the

    operation. (In the Graphics Area you see a graphic for the automatically-

    selected tool. Note how this has been given the diameter of the hole.)

    7. The Status Bar now prompts you to 'Digitise Stock'. Rest the cursor onone of the lines comprising the top profile of the stock. The line changes

    colour and the tooltip indicates 'Stock'. Double-click to select the whole top

    profile. Then right-click to terminate the stock selection. The Roughing

    operation is now created. The toolpath is displayed on the part.

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    8. Click the Sequence window tab. Now click the '+' symbol for the

    Roughing operation to see the instructions within the operation.

    Rest Roughing the Part

    In the previous roughing operation the tool was too large to remove all the

    material (the tool could not fit into the pockets, for example). You now 'rest rough'

    with a smaller tool to remove this material. To do this repeat the previous

    Roughing operation, but with slight changes. Here is a summary, with the changes

    marked '*':

    1. In the Operations toolbar clickRoughing Operation.

    2. Select the whole solid.

    3. Select no boundaries.

    4. In the Roughing Dialog, General tab, set Rest Rough to checked *, set

    Offset to 0.2, set Digitise Stock to unchecked * (you can leave the other

    settings as they are).

    5. Click the Tooling tab and from the ToolStore select the tool 6 mm

    Endmill - long series* (you can leave the other settings as they are).

    6. Click the Depth tab and set Clearance to 5, Level to 0, Depth to 0 andCut Increment to 2. Click OK to close the dialog and generate the

    operation (there will be no prompt for stock).

    7. In the Sequence window rest the cursor on 3Roughing Operation. Tool

    path for the operation becomes highlighted

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    Machining the Flat Lands

    A finishing tool on the flat areas, removing the material left by the0.2 offset

    in the previous Roughing operations:

    1. In the Operations toolbar click the Flatland Operationbutton.

    2. The Status Bar now prompts you to 'Digitise Geometry to machine'.Select the whole solid and terminate, as you did as you did before for the

    Roughing operations.

    3. At the 'Select boundary entities...' prompt right-click to terminate without

    making a selection.

    4. The Flatland Operation dialog now opens. In the General tab make these

    settings. (The Stand Off Distance leaves an unmachined border round the

    flats to be removed in subsequent Profiling operations.)

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    5. Click on the Tooling tab and from the ToolStore select 8 mm Endmill -

    long series as you did before for the Rest Roughing. (Other settings can be

    left as they are.)

    6. Click the Depth tab and set Clearance to 5, Level to -0.1 and Depth to

    0.

    7. ClickOKto close the dialog and generate the operation.

    Profiling the Inner Profile (Upper Boss)

    profile finish the upper central boss:

    1. In the Operations toolbar click the Profiling Operationbutton.

    2. The Status Bar now prompts you to 'Digitise Profile(s)'. Select the feature

    in the Features window and terminate as you did when drilling the hole.

    This time select the 7: 2D Boss feature.

    3. After terminating the geometry selection, terminate at the 'Select

    boundary entities' prompt without making a selection.

    4. The Profiling dialog now opens. In the General tab make these settings.

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    5. Click the Tooling tab and from the ToolStore select the 5 mm diameter

    SSM-ZX-2 Flute-5 (other settings can be left as they are).

    6. Click the Depth tab and set Clearance to 5, Level to 0, Depth to 0, Cut

    Increment to 2 and Cusp Height to 0.

    7. ClickOKto close the dialog and generate the toolpath.

    8. The tool graphic can sometimes get in the way. In the Display toolbarclick the ' ' symbol of the Toolbar Properties button and click Hide.

    Repeat to show the tool again. Set this as you prefer. With the tool hidden

    you have an unobstructed view of the part and its newThe tool graphic can

    sometimes get in the way. In the Display toolbar click the ' ' symbol of the

    Toolbar Properties button and clickHide. Repeat to show the tool again.

    Set this as you prefer. With the tool hidden you have an unobstructed view

    of the part and its new tool path

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    Profiling the Pockets

    Now start to machine the pockets. To do this repeat the previous Profiling

    operations, but with slight changes. Here is a summary, with the changes marked

    1. In the Operations toolbar clickProfiling Operation.

    2. Select all four pocket features *. To select all the pockets, click on the 3:

    2D Pocket then hold down the Shift key and click on 6: 2DPocket.

    3. Select no boundaries.

    4. In the Profiling dialog, General tab, set: Offset to 0 and Lead Radius 4.

    5. In the Profiling dialog Tooling tab open the ToolStore and select the

    3mm

    diameterSSM-ZX-2 Flute-3. (Other settings can be left as they are.)

    6. In the Profiling dialog Depth tab, set: Clearance to 5, Level to 0, Depthto 0, Cut Increment to 2, Cusp Height to 0. ClickOKto close the dialog

    and generate the operation.

    7. Rest the cursor on the new operation to highlight its

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    Simulating the Machining.

    In the Main toolbar underneath the Standard toolbar (or in the View

    menu) clickSimulate Machining.

    As the simulation continues, click the Speed Control button.

    In the Speed Control that appears, drag the slider to the left and right to control

    the speed of the simulation.

    Use these buttons to control the simulation at any time:

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    Editing the Profiling Operation

    As used the Operation as a quick way to generate a toolpath using automatic

    settings. The simulation highlighted a tool collision, but EdgeCAM allows you to

    'fine tune' the operation to correct this:

    1. In the Sequence window, click the '+' symbol of the last Profiling

    operation in the sequence. This expands the operation to show the

    instructions within it. The last instruction is 'Profiling'. This is the 'cycle',

    which controls the toolpath.

    2. Double-click on Profiling and in the Profiling dialog that opens, click the

    Linkstab and set (Long Links) Type to Clearance.

    3. Click OK to close the dialog. Repeat the simulation and collision has

    been

    eliminated.

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    Generating CNC Code

    Click the Generate Code button in the Main toolbar, underneath the

    Standard toolbar (or in the File menu). A message dialog now tells you

    that 'This option is not availablein the Student Edition', so this is as far

    as you can go with the liveexercise.

    After setting the CNC Name and clicking OK, the code would be

    generated. With Open Editor checked, the newly generated code is shown

    loaded into the Editor application.

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    RESULT

    Thus the basic study about CNC code generation for machiningcomponents

    of CNC machine have been studied.

    VIVA VOCE QUESTIONS

    1.what are the difference between CAD and CAM?

    2.Mention the major components of the CNC machine?

    3.What is the expansion of FANUC?

    4.What are the important lathe operation?5.what are the important milling operation?

    6.explain about G codes?

    7.Mention few important G codes?

    8.What is the use M codes?

    9.Write about some important M codes?

    10.What is the use of box facing cycle?

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    11.What is the difference between G00 and G01codes?

    12.How to make taper turning in lathe ?

    13.What is the code for multiple cycle?

    14.How to cut the thread in CNC lathe?

    15.How to change the tool in CNC program?

    16.How to change the tool speed in cnc lathe?17.what is the difference between absolute and incremental system?

    18.what are the axes to be considered while writing program for cnc lathe?

    19.what is the file extension of CNC program?

    20.what are the codes for coolants on or off?

    21.what is the g code for circular pocketing?

    22.How to change the depth of cut in milling operation?

    23.what is the use of mirroring?

    24.what are the functional keys use in fanuc programming?

    25.what is use of dry run option?

    26What are the important modeling operation?

    27.What are the advantages of CATIA?

    28.who is the developer of CATIA?

    29.what is the expansion of CATIA?

    30.what is the use of RIB command?

    31.What are important toolbars in catia?

    32.explain about dressing feature in CATIA?

    33.How to use Revolve command in catia?

    34.What are the important options in sketcher mode?

    35.How to import and export files from catia?

    36.What is the use of transformation?

    37.what is the use of AUTO constraint?

    38.What is the latest version of CATIA?.

    39What is the use of pad command?

    40.explain about loft command?

    41.what is the use of stiffener command?

    42.what is the use of shell command?

    43. what is the use of RIB command?

    44.What is the use of edge fillet?

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    45.what is the use of SHAFT command?

    46.What is the extension CATIA file?

    47.How to apply mirror command?

    48.Write about work bench?

    49.what is the use of pocket command?

    50.What are the features of CATIA


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