INTEGRATED DESIGN And MANUFACTURIG

Lab Manual
(19 ME C 104)

Department of Mechanical Engineering

M.E. CAD/CAM
Instruction 4 Periods per week
End Examination 50 Marks
Credits 2

CHAITANYA BHARATHI INSTITUTE OF TECHNOLOGY

(Autonomous)
Department of Mechanical Engineering
Gandipet, Hyderabad – 500 075.

Revision No: Prepared by Approved by Issued by

Copy No:

Page 1
Objectives:

To make the students to

1. Generate the part and assembly models using cad software
2. Create automated drawing and apply proper annotations on them.
3. Write different part programs for different components to be machined on lathe and milling
machine
4. Understand the reverse engineering concept
5. Understand the stl file generation and manipulations

Outcomes:

At the end of the course, student will be able to

1. Generate complex components in the part module and assemble them by using suitable
constraints
2. Generate engineering drawing and apply size, form and positional tolerances on the drawing
3. Write part programs using G and M codes for lathe and milling operations for various
components.
4. Differentiate additive and subtractive methods of manufacturing and their integration to build
the component
5. Gain confidence to operate the 3d printing machine.

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S.No. List of Experiments
Part modeling of simple and complex components by using various features of the
1 software
Assembly modeling of components using different constraints
2
Creation of Engineering drawing details and adding various annotations and generation
3 of automated BOM
Specifying tolerances for part and assembly Drawings
4
Writing of CNC programming for creation of Contours and Pockets
5
Surface Roughing of Crane Hook
6
Manufacturing of Bottle Die
7

8 Taper Turning and Multiple Turning on CNC Lathe Machine

Introduction to RP machine, Machine Specifications, Materials, Stl file generation

9

10 Slicing of stl files and obtaining the tool path data and sending it to RP machines

11 Demonstration of rapid tooling using fused deposition modeling

12 Conversion of physical model to digital data format to demonstrate Reverse Engineering

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Integrated Design and manufacturing lab explains the technology of modern
product manufacturing environment, and shows ho design and manufacturing are
integrated within it.

This lab shows the Benefis of Computer technology in modern product & process
manufacturing and design industries. Recognition of the interaction of design and
manufacturing in the product development cycle covering rapid prototyping.

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SOLIDWORKS

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EXERCISE-1 :

 Part modeling of simple and complex components by using

various features of the software

PART MODELS

Aim: Development of part drawings for various components in the form of

orthographic and isometric.
Create part models using sketch, feature commands: extrude, cut, revolve, loft,
sweep, rib, mirror, chamfer, fillet..

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Page 7
 Exercise no.1
PART MODELLING
AIM: To model the given drawing according to the given dimensions and generate
2d drawing

SOFTWARE USED: SOLIDWORKS 2018

PROCEDURE

1. Create a working directory.

2. Using the appropriate feature creation tools in the part module, model the
given part .mainly the following feature creation tools are used.

A) EXTRUDED BOSS/BASE B) EXTRUDED CUT C) FILLET

3. Apply Material

4. Mass Properties

5. Result: The component is modeled as per the given dimensions and its mass
properties are taken

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 Exercise no.2
PART MODELLING
AIM: To model the given drawing according to the given dimensions and generate
2d drawing

SOFTWARE USED: SOLIDWORKS 2018

PROCEDURE

1. Create a working directory.

2. Using the appropriate feature creation tools in the part module, model the
given part .mainly the following feature creation tools are used.

A) EXTRUDED BOSS/BASE B) EXTRUDED CUT C) FILLET

3. Apply Material

4. Mass Properties

5. Result: The component is modeled as per the given dimensions and its mass
properties are taken

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 Exercise no.3
PART MODELLING
AIM: To model the given drawing according to the given dimensions and generate
2d drawing

SOFTWARE USED: SOLIDWORKS 2018

PROCEDURE

1. Create a working directory.

2. Using the appropriate feature creation tools in the part module, model the
given part .mainly the following feature creation tools are used.

A) EXTRUDED BOSS/BASE B) EXTRUDED CUT C) FILLET

3. Apply Material

4. Mass Properties

5. Result: The component is modeled as per the given dimensions and its mass
properties are taken

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EXERCISE 5: Assembly of Petrol engine connecting rod

Aim : To model and assemble the components of Petrol Engine connecting

rod & generate 2d drawing it.

Objective: Create assembly of Petrol engine connecting rod and then estimate
the mass properties.

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EXERCISE 6: Assembly of Single Tool Post with finding mass properties

Aim : To create the assembly model of Single Tool Post shown in figure
below.

Objective: Make the part models, create Assembly and then make Drawing
of assembly model using Solidworks. Evaluate the mass properties of
assembly

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EXERCISE 7: Assembly of Eccentric with finding mass properties

Aim : To create the assembly model of Eccentric shown in figure below.

Objective: Make the part models, create Assembly and generate the Front
,Top and Side View of assembly model using Solidworks. Evaluate the mass
properties of assembly.

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COMPUTER AIDED MAUFACTURING

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Page 15
Introduction to CAM , G codes ; M codes
BASIC STEPS IN NC PROCEDURE

1. Process planning
2. Part programming
3. Part programming entry
4. Proving the part program
5. Production

Coordinate System for a CNC Lathe  RHCS

Thumb + x
Fore finger + y
Middle finger + z

Zero points & Reference Points:

1. Machine zero point.

- Specified by manufacturer.
- This is zero point for the coordinate
systems and reference points.
- Is at the centre of spindle nose face.
- When the tool traverses in the positive
direction, it moves away from the
workpiece.

2. Reference point.
- It has the same, precisely known
coordinates in relation to machine zero
point.
- This serves for calibrating and for
controlling the measuring system of the
slides and tool traverses.

3. Work piece zero point (W)

- Chosen by the programmer.
Determines workpiece coordinate system in relation to machine zero point.

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 G Codes: M05 Spindle stop
M06 Auto tool change
G00 Rapid traverse –
M08 Coolant on
positioning
M09 Coolant Off
G01 Linear interpolation -
M10 Chuck open
Feed
M11 Chuck Closed
G02 Circular interpolation
M13 Spindle forward and
CW
coolant on
G03 Circular interpolation
M14 Spindle reverse and
CCW
coolant on
G04 Dwell
M30 Program reset and
G21 Metric data input
rewind
G28 Reference point return
M98 Sub program call
G32 thread cutting
M99 Sub program end
G40 Tool nose radius
compensation - cancel
G70 Finishing cycle
G76 Thread cutting cycle
G90 Cutting cycle A: Turning
cycle
G94 Cutting cycle B: Facing
cycle
G97 CSS cancel – sets
spindle in RPM
G99 Feed per revolution
G96 Constant surface speed
(CSS control)

M Codes:

M00 Program stop

M01 Optional stop
M02 End of program
M03 Spindle forward
M04 Spindle reverse

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EXERCISE 8a: Contouring and Facing on CNC Milling Machine

Write the CNC Part Program to mill the component on CNC Milling
Machine (XL Mill) and write the process sheet for the same. The drawing
of the component is provided showing the required tool path of the
cutter.
CONTOUR MILLING

(understand that width of path on single cut = diameter of cutter)

Answer:
Contour (Milling)
CNC Part Program
G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T1
S1000 M03
G00 X10 Y30 Z10
G01 Z-.5 F50
G01 Y80
G02 X20 Y90 R10
G01 X50
G01 Y80 X65
G01 Y20
G02 X55 Y10 R10
G01 X30
G03 X10 Y30 R20
G00 Z20
M05
G21 G28 Z0
G28 X0 Y0

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M05
M30
Milling
PROCESS SHEET
Raw Material Program No. Metric/ Imperial
Material Size
75 x 100 mm Aluminium 01 Metric

Operation Operation Spindle Feed Tool

No. Speed mm/min No. Type Radius
rpm
1 Contour 1000 50 1 End 2 mm
Milling Mill

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EXERCISE 8(b) : Rectangular Pocketing on CNC Milling Machine.

Write the CNC Part Program to mill the component on CNC Milling
Machine (XL Mill) and write the process sheet for the same. The drawing
of the finished component is provided.
RECTANGULAR POCKET

Answer:
Rectangular Pocket
CNC Part Program

G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T01
M03 S1500
G90
G00 X0 Y0 Z5
G172 I-50 J-40 K0 P0 Q1 R0 X-25 Y-20 Z-3
G173 I0 K0 P75 T1 S1000 R30 F75 B1500 J75 Z20
G00 Z10
G91 G28 Z0
G28 X0 Y0
MK05
M30

Note
Understand the Syntax/ Usage of G172 and G173

G172 I-50 J-40 K0 P0 Q1 R0 X-25 Y-20 Z-3

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Input data for G172

I = Pocket X length
J = Pocket Y length
K = radius of corner roundness
P = roughing cycle
Q = pocket Z increment (peck increment in above cycle 2to 3 mm)
R = absolute Z ‘R’ point
X = Pocket corner X
Y = Pocket corner Y
Absolute position relative to the X and Y Datum Position
Z = Absolute Z base of pocket (-6; depth of 6mm)

G173I0 K0 P75 T1 S1000 R30 F75 B1500 J75 Z20

Input data for G173
I = Pocket side finish (0 for roughing cycle)
K = Pocket base finish
P = Cut width percentage (75% of total dia)
T = Pocket Tool (Tool 1)
S = Spindle Speed for Roughing (3000 rpm)
R = Roughing Feed for Z (75)
F = Roughing feed for X and Y (250)
B = Finishing Spindle Feed (3500 rpm)
J = Finishing Feed (200)
Z = Safety Z (5mm, above ‘R’ point)

Milling
PROCESS SHEET
Raw Material Program No. Metric/ Imperial
Material Size
75 x 100 mm Aluminium 05 Metric

Operation Operation Spindle Feed Tool

No. Speed mm/min No. Type Radius
rpm
1 Rectangular 1000 50 1 End 2.5
Pocketing Mill

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EXERCISE 8c : Circular Pocketing on CNC Milling Machine

Write the CNC Part Program to mill the component on CNC Milling
Machine (XL Mill) and write the process sheet for the same. The drawing
of the finished component is provided.
CIRCULAR POCKET

Answer:
Circular Pocketing
CNC Part Program

G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T01
S1000 M03
G90 G00 X0 Y0 Z5
G01 Z0
G170 R0 P0 Q1.5 X0 Y0 Z-3 I0 J0 K-25
G171 P75 S1000 R50 F60 B1500 J60
G00 Z10
G91 G28 Z0
G28 X0 Y0
M05
M30
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 Milling

PROCESS SHEET
Raw Material Size Material Program No. Metric/ Imperial
75 x 100 mm Aluminium 01 Metric

Operation Operation Spindle Feed Tool

No. Speed mm/min No. Type Radius
rpm
1 Circular 1000 50 1 End 2 mm
Pocketing Mill

NOTE:
Understand the usage of G170 and G171

G170 Circular Pocketing

R Surface if job or tool positioning
P Roughing cycle
Q Peck Improvement
X X axis
Y Y axis
Z Depth of Cut
I Side Finishing Allowance
J Bottom Finishing Allowance
K Radius of circle

G171 Circular Pocketing

P Cut width percentage
S Roughing Spindle Speed
R Roughing Feed in Z axis
F Roughing Feed in X, Y axis
B Finishing Spindle Speed
J Finishing Feed

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EXERCISE 8d : Taper Turning on CNC Lathe Machine

Write the CNC Part Program to turn the component on CNC Turning
Machine (XLTURN) and write the process sheet for the same. The drawing
of the finished component is provided.
TAPER TURNING

Taper Turning
CNC Part Program

[BILLET X25 Z75 ; G94 X0 Z-0.5 F50 ;

G90 X24.5 Z-45 ;

G21 G98; X24 ;

G28 U0 W0 ; X23.5 Z-6;

M06 T03 X23 ;

M03 S1000: X22.5 ;

G00 X25 Z1 ; X22 ;

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X21.5 ; X24 R-2 ;

X21 ; X24 R-2.5 ;

X20.5 ; X24 R-3 ;

X20 ; X24 R-3.5 ;

X19.5 ; X24 R-4 ;

X19 ; X24 R-4.5 ;

X18.5 ; X24 R-5 ;

X18 ; X24 R-5.5 ;

X17.5 ; X24 R-6 ;

X17 ; G00 X24 Z-24 ;

X16.5 ; G90 X23 R0.5 Z-39 F50 ;

X16 ; X22 R1 ;

X15.5 ; X21 R1.5 ;

X15 ; X20 R2 ;

X14.5 ; X19 R2.5 ;

X14 ; X18 R3 ;

X13.5 ; X17 R3.5 ;

X13 ; X16 R4 ;

X12.5 ; X15 R4.5 ;

X12 ; X14 R5 ;

G00 X24 Z-6 ; X13 R5.5;

G90 X24 Z-18 R-0.5 F50 ; X12 R6;

X24 R-1 ; G00 X24 Z-39 ;

X24 R-1.5 ; G90 X23.5 Z-45 F50 ;

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X23 ; G28 U0 W0 ;

X22.5 ; M30 ;

X22 ;

X21.5 ;

X21 ;

X20.5 ;

X20 ;

X19.5 ;

X19 ;

X18.5 ;

X18 ;

X17.5 ;

X17 ;

X16.5 ;

X16 ;

X15.5 ;

X15 ;

X14.5 ;

X14 ;

X13.5;

X13;

X12.5;

X12;

M05 ;

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NOTE:

Understand usage of G94 and G90

Facing cycle - G94

This cycle does a single facing cut (perpendicular to the part axis).

Format

G94 X_ Z_ F_

X = X coordinate of end point of cut

Z = Z coordinate of end point of cut

F = Feed rate

Turning cycle G90

Format of G90

G90 X_ Z_ R_ F_

X = X coordinate of end point of cut, absolute

Z = Z coordinate of end point of cut, absolute

R = Taper amount, radial.

F = Feed rate

The cut starts at point P1, ends at point P2.

R = (Diameter at start of cut – Diameter at end of cut) / 2

R must be specified with the proper sign.

The end point can be specified by incremental coordinates instead of absolute

coordinates. In this case: 1. Use addresses U and W instead of X and Z. 2. Use

appropriate signs with the end point, since incremental coordinates are

specified with reference to the start point.

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 Turning

PROCESS SHEET

Billet Size Material Program No. Metric/ Imperial

Φ 25 x 75 mm Aluminium 01 Metric

Operation Operation Spindle Feed Tool

No. Speed mm/min No. Type Radius
rpm
1 Facing 1000 50 3 Right

2 Taper 1000 50 3 Right

Turning

3 Turning 1000 50 3 Right

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EXERCISE9 : Manufacturing of Bottle Die
Botle is modeed using PRO/E

Core: The core which is the male portion of the mold forms the internal shape of
the molding.
Cavity: The cavity which is the female portion of the mold, gives the molding its
external form. core & cavity extraction in Pro/Engineer
File – new- manufacturing- core& cavity-OK Import reference model and
assemble by using Default option

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Select parting surface option and create parting surface Select mould volume option from menu
manager – select done – select parting surface option – select split option then it separates the
volume into two half’s.
Mould Design
Cavity: The cavity which is the female portion of the mold, gives the molding its external
form.Shrinkage allowance considered as 0.6% for zinc and the mould draft considered as 1°.

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 Additive Manufacturig

Additive manufacturing, also known as 3D printing, rapid prototyping or freeform

fabrication, is ‘the process of joining materials to make objects from 3D model
data, usually layer upon layer, as opposed to subtractive manufacturing
methodologies’ such as machining. The use of Additive Manufacturing (AM) with
metal powders is a new and growing industry sector with many of its leading
companies based in Europe. It became a suitable process to produce complex metal
net shape parts, and not only prototypes, as before. Additive manufacturing now
enables both a design and industrial revolution, in various industrial sectors such as
aerospace, energy, automotive, medical,toolin and consumer goods.

Flow layout of Pre 3D Printing

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Page 32
SPECIFICATIONS of FLA

Print Technology FFF

Assemble Type Assembled

Build Volume 230 x 150 x 160 mm (5.52 liters)

Number of Extruders Two

Layer Resolution 0.05–0.4 mm (50–400 microns)

Nozzle Diameter 0.4 mm

Position Accuracy XY-axis: 0.011 mm | Z-axis: 0.0025 mm

Print Technology 1.75 mm

Material Type PLA, ABS, TPU etc.

SD Card Reader, USB Port, Wi-Fi YES

Enclosed build chamber, Heated

Build Platform, Illuminated Build
YES
Area, Removable Build ,
Platform, Built-in Display
Included Software FlashPrint

Supported OS Windows, Mac OS X, Linux

File formats STL, OBJ, 3MF, FFP

Product Dimensions 485 x 344 x 382 mm

Product Weight 14 kg

Page 33
Printing Of Cube

In this First exercise we will design a simple Box as seen in the figure below. Fused
Filament Fabrication (FFF) is the most common method of 3D printing. It is also the method that
the Inventor uses. It works by melting plastic material (PLA-Poly Lactic Acid) called filament
onto a print surface in high temperature. The filament solidifies after it cools down, which
happens instantaneously after it is extruded from the nozzle.
3D objects areformed with the filament laying down multiple layers. This exercise will
build the foundations of how to design 3D parts in SolidWorks and introduce several
fundamental features such as Rafting, Supporting, and Printing
Step1. First we install 3d design software in your computer like solids work auto cad, etc.
Open the solids work software and click New option in software window

1. Click New , Option

2. Click Part and OK .
3. Click on Top Plane and click Sketch.
4. Click Rectangle , sketch a rectangle start from origin.
5. Click Smart Dimension , click side edge and click top edge to dimension it as 1.0in x 1.0in.
6. Click Features>Extruded Boss/Base set D1 as 1.0in and click .
7. It’s done. Simple Right?

Stemp 2: Slice software is the software that prepares 3D models for printing and turns them
into instructions for the 3D printers. FlashPrint is the slicing software used for the FlashForge
Inventor. Using FlashPrint, you can turn .stl files to be .g or .gx files for printing. Then the files
can be transferred to your Inventor via USB cable, SD card or Wi-Fi.

Stemp 3: Notice! After starting FlashPrint, you need to select the target machine type first.
When you start FlashPrint, a dialog box will pop up. Just need to select FlashForge Inventor in
the machine type list and click [OK]. You can also change the machine type via clicking [Print]--
[Machine type]. Please see graphic 6-2: 6-2 6.2.2 FlashPrint Menus 6-3 Inventor User Guide |
www.FlashForge.com 29 400-699- 1063 6.2.3 Loading You can load a model file or Gcode file
into your FlashPrint by the following six methods: Method 1: Click the Load icon on the main
interface. Then select the object file. Method 2: Select the file for loading and drag the file to the
main interface of the software. Method 3: Click [File]--[Load File]. Then select the object file for
loading. Method 4: Click [File]--[Examples] to load the example files

Stemp 4: Loading filament: Remove the lid of the Inventor Inventor User Guide | From the
main menu, tap the right icon labeled [Tool]. (4-10)Tap [Filament] and [Load Left]. Wait for the
extruder to heat up to the operating temperature. The extruder will alert you once it is at the
operating temperature. Load the filament by inserting it into the extruder at an upright angle.
Filament will start to extrude out of the nozzle. Continue loading to ensure that the filament is
extruding in a straight line. Refer to the troubleshooting section if the filament is extruding
abnormally. Then tap [Done] to finish loading.

In this First exercise we will design a simple Box as seen in the figure below. Fused Filament
Fabrication (FFF) is the most common method of 3D printing. It is also the method that the

Page 34
Inventor uses. It works by melting plastic material (PLA-Poly Lactic Acid) called filament onto a
print surface in high temperature. The filament solidifies after it cools down, which happens
instantaneously after it is extruded from the nozzle.
3D objects areformed with the filament laying down multiple layers. This exercise will
build the foundations of how to design 3D parts in SolidWorks and introduce several
fundamental features such as Rafting, Supporting, and Printing
Step1. First we install 3d design software in your computer like solids work auto cad, etc.
Open the solids work software and click New option in software window

1. Click New , Option

2. Click Part and OK .
3. Click on Top Plane and click Sketch.
4. Click Rectangle , sketch a rectangle start from origin.
5. Click Smart Dimension , click side edge and click top edge to dimension it as 1.0in x 1.0in.
6. Click Features>Extruded Boss/Base set D1 as 1.0in and click .
7. It’s done. Simple Right?

Step 2: Slice software is the software that prepares 3D models for printing and turns them into
instructions for the 3D printers. FlashPrint is the slicing software used for the FlashForge
Inventor. Using FlashPrint, you can turn .stl files to be .g or .gx files for printing. Then the files
can be transferred to your Inventor via USB cable, SD card or Wi-Fi.

Step 3: Notice! After starting FlashPrint, you need to select the target machine type first.
When you start FlashPrint, a dialog box will pop up. Just need to select FlashForge Inventor in
the machine type list and click [OK]. You can also change the machine type via clicking [Print]--
[Machine type]. Please see graphic 6-2: 6-2 6.2.2 FlashPrint Menus 6-3 Inventor User Guide |
www.FlashForge.com 29 400-699- 1063 6.2.3 Loading You can load a model file or Gcode file
into your FlashPrint by the following six methods: Method 1: Click the Load icon on the main
interface. Then select the object file. Method 2: Select the file for loading and drag the file to the
main interface of the software. Method 3: Click [File]--[Load File]. Then select the object file for
loading. Method 4: Click [File]--[Examples] to load the example files

Step 4: Loading filament: Remove the lid of the Inventor Inventor User Guide | From the
main menu, tap the right icon labeled [Tool]. (4-10)Tap [Filament] and [Load Left]. Wait for the
extruder to heat up to the operating temperature. The extruder will alert you once it is at the
operating temperature. Load the filament by inserting it into the extruder at an upright angle.
Filament will start to extrude out of the nozzle. Continue loading to ensure that the filament is
extruding in a straight line. Refer to the troubleshooting section if the filament is extruding
abnormally. Then tap [Done] to finish loading.

Aim: to print the cube in Flash Forge Inventor 3D-printer

Slicing Software: Flash Print

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Prninter Name: Flash Forge Inventor 3D-printer

Nozzle Dia: 0.40mm

Layer Height: 0.30mm

Printing Speed: 60 mm/sec

Inner Sheel Speed : 60 mm/sec

Outer Sheel Speed: 60 mm/sec

Infill Extrude: Primary Extruder

Infill density: 5%

Infill Speed: 60 mm/sec

Temperatur:

Bed Temperature: 60 deg

Primary Extruder Temp = 225 deg

Slice Time: 1 Hr 18 Min 51 Sec

Temp: Right Extrude- 215 deg

Plat form temp -50 deg

Others : Cooling Automatic

Result: The Cube Will be obtained in 36mn with given dimensions

Page 36
Generating stl format file with specifications

Page 37
Open flash print software for 3D printing

Page 38
Go to print
Print options
Slect machine type- flash forge inventor series

Material Right PLA/ABS

Materila Left PLA/ABS

Supports Enable/Disable/Right Extruder/Left Extruder

Raft Enable/Disable/Right Extruder/Left Extruder

Page 39
Page 40
Result:

The stl file as been sliced and is manufactured using 3D printing

Page 41