Cad Cam Lab Manual.docx

FRANCIS XAVIER ENGINEERING COLLEGE TIRUNELVELI – 627003.

DEPARTMENT OF MECHANICAL ENGINEERING

ME – 6611, CAD / CAM LABORATORY- Manual

Name

: .....................................................................................

Reg No

: ......................................................................................

Branch

: MECHANICAL ENGINEERING

Semester : VI Subject

: CAD/ CAM LABORATORY 1

College vision and mission: Vision: Our Vision is "To create innovative and vibrant young leaders and entrepreneurs in Engineering and Technology for building India as a super knowledge power and blossom into a University of excellence recognized globally". Mission: To provide education in Engineering with excellence and ethics and to reach the unreached. QUALITY POLICY

We aim at continuous pursuit for excellence through    

Quality education tapped from National and International Resources 14 Modular approach to channelize knowledge and programmed evaluation of knowledge accumulated Continuous reviewable and renewal of quality systems leading to quality output Producing Engineers with strong ethical and moral background

2

DEPARTMENT OF MECHANICAL ENGINEERING The Department of Mechanical Engineering was started in the year 2005 and offers a full time 4 year B.E Degree Program. The Department has conducted much national level Technical Symposium and Workshops. The Department is strongly built with excellent lab facilities and enriched by senior faculty members. The students are given theoretical and practical input.

The Vision of the Department is To produce competent mechanical engineers of excellent technical and managerial skills for national and global development.

The Mission of the Department is To provide best education in mechanical engineering, encouraging innovation and entrepreneurship through professional and moral ethics to improve the quality of the people worldwide. Programme Educational Objectives (PEO’s) S.No.

PEOs

Definition of PEOs

I

PEO 1 IMPARTING KNOWLEDGE

To impart intense knowledge in basic science and its applications in engineering.

II

PEO 2 MULTI DISCIPLINE

To integrate the knowledge on basic sciences and engineering concepts with industrial, social and environmental issues and to innovate technologies for betterment.

III

PEO 3 SKILL DEVELOPMENT

To develop interpersonal skills to strengthen team work, leadership quality and to promote awareness about continual learning not limited to higher studies.

IV

To enhance professionalism in problem solving through PEO 4 PROFESSIONALISM decisiveness, moral and professional ethics to shoulder social responsibility.

3

Programme Outcomes (PO’s) S.No. Programme Outcomes Engineering Knowledge: Apply knowledge of mathematics, science, engineering Pa fundamentals and an engineering specialization for building engineering models. Problem Analysis: Identify and solve engineering problems reaching conclusions Pb using mathematics and engineering sciences. Design/Development of Solutions: Design and develop solutions for engineering Pc problems that meet specified needs. Conduct Investigations of Complex Problems: Conduct investigations of complex Pd problems including design of experiments and analysis to provide valid solutions. Modern Tool Usage: Create and apply appropriate techniques, resources, and modern Pe engineering tools for executing engineering activities. The Engineer and Society: Apply reasoning of the societal, safety issues and the Pf consequent responsibilities relevant to engineering practice. Environment and Sustainability: Understand the impact of engineering solutions in Pg the environment and exhibit the knowledge for sustainable development. Ethics: Apply ethical principles and commit to professional ethics, responsibilities and Ph norms of engineering practice. Pi Individual and Team Work: Function effectively as an individual, and as a member or leader in diverse teams in multi-disciplinary settings. Communication: Communicate effectively to the engineering community and the Pj outside world and also to write effective reports. Pk Project Management and Finance: Understand engineering and management principles and apply them to handle projects in multi disciplinary environments. Pl Life-Long Learning: Recognize the need for life-long learning and apply in the context of technological change.

4

CAD/CAM LABORATORY INTRODUCTION: Introduction to computer-aided design (CAD) and computer-aided manufacturing (CAM) theory and applications. Topics include CAD/CAM systems (Hardware and Software), Geometric modeling using curves, surfaces and solids, CAD/CAM data exchange, CAD and CAM integration, Mechanical assembly, Mechanical Tolerance, Mass property calculations, Process planning and Tool path generation, integration of CAD/CAM with the production machine, and Computer control of machines and processes in manufacturing systems. Projects will focus on development of geometric procedures for design and manufacturing applications and the use of commercial CAD/CAM software for automating the production cycle. Applications include NC machining, design of (optimum) cutting tools and modeling and design of fixtures for dies and molds. Hands-on experience is attained through CNC machine tool laboratory.

OVERVIEW: After completion of this course, the students should be able to: 1. Explain the concepts and underlying theory of modeling and the usage of models in different engineering applications. Explain the benefits of a comprehensive and integrated CAD/CAM system. 2. Create accurate and precise geometry of complex engineering systems and use the geometric models in different engineering applications. 3. Compare the different types of modeling techniques and explain the central role solid models play in the successful completion of CAD/CAM-based product development. 4. Use and assess state-of-the-art CAD/CAM codes efficiently, effectively and intelligently in advanced engineering applications. 5. Develop algorithms for 2D and 3D geometric modeling. 6. Use current state-of-the-art CAD/CAM technology in research. 7. Explain the basic concepts of CNC programming and machining.

DOs and DON’T DOs in Laboratory: 1. Do not enter the laboratory without lab coat and shoes. 5

2. Do not engage in practical jokes or boisterous conduct in the laboratory. 3. Never run in the laboratory. 4. The use of personal audio or video equipment is prohibited in the laboratory. 5. The performance of unauthorized experiments is strictly forbidden. 6. Do not sit on laboratory benches 7. Follow the instructions given by the teacher.

Instruction to Teachers: 

Prepare an outline (on the board) of the lab activities



Do not hesitate to explain things more than once or answer questions that you may consider simple



Demonstrate new techniques to the class or small groups



Check the students are in proper lab uniform.



Visit with each student individually during the lab



Ask specific questions of the students in order to monitor their progress during the lab



Provide ample feedback to students during the lab

Instruction to students: 

Student should maintain discipline & silence inside the lab.



Follow the instructions given by the teacher



Students should bring their textbook, observation and record to the lab class and no other materials are allowed.



HEADINGS and DETAILS should be neatly written



i. Aim of the experiment



ii. Apparatus / Tools / Instruments required



iii. Procedure / Theory / Algorithm / Program



iv. Neat Diagram



v. Result / discussions.



Students should maintain the cleanliness of the lab. 6



Be PATIENT, STEADY, SYSTEMATIC AND REGULAR.

Lab Code of Conduct:

 Students should enter the lab with proper Dress code (i.e. with I.D card, shoes & lab coat)  Breakdown of apparatus /Equipment should be immediately intimated to the staff In-charge 

and proper entry should be made in the breakdown Register Students should log off the systems and arrange the chairs before leaving the lab.

Major Lab Equipments with Specifications: S.No

Description of Equipment

Specifications

HARDWARE 1

Computer nodes or systems

2

Laser Printer

3

CNC Lathe

4

CNC milling machine

Processor :Pentium (R) Dual-core Ram : 2 GB Hard Disk Capacity :320 GB HP laser Jet Printer XL Turn –MTAB CNC Short Bed Lathe Milling machine +8 station automatic tool changer with hydraulic power pack

SOFTWARE 5

6

Any High end integrated modeling and manufacturing CAD / CAM software –Solid Edge CAM Software for machining centre and turning centre (CNC Programming and tool path simulation for FANUC / Sinumeric and Heidenhain controller)

15 licenses

15 licenses

ANNA UNIVERSITY SYLLABUS - ME6611 CAD / CAM LABORATORY (Regulation -2013) LTPC 7

0032 COURSE OBJECTIVES:  To gain practical experience in handling 2D drafting and 3D modelling software systems.  To study the features of CNC Machine Tool.  To expose students to modern control systems (Fanuc, Siemens etc.,)  To know the application of various CNC machines like CNC lathe, CNC Vertical Machining centre, CNC EDM and CNC wire-cut and studying of Rapid prototyping. LIST OF EXPERIMENTS 1. 3D GEOMETRIC MODELLING

24 PERIODS

List of Experiments 1. Introduction of 3D Modeling software Creation of 3D assembly model of following machine elements using 3D Modeling software 2. Flange Coupling 3. Plummer Block 4. Screw Jack 5. Lathe Tailstock 6. Universal Joint 7. Machine Vice 8. Stuffing box 9. Crosshead 10. Safety Valves 11. Non-return valves 12. Connecting rod 13. Piston 14. Crankshaft * Students may also be trained in manual drawing of some of the above components 2. Manual Part Programming. 21 PERIODS (i) Part Programming - CNC Machining Centre a) Linear Cutting. b) Circular cutting. c) Cutter Radius Compensation. d) Canned Cycle Operations. (ii) Part Programming - CNC Turning Centre a) Straight, Taper and Radius Turning. b) Thread Cutting. c) Rough and Finish Turning Cycle. d) Drilling and Tapping Cycle. 8

3. Computer Aided Part Programming e) CL Data and Post process generation using CAM packages. f) Application of CAPP in Machining and Turning Centre. TOTAL: 45 PERIODS COURSE OUTCOMES Ability to develop 2D and 3D models using modeling software’s. Ability to understand the CNC control in modern manufacturing system. Ability to prepare CNC part programming and perform manufacturing. LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS S.No Description of Equipment

Qty

HARDWARE 1

Computer Server

1

2

30

3

Computer nodes or systems (High end CPU with at least 1 GB main memory) networked to the server A3 size plotter

4

Laser Printer

1

5

CNC Lathe

1

6

CNC milling machine

1

1

SOFTWARE 7 8

Any High end integrated modeling and manufacturing CAD / CAM software CAM Software for machining centre and turning centre (CNC Programming and tool path simulation for FANUC / Sinumeric and Heidenhain controller)

9

Licensed operating system Adequate

10

Support for CAPP Adequate

Mapping Of Course Outcomes with Program outcomes

9

15 licenses 15 licenses

Pa

Pb

Pc

Pd

Pe

Pf

Pg

Ph

Pi

Pj

Engineering Knowledge: Apply knowledge of PO engineering fundamentals and mathematics, science, an engineering specialization for building engineering models. Problem Analysis: Identify and solve engineering problems reaching conclusions using mathematics and engineering sciences. Design/Development of Solutions: Design and develop solutions for engineering problems that meet specified needs. Conduct Investigations of Complex Problems: Conduct investigations of complex problems including design of experiments and analysis to provide valid solutions. Modern Tool Usage: Create and apply appropriate techniques, resources, and modern engineering tools for executing engineering activities. The Engineer and Society: Apply reasoning of the societal, safety issues and the consequent responsibilities relevant to engineering practice. Environment and Sustainability: Understand the impact of engineering solutions in the environment and exhibit the knowledge for sustainable development. Ethics: Apply ethical principles and commit to professional ethics, responsibilities and norms of engineering practice. Individual and Team Work: Function effectively as an individual, and as a member or leader in diverse teams in multi-disciplinary settings. Communication: Communicate effectively to the engineering community and the outside world and also to write effective reports.

10

X

PROFESSIONA LISM

X

X

X

X

SKILL DEVELOPMEN T

MULTI DISCIPLINE

PEO

IMPARTING KNOWLEDGE

S. No.

X

X

X

X

X

X

X

X

X

X

X

X

Pl

11

MULTI DISCIPLINE

PROFESSIONA LISM

Project Management and Finance: Understand engineering and PO management principles and apply them to handle projects in multi disciplinary environments. Life-Long Learning: Recognize the need for lifelong learning and apply in the context of technological change.

SKILL DEVELOPMEN T

Pk

PEO

IMPARTING KNOWLEDGE

S. No.

X

X

X

LIST OF EXPERIMENTS Index EX.NO

DATE

EXERCISES

PAGE NO

MARKS AWARDED

CAD EXERCISES (1. 3D GEOMETRIC MODELLING) 1

INTRODUCTION OF 3D MODELING SOFTWARE

2

SOLID MODELING AND ASSEMBLY OF FLANGE COUPLING

3

SOLID MODELING AND ASSEMBLY OF PLUMMER BLOCK

4

SOLID MODELING AND ASSEMBLY OF SCREW JACK

5

SOLID MODELING AND ASSEMBLY OF LATHE TAIL-STOCK

6

SOLID MODELING AND ASSEMBLY OF UNIVERSAL COUPLING

7

SOLID MODELING AND ASSEMBLY OF MACHINE VISE

8

SOLID MODELING OF STUFFING BOX

9

SOLID MODELING AND ASSEMBLY OF CROSS HEAD SOLID MODELING AND ASSEMBLY OF LEVER CHECK VALVE SOLID MODELING AND ASSEMBLY OF CONNECTING ROD SOLID MODELING AND ASSEMBLY OF PISTON

10 11 12

CAM EXERCISES (2. Manual Part Programming) 1

STUDY OF “G” CODES AND “M” CODES

2

CNC-MILLING RECTANGULAR POCKETING

3

CNC-MILLING CIRCULAR POCKETING

4

CNC-SIMPLE TURNING

5

CNC-STEP TURNING

6

CNC LATHE –RIGHT HAND TAPER TURNING

7

CNC LATHE –LEFT HAND TAPER TURNING

8

CNC LATHE –THREAD CUTTING OPERATION

12

STAFF SIGNATURE

CAD – exercises

13

EX. No. 01 Date:

INTRODUCTION TO SOLID EDGE

Solid Edge, a product of Siemens, is one of the world’s fastest growing solid modeling software. Solid Edge with Synchronous Technology combines the speed and flexibility of direct modeling with precise control of dimension-driven through precision sketching, region selection, face selection, and handle selection. Solid Edge ST4 integrates the synchronous modeling with the traditional modeling into a single environment. It is an integrated solid modeling tool, which not only unites the synchronous modeling with traditional modeling but also address every design-through-manufacturing process. In Solid Edge, the 2D drawing views can be easily generated in the drafting environment after creating solid models and assemblies. The drawing views that can be generated include orthographic views, isometric views, auxiliary views, section views, detail views and so on. The user can use any predefined drawing standard file for generating the drawing views. The user can display model dimensions in the drawing views or add reference dimensions whenever he wants. The bidirectional associative nature of this software ensures that any modifications made in the model is automatically reflected in the drawing views. To make the design process simple and efficient, the software package divides the steps of designing into different environments. This means, each step of the design process is completed in a different environment. Generally, a design process involves the following Steps:  Sketching by using the basic sketch entities and converting them into features or parts. These parts can be sheet metal parts, surface parts or solid parts.  Assembling different parts and analyzing them  Generating drawing views of the parts and the assembly. Solid Edge supports data migration from various CAD packages such as IDEAS, AutoCAD, Mechanical Desktop, Pro/E, Inventor, CATIA, and NX documents. As a result, all files and documents created in this software into a Solid Edge document. Solid Edge Environments To reduce the complications of a design, this software package provides you with various design environments. a. Part Environment This environment is used to create solid as well as surface models. The part environment consists of two environments namely Synchronous Part and Ordered Part. Synchronous is the 14

default environment in ST4. In this environment, there is no separate environment to draw sketches; rather the sketching tools are available in the Synchronous Part environment itself. b. Assembly Environment This environment is used to create an assembly by assembling the components that were created in the Part environment. This environment supports animation, rendering, piping, and wiring. c. Draft Environment This environment is used for the documentation of the parts or the assemblies in the form of drawing views. The drawing views can be generated or created. All the dimensions added to the component in the part environment during its creation can be displayed in the drawing views in this environment. d. Sheet Metal Environment This environment is used to create sheet metal components. e. Weldment Environment This environment enables you to insert components from the part or the assembly environment and apply weld beads to the parts or the assembly. This environment is associative with the part and assembly environment. User Interface of Solid Edge Prompt Line: If the user invokes a tool, the prompt line is displayed below the command bar. This line is very useful while creating a model, because it provides the user with the prompt sequences to use a tool. Path Finder: The Path Finder is present on the left of the drawing area. It lists all occurences of features and sketches of a model in a chronicle sequences. Docking Window: The docking window is available on the left of the screen and remains collapsed by default. It has different tabs on the top. These tabs can be used to activate the feature library, family of parts etc. Ribbon: The Ribbon is available at the top of the solid edge window and contains all application tools. It is a collection of tabs. Each tab has different groups and each group is a collection of similar tools.

15

Quick Access toolbar: It is available on the top-left of the title bar of the solid edge window. It proves an access to the frequently used commands such as New, Open, Undo, Redo, Save and Print. Application Button: It is available on the top left corner of the solid edge window. It is present in all environments. On choosing this button, the Application menu containing the options for creating, opening, saving, and managing documents will be displayed. Status Bar: It is available at the bottom of the solid edge window. It enables the user to quickly access all the view controls like Zoom Area, Zoom, Fit, Pan, Rotate, Sketch View, View Orientation, and View styles. Quick Bar: It provides the command options for the active tool. Radial Menu: Radial menu is a set of tools arranged radially. To invoke a tool from the radial menu, press the right mouse button and drag the cursor. Keeping the right mouse button pressed, move the cursor over the tool to be invoked. The user can add or remove tools from the radial menu. Part Environment Tabs: There are several tabs in the Ribbon that can be invoked in the part environment. i. Home ii. Sketching iii. Surfacing iv. PMI v. Simulation vi. Inspect vii. Tools viii. View    Circle     

Tools used in Solid Edge DRAW tools: Line  Line  Curve  Point Rectangle  Rectangle by Center 16

Rectangle by 2 Points Rectangle by 3 Points Polygon by Center Circle by 3 Points Circle by Center Point Tangent Circle Ellipse by Center point Ellipse by 3 Points

Arc

RELATE tools:  Connect  Parallel  Concentric  Horizontal/Vertical  Equal  Tangent  Symmetric  Perpendicular  Lock

 Tangent Arc  Arc by 3 Points  Arc by Center Point Fillet Chamfer Extend to Next Trim Trim Corner Offset Move Rotate Split Mirror Scale Stretch  Angular Coordinate Dimension  Coordinate Dimension  Symmetric Diameter

DIMENSION tools:  Smart Dimension  Distance Between  Angle Between          

SOLIDS tools:  Extrude  Revolve  Hole  Hole  Thread  Round

17

Round Blend Chamfer Equal Setbacks Chamfer Unequal Setbacks Draft Thin Wall Rib Web Network Lip Vent

FLANGE COUPLING

18

Flange coupling

19

EX. No. 02

SOLID MODELING AND ASSEMBLY OF FLANGE COUPLING

Date:

AIM: To generate the 3-D model of flange coupling using Solid Edge software. System Requirements:  Personal computer  Solid modeling software (solid edge).

Bill of materials: Part no 1 2 3 4 5

Description Flange shaft Taper key Hex.bolt Hex.bolt

Material Cast iron Fe -410 w Fe - 410 w Fe - 410 w Fe - 410 w

Numbers 2 2 2 4 4

Description:  A flange coupling usually applies to a coupling having two separate cast icon flanges. Each flange is mounted on the shaft end and keyed to it.  The faces are turned up at right angle to the axis of the shaft. One of the Flange has a projected portion and the other flange has a corresponding recess. This helps to bring the shafts into line and to maintain alignment. the two flanges are coupled together by means of bolts and nuts. The flange coupling is adopted to heavy loads and hence it is used on large shafting. The flange couplings are of the following three types. 1. Unprotected type flange coupling 2. Protected type flange coupling. 3. Machine type flange coupling. 4. In main type flange coupling, the flanges are forged integral with the shafts. Commands used: The following commands are used in the creation of components and assembly of flanged coupling.  Protrusion  Coincident plane  Cutout  Revolved protrusion 20

    

Revolved cutout Mate Axial align Panel align Trim

PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8.

Using sketch protrusion, fillet, contour and pattern command as flange is created. Using sketch protrusion and cutout command shaft end is created. Using sketch protrusion command a taper key is created. Using sketch &protrusion command a hexagonal bolt is created. Similarly hexagonal nut is created. Using axial align, planar align command flange and shaft are assembled. Using mate command, taper key is positioned. This assembly is inserted twice in an assembly window and mated together by mate command. Bolts and nuts are assembled by using axial align and mate command respectively.

RESULT: Thus the 3-D model of Flange coupling is generated Solid Edge software.

21

PLUMMER BLOCK

22

Plummer block

23

EX. No. 03

SOLID MODELING AND ASSEMBLY OF PLUMMER BLOCK

Date: AIM: To draw the components of Plummer Block and to assemble them using Solid Edge software. System Requirements:  Personal computer  Solid modeling software (solid edge). Bill of materials: Part no 1 2 3 4 5 6

Description A cap Spilt bushes Square head bolts Hexagonal nuts Shaft Body

Material Cast iron Brass Fe 410 w Fe 410 w Fe 410 w Cast iron

Numbers 1 2 2 2 1 1

Description:  When a long shaft is to be supported at intermediate points, bushed bearing are not used due to their limitations. In such cases plummer blocks are used.  In the plummer block bearing, the body is split horizontally along or near axis of the shaft. This will enable to overcome the disadvantage of the bushed bearings.  The bottom of the body is relieved leaving a narrow machined strip all rounds and it reduces the extent of preparation and leveling of the bearing area relatively.  Split bush is fitted in the body, the projecting snug of the split bush fits into the corresponding hole drilled in the body. This prevents the rotation of the bushes along with the shaft and axial movement of the split bushes are prevented by collars.  After assembling a small clearance will be left between cap and the body. This clearance enables to provide the necessary clamping grip. Commands used: The following commands are used in the creation of components and assembly of flanged coupling.  Protrusion  Coincident plane  Cutout 24

     

Round chamfer Mate Axial align Panel align Trim

PROCEDURE: 1. Model different parts of a Plummer block using extrude, revolve features. 2. Select the drawing in solid works main menu. 3. Using inset component icon of property manager, insert base component and next components to assemble. 4. Assemble using mate feature. 5. Continue the inserting components and waiting until the entire components are assembled. 6. Save the assembly. 7. From the main menu of solid works select the drawing option. 8. Select the drawing sheet format as A4 landscape. 9. Using model view manager, browse the document to be open. 10. Click the view orientation from the model view manager. 11. Place the drawing view in the proper place in the sheet. 12. Using the placed view as parent view, project the other or needed views. 13. Move cursor to anyone view and right click the muse button. 14. Place the BOM in the proper place in the drawing sheet. 15. Save the drawing sheet.

RESULT: Thus the components of Plummer Block have been drawn and assembled using Solid Edge software. 25

SCREW JACK

26

Screw jack

27

EX.NO:04

SOLID MODELING AND ASSEMBLY OF SCREW JACK

Date: Aim: To model and assemble the components of screw jack as per the given dimensions and to covert the 3D views with bill of materials. System requirement:  Personal computer  Solid modeling software (solid edge). Bill of materials: Part no 1 2 3 4 5 6 7

Description Body Nut Screw spindle Cup Washer special Counter shunk screw Tommy bar

Material Cast iron Gun metal Fe - 410 w Cast Steel Fe - 410 w Fe - 410 w Fe - 410 w

Numbers 1 1 1 1 1 1 1

Commands used: Command part sketch protrusion Cutout round chamfer offset extend Assembly Axial align mate

Menu operation Draw toolbar Feature- toolbar sketch-specify direction thickness Feature -toolbar -sketch- specify direction and thickness Feature -toolbar -select chain -specified radius Feature – tool bar –select chain –specify length Feature – select thickness Feature – select the line to extend it Menu operation Relationship -toolbar -pick the object surfaces Relationship toolbar. pick object surface and insect.

28

Procedure: 1. 2. 3. 4. 5. 6. 7. 8. 9.

From the main menu of solid work, select the drawing option. Select the drawing sheet format as A4 landscape. Using the model view manager browse the document to be open Click the view orientation from the model view manager and place the drawing view in the proper place in the sheet. Model the different parts of screw jack by using sketch, protrusion, extend command. By using offset command, body of the screw jack is drawn. By using cutout command, counter shunk screw is drawn. All the parts of screw jack are drawn by revolved protrusion, select axis of rotation line and draw the half side of the parts and revolved it. Click the parts and drag it on the assemble it and select the mating option to assemble the components.

Result:

Thus the screw jack is modeled and assembled by using the several commands of solid works and it is converted into different views respectively. 29

LATHE TAIL-STOCK

30

Lathe tail stock

31

EX. No. 05

SOLID MODELING AND ASSEMBLY OF LATHE TAIL-STOCK

Date: AIM: To draw the components of Lathe Tail-stock and to assemble them using software. PROCEDURE: 1. 2. 3. 4. 5. 6. 7. 8.

From the main menu of solid work, select the drawing option. Select the drawing sheet format as A4 landscape. Using the model view manager browse the document to be open Click the view orientation from the model view manager and place the drawing view in the proper place in the sheet. Model the different parts of Lathe tail-stock by using sketch, protrusion, extend command. By using offset command, body of the Lathe tail-stock is drawn. All the parts of Lathe tail-stock are drawn by revolved protrusion, select axis of rotation line and draw the half side of the parts and revolved it. Click the parts and drag it on the assemble it and select the mating option to assemble the components.

RESULT: Thus the components of Lathe Tail-stock have been drawn and assembled using solid Edge Software.

32

COMPONENTS OF UNIVERSAL COUPLING

33

34

Universal coupling

35

EX.NO:6

SOLID MODELING AND ASSEMBLY OF UNIVERSAL COUPLING

Date: Aim: To model and assemble the universal coupling as per the dimensions given and also covert the 3D model into the different views with the bill of material. System Requirements:  Personal computer  Solid modeling software (solid edge). Bill of materials: Part no 1 2 3 4 5 6 7

Description Fork centre shaft Parallel key pin collar Taper pin

Material Cast steel Cast iron Fe -410 w Fe - 410 w Fe - 410 w Fe - 410 w Fe – 410 w

Numbers 2 1 2 2 2 2 2

Description:  An universal or hooke’s coupling is used to connect the two shafts whose axis intersect at a small angle.  The inclination is transmitted from one shaft to another.  The main application of the universal coupling is found in the transmission from the gear box to the differential or back axle of the automobiles.  In such a case, we use two universal couplings. One at each end of the propeller shaft connects the gear box at one end and the differential at other end.  The universal coupling is also used for transmission of power to different spindles of multiple drilling machine.  It is used to a knee joint in the milling machine. Command part

Menu operation 36

sketch protrusion Cutout hole pattern round Revolved cutout Assembly Axial align Planar align mate angle

Draw toolbar Feature toolbar sketch, specify direction thickness Feature toolbar sketch- specify direction thickness Feature toolbar sketch specified direction Feature toolbar select radius direction number of feature Feature toolbar select chain specified radius Feature toolbar sketch, specify radius direction Menu operation Relationship toolbar pick the object surfaces Relationship toolbar, pick object and faces Relationship toolbar. pick object surface and insect. Relationship toolbar. specify the angle

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

Result: Thus the given universal coupling is modeled; assembled and different views are taken. 37

MACHINE VISE

38

MACHINE VISE

39

EX. No. 7

SOLID MODELING AND ASSEMBLY OF MACHINE VISE

Date: AIM: To draw the components of Machine vise and to assemble them using Solid Edge software. PROCEDURE: 1. Model different parts of a Machine vise using extrude, revolve features. 2. Select the drawing in solid works main menu. 3. Using inset component icon of property manager, insert base component and next components to assemble. 4. Assemble using mate feature. 5. Continue the inserting components and waiting until the entire components are assembled. 6. Save the assembly. 7. From the main menu of solid works select the drawing option. 8. Select the drawing sheet format as A4 landscape. 9. Using model view manager, browse the document to be open. 10. Click the view orientation from the model view manager. 11. Place the drawing view in the proper place in the sheet. 12. Using the placed view as parent view, project the other or needed views. 13. Move cursor to anyone view and right click the muse button. 14. Place the BOM in the proper place in the drawing sheet. 15. Save the drawing sheet.

RESULT: Thus the assembly of machine vise has been drawn and assembled using Solid Edge Software.

40

STUFFING BOX

41

STUFFING BOX

42

Ex. No. 08

SOLID MODELING OF STUFFING BOX

Date: AIM: To generate the 3-D model of gland and stuffing box using Solid Edge software. 43

SYSTEM REQUIREMENTS: 40 GB hard disks, 1GB RAM, WINDOWS XP, P4 processor. TOLLS USED: Sketcher, features, smart dimension. PROCEDURE: 1. Open the solid work application. 2. The geometry parts are drawn using the sketches tools such as line, circle, etc. & dimensions are made. 3. By using the feature tools, the 2-D objects is extruded and rotated into 3-D solid. 4. The 3D model is modified using the pocket, chamfer, shell, etc. according to requirements. 5. All the components are drawn as 3-D Solids and assembled using the assembly design. 6. Finally gland and stuffing the assembled model is saved in the desired folder.

RESULT: Thus the 3-D model of gland & Stuffing box is generated using the Solid Edge software. CROSS HEAD

44

CROSS HEAD 45

Ex. No. 09

SOLID MODELING AND ASSEMBLY OF CROSS HEAD

Date: 46

AIM: To draw the components of Cross Head and to assemble them using Solid Edge software. PROCEDURE: 1. Open Solid Edge software. Select file -New-Part and select dimension as mm. 2. Depending on the component select the plane (Front or Top or Right or Left) and click sketch. 3. Select the axis for the plane using axis line command and using line and circle command draw the required views of the component. 4. Using delete command, remove unwanted lines and circles 5. After completing the view click button. Now depending on shape of the component either click revolve or extrude command. 6. In order to make a hole, click - extrude and click remove material. 7. After extruding or revolving click button to get the complete solid component. 8. Save the part using file - save a copy, command. 9. All remaining components are drawn in similar manner. 10. The drawn solid components are assembled.

RESULT: Thus the components of Cross Head have been drawn and assembled using Solid Edge software.

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LEVER CHECK VALVE

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LEVER CHECK VALVE

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LEVER CHECK VALVE

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EX. No. 10

SOLID MODELING AND ASSEMBLY OF LEVER CHECK VALVE

Date: AIM: To draw the components of Lever Check Valve and to assemble them using Solid Edge software. PROCEDURE: 1. Open Solid Edge software. Select file -New-Part and select dimension as mm. 2. Depending on the component select the plane (Front or Top or Right or Left) and click sketch. 3. Select the axis for the plane using axis line command and using line and circle command draw the required views of the component. 4. Using delete command, remove unwanted lines and circles 5. After completing the view click button. Now depending on shape of the component either click revolve or extrude command. 6. In order to make a hole, click - extrude and click remove material. 7. After extruding or revolving click button to get the complete solid component. 8. Save the part using file - save a copy, command. 9. All remaining components are drawn in similar manner. 10. The drawn solid components are assembled.

RESULT: Thus the assembly of Lever Check Valve has been drawn and assembled using Solid Edge software. 51

CONNECTING ROD

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CONNECTING ROD

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EX. No. 11

SOLID MODELING AND ASSEMBLY OF CONNECTING ROD

Date: AIM: To draw the components of Connecting Rod and to assemble them using Solid Edge software. PROCEDURE: 1. Open Solid Edge software. Select file -New-Part and select dimension as mm. 2. Depending on the component select the plane (Front or Top or Right or Left) and click sketch. 3. Select the axis for the plane using axis line command and using line and circle command draw the required views of the component. 4. Using delete command, remove unwanted lines and circles 5. After completing the view click button. Now depending on shape of the component either click revolve or extrude command. 6. In order to make a hole, click - extrude and click remove material. 7. After extruding or revolving click button to get the complete solid component. 8. Save the part using file - save a copy, command. 9. All remaining components are drawn in similar manner. 10. The drawn solid components are assembled.

RESULT: Thus the assembly of connecting rod has been drawn and assembled using Solid Edge software. 54

ASSEMBLY OF PISTON

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PISTON

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EX. No. 12

SOLID MODELING AND ASSEMBLY OF PISTON

Date: AIM: To draw the components of Piston Block and to assemble them using Solid Edge software. PROCEDURE: 1. Open Solid Edge software. Select file -New-Part and select dimension as mm. 2. Depending on the component select the plane (Front or Top or Right or Left) and click sketch. 3. Select the axis for the plane using axis line command and using line and circle command draw the required views of the component. 4. Using delete command, remove unwanted lines and circles 5. After completing the view click button. Now depending on shape of the component either click revolve or extrude command. 6. In order to make a hole, click - extrude and click remove material. 7. After extruding or revolving click button to get the complete solid component. 8. Save the part using file - save a copy, command. 9. All remaining components are drawn in similar manner. 10. The drawn solid components are assembled.

RESULT: Thus the components of Piston Block have been drawn and assembled using Solid Edge software. 57

CAM – exercises

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EX.NO:1

STUDY OF “G” CODES AND “M” CODES

Date: Aim: To study the “G” codes and “M” codes for the CNC milling machine. Programming codes:  Codes are model and do not have to be repeated in every sequence line.  All dimensions are entered as decimals. G –codes for turning machine: MTAB INDIA PVT LTD G- To define tool movement for preparatory function. G OO > Rapid movement G O1 > Linear movement with feed rate G 02 > Circular interpretation clockwise with feed rate G 03 > Circular interpretation counterclockwise with feed rate G 04 > Dwell time in seconds G 17 > XY plane G 18 > XZ plane G 19 > YZ plane G 20 > Inch mode input (in”) G 21 > multi mode input (mm) G 28 > return to reference point (home position) G 40 > tool nose radius compensation cancel G 41 > tool nose radius compensation left G 42 > tool nose radius compensation right G 70 > finishing cycle G 71 > multiple turning cycle G 72 > multiple facing cycle G 74 > deck drilling cycle in z axis G 75 > grooving cycle in z axis G 76 > thread cutting cycle G 90 > turning cycle 59

G 92 > thread cutting cycle G 94 > facing cycle G 98 > feed per minute, G 99 > feed per revolution M- Codes / Miscellaneous codes: M 00 > program stop M 01 > optional stop M 02 > program end M 03 > spindle forward (cw) M 04 > spindle reverse ( ccw) M 05 > spindle stop M 06 > tool change M 08 > coolant ON M 09 > coolant OFF M 10 > chuck open M 11 > chuck close M 30 > program stop and restart M 98 > sub program call M 99 > sub program exit

G- CODES FOR MILLING MACHINES: HYTECH CNC MACHINE, PUNE G 00 > point to point rapid positioning G 01 > linear interpretation G 02 > Circular interpretation arc clockwise G 03 > Circular interpretation arc counterclockwise G 04 > Dwell time in seconds G 12 > circular pocketing clockwise G 13 > circular pocketing anticlockwise G 15 > polar coordinate system OFF G 16 > polar coordinate system ON G 17 > XY plane selection for arc movement G 18 > XZ plane selection for arc movement G 19 > YZ plane selection for arc movement G 20 > selecting inch mode input G 21 > selecting metric mode input G 40 > cutter compensation/offset,cancel 60

G 41 > cutter radius compensation / offset-left G 42 > cutter radius compensation / offset-right G 43 > tool length compensation -positive G 44 > tool length compensation -negative G 49 > tool length compensation -cancel G 50 > scaling mode cancel (OFF) G 51 > scaling mode ON G 54 > shift of coordinate G 55 > shift of coordinate G 56 > shift of coordinate G 57 > shift of coordinate G 58 > shift of coordinate G 59 > shift of coordinate G 68 > coordinate rotation system ON G 69 > coordinate rotation system ON G 70 > Inch programming G 71 > metric programming G 80 > drilling cycle G 81 > fixed cycle no 1 drill, spot drill G 82 > fixed cycle no 2 drill, counter bore G 83 > fixed cycle no 3 drill, deep hole G 84 > tapping cycle G 85 > fixed cycle no 4 drill, bore G 86 > boring cycle G 87 > back boring cycle G 88 > boring cycle G 89 > boring cycle G 90 > absolute dimension input G 91 > incremental dimension input G 94 > feed rate selection per min G 95 > feed rate selection per minute G 98, 99 > tool return position G 28 > return to reference point (home position) G 40 > tool nose radius compensation cancel G 41 > tool nose radius compensation left G 42 > tool nose radius compensation right G 70 > finishing cycle G 71 > multiple turning cycle G 72 > multiple facing cycle 61

G 74 > peck drilling cycle in z axis G 75 > grooving cycle in z axis G 76 > thread cutting cycle G 90 > turning cycle G 92 > thread cutting cycle G 94 > facing cycle G 98 > feed per minute G 99 > feed per revolution M- Codes / Miscellaneous codes: M 00 > program stop M 01 > optional program stop M 02 > program end M 03 > spindle motor ON and forward direction (cw) M 04 > spindle motor ON and reverse direction ( ccw) M 05 > spindle stop M 06 > automatic tool change M 08 > coolant pump motor ON M 09 > coolant pump motor OFF M 21 > mirror image along x axis M 22 > mirror image along y axis M 23 > mirror image along z axis M 30 > program stop and restart M 98 > sub program call M 99 > sub program exit

RESULT Thus the “G” codes and “M” codes for the CNC milling & Turning machines were studied.

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EX.NO:2

CNC-MILLING RECTANGULAR POCKETING

DATE: Aim: To perform a rectangular milling operation by using CNC milling programming codes. Apparatus required:  CNC machine  Personal computer  CNC software Program: M 03 S 1500 (Stock /block 100,100, 10, -4, -4, -7) (tool /mill 10, 0, 30, 0) (color 0, 255, 0) G21 G98 G00 X0 Y0 Z5 G00 X10 Y10 Z5 F120 G01 X60 Y10 Z-3 F120 G01 X60 Y60 Z-3 F120 G01 X10 Y60 Z-3 F120 G01 X10 Y10 Z-3 F120 G00 X0 Y0 Z5 M05 M30

RESULT: Thus the rectangular milling operations by using CNC milling programming codes were performed. 64

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EX.NO:3

CNC-MILLING CIRCULAR POCKETING

DATE: Aim: To write a manual part program for performing a circular pocketing milling operation by using CNC milling programming codes. Apparatus required:    

CNC machine Personal computer CNC software Work piece (100 x100 x 10 mm)

Program: (Stock /block 100,100, 10, 15, 10) (tool /mill 5, 0, 50, 0) (color 255,255, 255) G21 G98 M05 S1500 G00 X0 Y0 Z5 G00 X50 Y50 Z5 G01 X50 Y50 Z-2 F50 G02 I5 F50 G02 I9 F50 G02 I12 F50 G00 X50 Y50 Z5 G00 X0 Y0 Z5 M05 M30. RESULT: Thus the circular milling operations by using CNC milling programming codes were performed. 66

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EX.NO:4

CNC LATHE-SIMPLE TURNING

DATE: Aim: To perform the simple turning operation by using CNC programming codes. Apparatus required:     

CNC machine Personal computer CNC software Cutting tool Work piece

Program: Billet X32 Z70 G21 G98 G28 U0 W0 M06 T02 M03 S1000 G00 X32 Z3 G90 X31 Z-28 F100 X30 X29 X28 G28 U0 W0 M05 M30

RESULT: Thus the simple turning operation was performed by using CNC Lathe programming codes. 68

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EX.NO:5

CNC LATHE-STEP TURNING

DATE: Aim: To perform the step turning operation by using CNC programming codes. Apparatus required:     

CNC machine Personal computer CNC software Cutting tool Work piece

Program: Billet X32 Z70 G21 G98 G28 U0 W0 M06 T01 M03 S1500 G00 X32 Z5 G90 X31 z-30 X30 Z-25 X28 Z-20 X24 Z-15 G28 U0 W0 M05 M30

RESULT: Thus the step turning operation was performed by using CNC Lathe programming codes. 70

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EX.NO:6

CNC LATHE –RIGHT HAND TAPER TURNING

DATE: Aim: To perform the right hand taper turning operation by using CNC programming codes. Apparatus required:     

CNC machine Personal computer CNC software Cutting tool Work piece

Program: Billet X32 Z70 G21 G98 G28 U0 W0 M06 T01 M03 S1500 G00 X32 Z5 G90 X30 Z-30 R-1 F50 R-2 R-3 G28 U0 W0 M05 M30

RESULT: Thus the right hand taper turning operation was performed by using CNC Lathe programming codes. 72

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EX.NO:7

CNC LATHE –LEFT HAND TAPER TURNING

DATE: Aim: To perform the left hand taper turning operation by using CNC programming codes. Apparatus required:     

CNC machine Personal computer CNC software Cutting tool Work piece

Program: Billet X32 Z70 G21 G98 G28 U0 W0 M06 T01 M03 S1500 G00 X32 Z5 G90 X30 Z-30 R-1 F50 X28 R2 X26 R3 G28 U0 W0 M05 M30

RESULT: Thus the left hand taper turning operation was performed by using CNC Lathe programming codes. 74

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EX.NO:8

CNC LATHE –THREAD CUTTING OPERATION

DATE: Aim: To perform thread cutting operation by using CNC programming codes. Apparatus required:     

CNC machine Personal computer CNC software Cutting tool Work piece

Program: Billet X32 Z70 G21 G99 G28 U0 W0 M06 T02 M03 S1500 G00 X32 Z5 G94 X31 Z45 F1.5 X30.5 X30 G00 X29.3 Z2 G76 P1 Q12 R0.7 F0.5 G76 X28.05 Z40 P12 Q12 F0.5 X28.6 R1.4 X28 R1.95 G28 U0 W0 M05 M30 RESULT: Thus the thread cutting operation was performed by using CNC Lathe programming codes. 76

VIVA-VOCE QUESTIONS AND ANSWERS 1. What are the applications of CAD?    

Design of machine elements, CNC machine tools, robotics etc Panel design and circuit layout Mapping ,building plans, contour plotting and structural drawing Interior design and modeling.

2. Define absolute co-ordinates? Values locating a point in space that describe its displacement from origin (0, 0, 0) point of the drawing. 3. Define polar co ordinates. Values are locating a point in space that describes its location relative to the last point picked as defined by an angle and distance. 4. What is the default position of the UCS ICON? 0, 0, 0 5. What are the two main types of projection? Perspective and Parallel. 6. List out some of the modeling software currently available? Solid works, CATIA, Pro-E, IDEAS. 7. What is universal coupling? A universal joint, universal coupling,U-joint,Cardan joint, Hardy Spicer joint, or Hooke's joint is a joint or coupling in a rigid rod that allows the rod to 'bend' in any direction, and is commonly used in shafts that transmit rotary motion. 8. What is the application of Screw jack? Screw jack it is commonly used to lift heavy weights such as the foundations of houses, or large vehicles. 9. What are the constraints available for assembly? Mate constraint, angle constraint, and tangent constraint and insert constraint. 77

10. What are the difference between CAD and CAM? Computer aided drafting (CAD) is the process of creating a design, known as drafting, using computer technology. Computer aided manufacturing (CAM) is the use of computers and computer software to guide machines to manufacture something, usually a part that is massproduced. 11. What are the important modeling operations? Extrude, revolve, sweep. 12. How to use Revolve command in SOLIDWORKS? Using this tool, the sketch is revolved about the revolution axis. 13. Explain about G codes? G-code is the common name for the most widely used numerical control (NC) programming language, which has many implementations. Used mainly in automation, it is part of computeraided engineering. G-code is sometimes called G programming language. 14. Mention few important G codes? G00 -Positioning at rapid speed; Mill and Lathe G01 -Linear interpolation (machining a straight line); Mill and Lathe G02 -Circular interpolation clockwise (machining arcs); Mill and Lathe G03 -Circular interpolation, counter clockwise; Mill and Lathe G20 -Inch units; Mill and Lathe G21 -Metric units; Mill and Lathe. 15. What is the use M code? A word used to signal an action from a miscellaneous group of commands. M codes change cutting tools, turn on or turn off the coolant, spindle, or work piece clamps, etc. 16. Write about some important M codes? M00 -Program stop; Mill and Lathe 78

M01 -Optional program stop; Lathe and Mill M02 -Program end; Lathe and Mill M05 -Spindle off; Lathe and Mill. 17. What are the axes to be considered while writing program for CNC lathe? X and Z Axis. 18. What is the code for Incremental and absolute co-ordinate system? G90 and G91. 19. What is the code for coolant control?  M7-turn mist coolant on.  M8-turn flood coolant on.  M9-turn all coolant off. 20. What is use of dry run option? A dry run (or a practice run) is a testing process where the effects of a possible failure are intentionally mitigated.

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