LAB MANUAL / OBSERVATION

Transcription

1 DHANALAKSHMI COLLEGE OF ENGINEERING DR. VPR NAGAR, MANIMANGALAM, CHENNAI DEPARTMENT OF MECHANICAL ENGINEERING LAB MANUAL / OBSERVATION ME6611- CAD/CAM LABORATORY STUDENT NAME REGISTER NUMBER YEAR / SEM / SEC DEPARTMENT REGULATION : : : : :

2 ME6611- CAD / CAM LABORATORY 2

3 ME6611- CAD / CAM LABORATORY 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 List of Experiments 1. Introduction of 3D Modelling software Creation of 3D assembly model of following machine elements using 3D Modelling 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 24 PERIODS * Students may also be trained in manual drawing of some of the above components 2. MANUAL PART PROGRAMMING (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. 21 PERIODS 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 ME6611- CAD / CAM LABORATORY 3

4 OUTCOMES: modelling software. LIST OF EQUIPMENT FOR A BATCH OF 30 STUDENTS S.No. DESCRIPTION OF THE EQUIPMENT Quantity HARDWARE 1 Computer Server 1 2 Computer nodes or systems (High end CPU with atleast 1 GB 30 main memory) networked to the server 3 A3 size plotter 1 4 Laser Printer 1 5 CNC Lathe 1 6 CNC milling machine 1 SOFTWARE 7 Any High end integrated modelling and manufacturing CAD / CAM software 8 CAM Software for machining centre and turning centre (CNC Programming and tool path simulation for FANUC / Sinumeric and Heidenhain controller) 15 licenses 15 licenses 9 Licensed operating system Adequate 10 Support for CAPP Adequate ME6611- CAD / CAM LABORATORY 4

5 NAME: Sl. No. Date INDEX Exp. No. Name of the Experiments Marks Sign. 3D GEOMETRIC MODELING (CAD) 1 Introduction to modeling software Pro-E 2 1 3D Part Modeling D Part Modeling D Part Modeling D Assembly of Flange Coupling 6 5 3D Assembly of Plummer Block 7 6 3D Assembly of Screw Jack 8 7 3D Assembly of Lathe Tailstock 9 8 3D Assembly of Universal Joint D Assembly of Machine Vice D Assembly of Stuffing box D Assembly of Crosshead D Assembly of Connecting rod D Assembly of Piston D Assembly of Crankshaft D Assembly of Safety Valves (Practice) D Assembly of Non-return valves (Practice) COMPUTER AIDED PART PROGRAMMING (CAM) 18 Study of CNC Machine and Part Programming 1. TURNING EXERCISES Step Turning External Multiple Turning Grooving and Threading Operations Drilling and Boring Operations Internal Multiple Turning 2. MILLING EXERCISES Contour Milling Drilling Mirroring Circular Pocketing REG. No.: Lab Incharge HoD/Mech ME6611- CAD / CAM LABORATORY 5

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7 Introduction: INTRODUCTION TO MODELLING SOFTWARE PRO-E Pro-E is a high end cad package. Pro-E is a parametric solid model. It was developed by parametric technology corporation. It is suite of programs that are used in design analysis and manufacturing of a virtually unlimited range of products. Feature based: Pro-E is a feature based solid modeling tool. It builds the model using individual building blocks one at a time. Designers can think at a high level and leave all the low level geometry details, for Pro-E to figure out. Associative: We can use Pro-E to document model by creating parts, assemblies and drawing all these functions are really associative. Parametric: Parametric means that the physical shape of the part is driven by the values assigned to the attributes of its features. Solid modeling: Solid modeling means that the computer model we create is able to contain all the information that a real solid object would have the material. Parent - child Relationship: An important aspect to feature based modeling in Pro-E is the concept of modeling in pro-e parent - child relationship. Datum plane: A datum plane representation of an infinite large power surface area of a user defined orientation and location that are continuously adjusted automatically to be slightly larger than the object. ME6611- CAD / CAM LABORATORY 7

8 Plane-Insert-Datum-Plane: Default method creates three mutually perpendicular datum planes intersecting at the origin at the default coordinate system. These three planes represents XY, YZ & ZX planes are named as follows: DTM1 represents YZ plane DTM2 represents ZX plane DTM3 represents XY plane Datum axis: It can be used as a reference for features creation. It is particularly useful for making datum planes placing items concentrically and creating radial patterns. Part modeling: Pro-E is a feature based modeling software. Features in Pro-E are of two kinds. Place features extrude, revolve, sweep and blend are examples of sketched features. Sketches features: Protrusion features: Protrusion is the method of adding a solid material of the method. Pro-E provides the following basic methods of adding material to a method. Extrude: creates a solid feature by extruding a section named to the section. Revolve: creates a solid surface by revolving a section about an axis. Sweep: creates a solid feature by sweeping a section about a path. Blend: creates a solid feature by blending various cross sections at various levels. Extrusion: Features create solid protrusion extrude Attribute types: One side: Adds the material in one side of the cross section only. Both sides: Adds the material on both sides of the cross section. Defining sketching plane: We have to specify the sketch plane to draw the cross section. ME6611- CAD / CAM LABORATORY 8

9 Direction of feature creation: Once the direction of extrusion is defined Pro-E will promote for orienting the sketch plane. Orientation plane can lie horizontally or vertically in the section view sketch plane once the orientation plane is defined, tools needed for sketching the cross section will be provided by Pro-E. Sketch reference: Pro-E automatically selects two mutually perpendicular lines which are normal to the sketching plane as horizontal and vertical reference for dimensioning and constraining the sketch. Extrusion depth: Blind: Enter a dimension for the feature depth. We can then control the feature depth by changing the depth dimension Through next: Terminate the features at the next part surface Through all: The new surface intersects all surface Rib: Feature create solid rib A rib is a special type of protrusion designed to create a thin wall or web to support two surface. All straight holes are created with constant diameter. A hole from feature always removes material from our model. Round: Features create solid round It creates smooth transition with circular or profile between adjacent surface. An edge round smoothness the hard edges between adjacent surface. Sweep: Feature create solid protrusion sweep A sweep is create by defining two sections. The section is the trajectory and the second cross section. Sweep can be used on for protrusion cut and slots. ME6611- CAD / CAM LABORATORY 9

10 Blend: Feature create solid protrusion blend Blending is the method of defining a volume by connecting series of at least two planner sections together, at their edges with transitional surface. Assembly creation: Assembly mode in Pro-E enable us to place component parts and use assemblies together to form assemblies as well as to design parts based on how they should fit together. Mate: Selected surface point in opposite direction and become coplanar. Mate offset: Selected surface point in opposite direction and are offset by specific value. Align: Selected surface point in opposite direction and become coplanar axis may be co-axial with the align command. Align offset: Selected surface point in opposite direction and are offset by a specific value which is to be modified to provide design flexibility. Orient: Make the two surface of revolution co-axial. ME6611- CAD / CAM LABORATORY 10

11 3D PART MODELING ME6611- CAD / CAM LABORATORY 11

12 Ex. No: 01 3D PART MODELING - 1 ME6611- CAD / CAM LABORATORY 12

13 Ex. No: 01 3D PART MODELING - 1 Aim: To create a 3D part model by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Result: Thus the given 3D part model was created by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 13

14 Ex. No: 02 3D PART MODELING - 2 ME6611- CAD / CAM LABORATORY 14

15 Ex. No: 02 3D PART MODELING - 2 Aim: To create a 3D part model by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Result: Thus the given 3D part model was created by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 15

16 0. Adjust the coolant nozzle on the cutting edges and start the coolant pump. Ex. No: 03 3D PART MODELING - 3 ME6611- CAD / CAM LABORATORY 16

17 Ex. No: 03 3D PART MODELING - 3 Aim: To create a 3D part model by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Result: Thus the given 3D part model was created by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 17

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19 ASSEMBLY DRAWINGS ME6611- CAD / CAM LABORATORY 19

20 Ex. No: 04 3D ASSEMBLY DRAWING OF FLANGE COUPLING ME6611- CAD / CAM LABORATORY 20

21 Ex. No: 04 3D ASSEMBLY DRAWING OF FLANGE COUPLING Aim: To create various parts of flange coupling and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A coupling is a device used to connect two shafts together at their ends for the purpose of transmitting power permitting some degree of misalignment or end movement or both. Assembly: The shaft end is fitted to both male and female flange. Now both the male and female flange are joined together with help of the nut and bolt. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 21

22 Ex. No: 04 3D ASSEMBLY DRAWING OF FLANGE COUPLING ME6611- CAD / CAM LABORATORY 22

23 Ex. No: 04 3D ASSEMBLY DRAWING OF FLANGE COUPLING Result: Thus the given various part of flange coupling had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 23

24 Ex. No: 05 3D ASSEMBLY DRAWING OF PLUMMER BLOCK ME6611- CAD / CAM LABORATORY 24

25 Ex. No: 05 3D ASSEMBLY DRAWING OF PLUMMER BLOCK Aim: To create various parts of Plummer block and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A Plummer block is known as pillow block or bearing housing, is a pedestal used to provide support for a rotating shaft with the help of compatible bearings. Assembly: The brass part is mounted over the block. The block is covered along with brass part with help of a cover nut and lock nut. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 25

26 Ex. No: 05 3D ASSEMBLY DRAWING OF PLUMMER BLOCK ME6611- CAD / CAM LABORATORY 26

27 Ex. No: 05 3D ASSEMBLY DRAWING OF PLUMMER BLOCK Result: Thus the given various part of Plummer block had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 27

28 Ex. No: 06 3D ASSEMBLY OF SCREW JACK ME6611- CAD / CAM LABORATORY 28

29 Ex. No: 06 3D ASSEMBLY OF SCREW JACK Aim: To create various parts of screw jack and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A screw jack is used to raise heavy loads through a small vertical distance. In automobile industries, it is used to raise the vehicles for repair works. The nut is a separate piece press fitted into the hole of the body. Assembly: The cut is fitted on the top of the screw spindle. The nut arrangement is kept in between the screw spindle and the body. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 29

30 Ex. No: 06 3D ASSEMBLY OF SCREW JACK ME6611- CAD / CAM LABORATORY 30

31 Ex. No: 06 3D ASSEMBLY OF SCREW JACK Result: Thus the given various part of screw jack had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 31

32 Ex. No: 07 3D ASSEMBLY OF LATHE TAIL STOCK ME6611- CAD / CAM LABORATORY 32

33 Ex. No: 07 3D ASSEMBLY OF LATHE TAIL STOCK Aim: To create various parts of lathe tail stock and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: Tail stock is a part of lathe. It is mounted on the bed ways opposite to the head stock. It can be moved on the bed and clamped at any desired place on the bed. It is used to support the long work and sometimes tools like drill, reamer, etc. Assembly: This body of the tail stock has a hollow cylinder at the top and four rectangular blocks the bottom. The bore of the cylinder is to receive the barrel. Taper hole at the front end of the barrel is to receive the centre. The remaining hole portion of the barrel has threads. The barrel has a long key way to accommodate the feather key. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerlines Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 33

34 Ex. No: 07 3D ASSEMBLY OF LATHE TAIL STOCK ME6611- CAD / CAM LABORATORY 34

35 Ex. No: 07 3D ASSEMBLY OF LATHE TAIL STOCK Result: Thus the given various part of lathe tail stock had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 35

36 Ex. No: 08 3D ASSEMBLY OF UNIVERSAL COUPLING ME6611- CAD / CAM LABORATORY 36

37 Ex. No: 08 3D ASSEMBLY OF UNIVERSAL COUPLING Aim: To create various parts of universal coupling and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: Universal coupling is used to connect two shafts having intersecting axes. The angle between the two shafts is less than 30. It consists of two forks, centre blocks, pins. Assembly: The centre block is inserted into one of the forks. A collar is assembled on the other ends of the pin and locked by means of a cotter, the centre block such that the two fork ends are at right angles to each other. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 37

38 Ex. No: 08 3D ASSEMBLY OF UNIVERSAL COUPLING ME6611- CAD / CAM LABORATORY 38

39 Ex. No: 08 3D ASSEMBLY OF UNIVERSAL COUPLING Result: Thus the given various part of universal coupling had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 39

40 Ex. No: 09 3D ASSEMBLY OF MACHINE VICE ME6611- CAD / CAM LABORATORY 40

41 Ex. No: 09 3D ASSEMBLY OF MACHINE VICE Aim: To create various parts of machine vice and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: Machine vice is a work holding device. It is used to machine shape. The machine vice consists of a brass, a block, fixed jaw, screw, spindle and plate, set screws, etc. Assembly: The block is screwed to the base at one end. At another end the fixed end jaw is screwed. The spindle is then screwed through the block and sliding. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 41

42 Ex. No: 09 3D ASSEMBLY OF MACHINE VICE ME6611- CAD / CAM LABORATORY 42

43 Ex. No: 09 3D ASSEMBLY OF MACHINE VICE Result: Thus the given various part of machine vice had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 43

44 Ex. No: 10 3D ASSEMBLY OF STUFFING BOX ME6611- CAD / CAM LABORATORY 44

45 Ex. No: 10 3D ASSEMBLY OF STUFFING BOX Aim: To create various parts of stuffing box and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A stuffing box is an assembly which is used to house a gland seal between sliding or turning parts of machine elements. Assembly: The gland bush is inserted into the body. The studs are placed on both the holes on either sides of the body. The piston rod is inserted into the hole of the assembly. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok Result: Thus the given various part of stuffing box had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 45

46 Ex. No: 11 3D ASSEMBLY OF CROSS HEAD ME6611- CAD / CAM LABORATORY 46

47 Ex. No: 11 3D ASSEMBLY OF CROSS HEAD Aim: To create various parts of cross head and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A crosshead is a mechanism used in long reciprocating engines and reciprocating compressors to eliminate sideways pressure on the piston. Also the crosshead enables the connecting rod to freely move outside the cylinder. Assembly: The crosshead, with the help of slide block, reciprocates between two guides provided in the engine frame. The gudgeon pin, connects the slide blocks with the crosshead block. This acts as a pin joint for the connecting rod. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok Result: Thus the given various part of cross head had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 47

48 Ex. No: 12 3D ASSEMBLY OF CONNECTING ROD ME6611- CAD / CAM LABORATORY 48

49 Ex. No: 12 3D ASSEMBLY OF CONNECTING ROD Aim: To create various parts of connecting rod and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A connecting rod is an engine component that transfers motion from the piston to the crankshaft and functions as a lever arm. Assembly: The bearing bush which is in one piece, is fitted at the small end of the connecting rod. The small end of the rod is connected to the piston. The main bearing bush, which is split into two halves, is placed at the big end of the connecting rod. The big end of the rod is connected to the crank pin of the center crank. First, the split bearing brasses are placed on the crank pin, then the big end of the connecting rod and the cap are clamped onto these, by means of two bolts and nuts. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 49

50 Ex. No: 12 3D ASSEMBLY OF CONNECTING ROD ME6611- CAD / CAM LABORATORY 50

51 Ex. No: 12 3D ASSEMBLY OF CONNECTING ROD Result: Thus the given various part of connecting rod had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 51

52 Ex. No: 13 3D ASSEMBLY OF PISTON ME6611- CAD / CAM LABORATORY 52

53 Ex. No: 13 3D ASSEMBLY OF PISTON Aim: To create various parts of piston and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A piston is a component of reciprocating engines, used to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. Assembly: The connecting rod is attached to the piston by a swiveling gudgeon pin. This pin is mounted within the piston. The pin itself is of hardened steel and is fixed in the piston, but free to move in the connecting rod. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok Result: Thus the given various part of connecting rod had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 53

54 Ex. No: 14 3D ASSEMBLY OF CRANK SHAFT ME6611- CAD / CAM LABORATORY 54

55 Ex. No: 14 3D ASSEMBLY OF CRANK SHAFT Aim: To create various parts of crank shaft and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: A crankshaft is a mechanical part able to perform a conversion between reciprocating motion and rotational motion. In a reciprocating engine, it translates reciprocating motion of the piston into rotational motion. Assembly: The crankshaft has a linear axis about which it rotates, typically with several bearing journals riding on replaceable bearings (the main bearings) held in the engine block. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok Result: Thus the given various part of crank shaft had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 55

56 Ex. No: 15 3D ASSEMBLY OF SAFETY VALVES ME6611- CAD / CAM LABORATORY 56

57 Ex. No: 15 3D ASSEMBLY OF SAFETY VALVES Aim: To create various parts of safety valves and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: Safety valves are used to release some of the steam from the boiler when the pressure rises higher than the safe limit. Assembly: The valve seat is screwed in the valve body. The spindle and toggle together keeps the valve 3 pressed against the seat. The top of the valve body is closed with a cover with the help of six studs. A cover bush is used to prevent the leakage through the central hole of the cover. A lever guide is screwed to the cover in order to restrict the lever movement. The weight is attached to the lever by means of lever pin. The toggle is held in position by means of toggle pin. Fulcrum pin is used to connect the lever and the cover, to act as the fulcrum. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok ME6611- CAD / CAM LABORATORY 57

58 Ex. No: 15 3D ASSEMBLY OF SAFETY VALVES ME6611- CAD / CAM LABORATORY 58

59 Ex. No: 15 3D ASSEMBLY OF SAFETY VALVES Result: Thus the given various part of safety valves had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 59

60 Ex. No: 16 3D ASSEMBLY OF NON-RETURN VALVES ME6611- CAD / CAM LABORATORY 60

61 Ex. No: 16 3D ASSEMBLY OF NON-RETURN VALVES Aim: To create various parts of non-return valves and assemble them by using standard CAD software Pro-E. Hardware required: 250 GB hard disc,8 GB ram, core 2 quad processor, NVIDA graphic card, monitor, mouse and key board. Software required: Pro-E Wildfire 4.0 Description of the component: Valve is a device used for regulating the flow of fluid. In the non-return valve, the pressure of the fluid allows the flow in one direction only. Assembly: It consists of a body with flanges at right angle, for the purpose of mounting the same. The valve seat is introduced into the body from top and secured in place by setscrew. The valve is also introduced from top and located in the valve seat. The valve seat allows free sliding of the valve in it. The studs are first screwed into the body and after placing the cover, it is tightened with nuts. Commands used: Part diagram: Extrude Sketch Sketch to dimension Ok Hole Sketch Given dimension Ok Revolve Sketch plane Sketches Centerline Sketch to dimension Ok Assembly: Assembly Set default Assembly according to alignment Fully constrained Ok Result: Thus the given various part of non-return valves had been created and assembled by using standard CAD software Pro-E. ME6611- CAD / CAM LABORATORY 61

62 ME6611- CAD / CAM LABORATORY 62

63 COMPUTER AIDED PART PROGRAMMING ME6611- CAD / CAM LABORATORY 63

64 ME6611- CAD / CAM LABORATORY 64

65 STUDY OF CNC MACHINES AND PART PROGRAMMING Introduction: CAM: CAM is a team, which means the Computer Aided Manufacturing. CAM can be defined, as the use of the computer systems to plan, manage and control the operation of manufacturing interface with the plant is production resources. CNC machines: CNC stands for Computer Numerical Controlled machine is on NC system that utilizes a delectated stored program computer to perform some are all the basic numerical control functions. Part programming are entered and stored in computer memory CNC offers additional flexibility and computation capacity. New system options can be incorporated into the CNC controller simple by programming the unit. Classification of CNC machines: 1) MACHINING CENTRE a) Horizontal spindle machining center b) Vertical spindle machining center c) Universal machines. 2) TURNING CENTER CNC LATHES a) Horizontal machines b) Chucking machines c) Shaft machines d) Universal machines 3) CNC DRILLING AND MILLING MACHINES 4) CNC GRINDING MACHINE a) Surface grinding b) Cylindrical grinding c) Tool and cutter grinder d) Profile grinder 5) GEAR HOBBING MACHINES 6) PUNCHING AND FORMING MACHINES ME6611- CAD / CAM LABORATORY 65

66 Co-ordinate system: In order for the part programmer to plan the sequence of positions of moments of the cutting tool. Machine to the WIP, it is memory to establish a standard axis system by which the relative positions can be specified. Two axis X & Y are defined in the plane of the table, the z axis in perpendicular. In this plane of the table the vertical motion of the spindle controls the z direction. The positive and negative directions motion of the tool. Programming methods: 1) Incremental method 2) Absolute method 1) Incremental Method: In this method, every point is considered as origin from this point, the values are calculated, for example Point A = (10, 0) Point B = (20, 0) Point C = (10, 0) Point D = (20, 0) 2)Absolute method: In this absolute system, the set point is considered as a reference point as from that point, all the values are calculated, for example Point A = (10, 0) Point B = (20, 0) Point C = (30, 0) Point D = (50, 0) Programming methods: In CNC machines program are programmed by two methods. 1) Manual part programming 2) Computer assisted part programming 1) Manual part programming: To prepare a part program using the manual method, the programmer writes the machining instruction is must be hence, menu script the instruction is must be prepared in a ME6611- CAD / CAM LABORATORY 66

67 very precise manner because the typist prepare the NC type directory from the Manu script some in various form expending on the machine tool and tape format used. 2) computer assisted part programming: In the more complicated point and in contour application using manual part programming because an extremely tedious basic and subject to errors. It is must more appropriate to employ the high speed digital computer to assist the part programming languages system have been developed to perform automatically most of the calculation which the programmer would otherwise be forced to do. It several time and more efficient part program. PREPARATORY FUNCTIONS (G-CODE): Preparatory functions are used for cutting operations like facing, turning, thread cutting, drilling, etc., MISCELLANCEOUS FUNCTIONS (M-CODE) : Miscellaneous functions are used for other than cutting operations like spindle ON/OFF, coolant ON/OFF, tool change, etc., COMMON G CODES AND M CODES FOR CNC MACHINE CONTROLS CNC 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 G04 - Mill and Lathe, Dwell G09 - Mill and Lathe, Exact stop G10 - Setting offsets in the program; Mill and Lathe G12 - Circular pocket milling, clockwise; Mill G13 - Circular pocket milling, counterclockwise; Mill G17 - X-Y plane for arc machining; Mill and Lathe with live tooling G18 - Z-X plane for arc machining; Mill and Lathe with live tooling G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling G20 - Inch units; Mill and Lathe ME6611- CAD / CAM LABORATORY 67

68 G21 - Metric units; Mill and Lathe G27 - Reference return check; Mill and Lathe G28 - Automatic return through reference point; Mill and Lathe G29 - Move to location through reference point; Mill and Lathe G31 - Skip function; Mill and Lathe G32 - Thread cutting; Lathe G33 - Thread cutting; Mill G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe G43 - Tool length compensation; Mill G44 - Tool length compensation cancel; Mill (sometimes G49) G50 - Set coordinate system and maximum RPM; Lathe G52 - Local coordinate system setting; Mill and Lathe G53 - Machine coordinate system setting; Mill and Lathe G54~G59 - Work piece coordinate system settings #1 to #6; Mill and Lathe G61 - Exact stop check; Mill and Lathe G65 - Custom macro call; Mill and Lathe G70 - Finish cycle; Lathe G71 - Rough turning cycle; Lathe G72 - Rough facing cycle; Lathe G73 - Irregular rough turning cycle; Lathe G73 - Chip break drilling cycle; Mill G74 - Left hand tapping; Mill G74 - Face grooving or chip break drilling; Lathe G75 - OD groove pecking; Lathe G76 - Fine boring cycle; Mill G76 - Threading cycle; Lathe G80 - Cancel cycles; Mill and Lathe G81 - Drill cycle; Mill and Lathe G82 - Drill cycle with dwell; Mill ME6611- CAD / CAM LABORATORY 68

69 G83 - Peck drilling cycle; Mill G84 - Tapping cycle; Mill and Lathe G85 - Bore in, bore out; Mill and Lathe G86 - Bore in, rapid out; Mill and Lathe G87 - Back boring cycle; Mill G90 - Absolute programming G91 - Incremental programming G92 - Reposition origin point; Mill G92 - Thread cutting cycle; Lathe G94 - Per minute feed; Mill G95 - Per revolution feed; Mill G96 - Constant surface speed control; Lathe G97 - Constant surface speed cancel G98 - Per minute feed; Lathe G99 - Per revolution feed; Lathe CNC M Codes M00 - Program stop; Mill and Lathe M01 - Optional program stop; Lathe and Mill M02 - Program end; Lathe and Mill M03 - Spindle on clockwise; Lathe and Mill M04 - Spindle on counterclockwise; Lathe and Mill M05 - Spindle off; Lathe and Mill M06 - Tool change; Mill M08 - Coolant on; Lathe and Mill M09 - Coolant off; Lathe and Mill M30 - Program end, return to start; Lathe and Mill M97 - Local sub-routine call; Lathe and Mill M98 - Sub-program call; Lathe and Mill M99 - End of sub program; Lathe and Mill ME6611- CAD / CAM LABORATORY 69

70 Ex. No: 17 STEP TURNING Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 70

71 Ex. No: 17 STEP TURNING Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer lathe. Equipment required: M TAB CNC lathe (FLEXTURN) Travel x - axis 95 mm Travel z - axis 210 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for step turning operation is written & simulated by using CNC trainer lathe. ME6611- CAD / CAM LABORATORY 71

72 Ex. No: 18 EXTERNAL MULTIPLE TURNING CYCLE Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 72

73 Ex. No: 18 EXTERNAL MULTIPLE TURNING CYCLE Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer lathe. Equipment required: M TAB CNC lathe (FLEXTURN) Travel x - axis 95 mm Travel z - axis 210 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for external multiple turning operation is written & simulated by using CNC trainer lathe. ME6611- CAD / CAM LABORATORY 73

74 Ex. No: 19 GROOVING AND THREADING OPERATIONS Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 74

75 Ex. No: 19 GROOVING AND THREADING OPERATIONS Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer lathe. Equipment required: M TAB CNC lathe (FLEXTURN) Travel x - axis 95 mm Travel z - axis 210 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for grooving and threading operations are written & simulated by using CNC trainer lathe. ME6611- CAD / CAM LABORATORY 75

76 Ex. No: 20 DRILLING AND BORING OPERATIONS Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 76

77 Ex. No: 20 DRILLING AND BORING OPERATIONS Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer lathe. Equipment required: M TAB CNC lathe (FLEXTURN) Travel x - axis 95 mm Travel z - axis 210 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for drilling and boring operations are written & simulated by using CNC trainer lathe. ME6611- CAD / CAM LABORATORY 77

78 Ex. No: 21 INTERNAL MULTIPLE TURNING CYCLE Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 78

79 Ex. No: 21 INTERNAL MULTIPLE TURNING CYCLE Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer lathe. Equipment required: M TAB CNC lathe (FLEXTURN) Travel x - axis 95 mm Travel z - axis 210 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for internal multiple turning operations are written & simulated by using CNC trainer lathe. ME6611- CAD / CAM LABORATORY 79

80 Ex. No: 22 CONTOUR MILLING Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 80

81 Ex. No: 22 CONTOUR MILLING Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer mill. Equipment required: M TAB CNC milling machine (FLEXMILL) Travel x - axis 250 mm Travel y - axis 150 mm Travel z - axis 220 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation. 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Mill. Thus the program for contour milling is written & simulated by using CNC trainer ME6611- CAD / CAM LABORATORY 81

82 Ex. No: 23 DRILLING Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 82

83 Ex. No: 23 DRILLING Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer mill. Equipment required: M TAB CNC milling machine (FLEXMILL) Travel x - axis 250 mm Travel y - axis 150 mm Travel z - axis 220 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation. 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for drilling operation in milling is written & simulated by using CNC trainer Mill. ME6611- CAD / CAM LABORATORY 83

84 Ex. No: 24 MIRRORING Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 84

85 Ex. No: 24 MIRRORING Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer mill. Equipment required: M TAB CNC milling machine (FLEXMILL) Travel x - axis 250 mm Travel y - axis 150 mm Travel z - axis 220 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation. 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for mirroring operation in milling is written & simulated by using CNC trainer Mill. ME6611- CAD / CAM LABORATORY 85

86 Ex. No: 25 CIRCULAR POCKETING Program: ALL DIMENSIONS ARE IN mm ME6611- CAD / CAM LABORATORY 86

87 Ex. No: 25 CIRCULAR POCKETING Aim: To write and simulate part program of the given component for the required dimensions by using CNC trainer mill. Equipment required: M TAB CNC milling machine (FLEXMILL) Travel x - axis 250 mm Travel y - axis 150 mm Travel z - axis 220 mm Spindle speed rpm Tool holder 8 station ATC Algorithm: 1. First start the program. 2. Mention the feed rate whether metric or inches. 3. Indicate the reference point. 4. Change the tool for required operation. 5. Give the spindle speed. 6. Transverse motion of the tool to x31z1. 7. Give the linear interpolation motion of tool and feed rate. 8. Move the tool in x and z direction to obtain the required size. 9. Move the tool to required point. 10. Stop the program. Result: Thus the program for circular pocketing in milling is written & simulated by using CNC trainer Mill. ME6611- CAD / CAM LABORATORY 87