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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