ME 408.01 - Computer Aided Manufacturing - Lab Manual
ME 408.01 - Computer Aided Manufacturing - Lab Manual
INDEX
No.
Sr. Date of Sign of
Date Title of Marks
No. Assessment Faculty
Pages
7 Rapid Prototyping
Practical No. 1
CONSTRUCTION AND WORKING OF NC/CNC MACHINE
TOOLS
AIM
To study various parts of NC/CNC machine tools and their working
OBJECTIVES
To study different parts of CNC machine tools in general.
THEORY
It is important to know how your CNC machine is constructed. Understanding your machine's
construction will help you to gauge the limits of what is possible with your machine. The
CNC programmer understands the basic workings of the CNC machine in order to get the
most from the CNC machine tool.
For a universal style slant bed turning center, for example, the programmer should know the
most basic machine components, including bed, way system, headstock & spindle, turret
construction, tailstock, and work holding device. Information regarding the machine's
construction including assembly drawings is usually published right in the machine tool
builder's manual. Truly, the more you know about your machine's capacity and construction,
the easier it will be to get comfortable with the machine. Any CNC machine tool essentially
consists of the following parts:
a) Part program
b) Program input device
c) Machine Control Unit
d) Drive System
e) Machine Tool
f) Feed Back System
QUESTIONS
1. What are the special constructional features of CNC machine tools?
2. Describe with sketch the working and construction of recirculating ball screw used in
CNC machine tools stating advantages. What is preloading?
3. Describe with sketch an automatic tool changer (ATC).
4. Describe the principle of working of an automatic pallet changer (APC).
5. List the types of drives used for stepless control of NC machine tool spindles.
REFERENCES
1. Computer Aided Manufacturing by P N Rao, N K Tewari & T K Kundra
2. CAD/CAM/CIM by P. Radhakrishnan & S. Subranarayan
3. CNC Machines by P. Radhakrishnan
Practical No. 2
CONFIGURATION OF CNC MACHINES
AIM
To study the configuration of CNC machines
OBJECTIVE
To study the constructional and control features of CNC Lathe & Milling
THEORY
CNC machine tools have evolved from the basic machines to the very sophisticated systems
that provide lot of flexibility as well as productivity. Generally speaking, any CNC machine
tool consists of the following units: Computers, Control systems, Drive motors & Tool
changer.
The control systems used on NC/CNC machines are open-loop and closed-loop. The open-
loop control system does not provide positioning feedback to the control unit, while in the
closed-loop control this is monitored by the feed back device.
The majority of NC/CNC machine tools are equipped with automatic tool changers, such as
magazines on machining centers & turrets on turning centers. They allow tool changing
without the intervention of the operator.
QUESTIONS
1. How are the axes designated in NC/CNC machine tools? Sketch and designate the axes of
CNC machine tools in the laboratory.
2. Explain with the sketch, the types of control with reference motion in NC/CNC machines.
3. Discuss difference between open-loop and close-loop systems.
4. List the typical specifications of CNC machines available in the laboratory.
REFERENCES
1. Computer Aided Manufacturing by P N Rao, N K Tewari & T K Kundra
2. CAD/CAM/CIM by P. Radhakrishnan & S. Subranarayan
3. CNC Machines by P. Radhakrishnan
Controller Specifications
General Specifications
Controller Specifications
Practical No. 3
MANUAL PART PROGRAMMING FOR CNC MILLING & LATHE
AIM
To study the concept of NC/CNC manual part programming
OBJECTIVE
To write the part program for the given exercise on CNC Milling & Lathe
THEORY
CNC part program is a detailed list of instruction that needs to be executed by the
machine control unit (MCU) to achieve the final component shape. The machining sequence
needed to manufacture a given part is broken down into small elements and written in a
specific format understood by MCU. The programming language needs to be studied to
develop meaningful part programs.
The following steps are involved in the development of a part program and it’s proving:
Process planning
Axes and Tool selection
Cutting process parameters planning
Job and tool setup planning
Machining path planning
Part program writing and proving
EXERCISES
1. Write a manual part program for profile end milling the component shown in Figure 1.
Assume speed, feed and necessary data clearly. Use absolute mode and draw the tool
path. The cutter diameter is 20mm. For the same component write the NC program using
cutter radius compensation. Also simulate the same using cam software.
2. For the component shown in Figure 2 make a part program on a vertical axis-machining
center. Clearly show the set point and axes on the sketch of the part. Show all necessary
calculations. For the same component write the NC program using canned cycles. Also
simulate the same using cam software.
3. Write manual part programs using absolute mode for turning components shown in
Figure 3. Assume speed, feed and necessary data stating clearly. Also simulate the same
using cam software.
REFERENCES
1. Numerical Control & CAM by Kundra, Rao & Tewari
2. CAD/CAM – Principles & Applications by P.N. Rao
3. CAD/CAM/CIM by P. Radhakrishnan, S. Subramanyam
Practical No. 3
MANUAL PART PROGRAMMING FOR CNC MILLING & LATHE
Figure 1
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Practical No. 3
MANUAL PART PROGRAMMING FOR CNC MILLING & LATHE
Figure 2
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Practical No. 3
MANUAL PART PROGRAMMING FOR CNC MILLING & LATHE
Figure 3
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Practical No. 4
COMPUTER ASSISTED PART PROGRAMMING
AIM
To study the Computer Assisted Part Programming
OBJECTIVE
To write the APT programming for the given exercise on Milling & Turning Center
THEORY
The APT (Automatically Programmed Tool) programming language was developed in early
1960s to assist engineers in defining the proper instructions and calculations for NC part
programming. A great strength of APT is its ability to perform precise calculations for
complicated tool paths when contouring on a three dimensional surface in a multi- axis
programming mode.
The complete APT part program consists of the following four types of statements:
1. Geometry,
2. Motion,
3. Post Processor &
4. Compilation control.
EXERCISE
1. Write an APT program to machine the bracket shown in Figure 1. Assume the component
to be 10 mm thick. The post processor statement is MACHIN/MMPOST, 3. The end mill
used is 10 mm in diameter. Assume spindle speed as 1000 rpm and feed rate as 0.3
mm/rev.
2. Write a complete APT program to turn a shaft as shown in Figure 2. The post processor
call statement is MACHIN/CLAT, 1. The tool has a nose radius of 3 mm. Assume spindle
speed as 300 rpm and feed rate for machining as 0.3 mm/rev.
REFERENCES
Practical No. 4
COMPUTER ASSISTED PART PROGRAMMING
Figure 1
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Practical No. 4
COMPUTER ASSISTED PART PROGRAMMING
Figure 2
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Practical No. 5
PROGRAMMING FOR MACHINING CENTRE USING CAM
SOFTWARE
AIM
To refer the case study on CAD/CAM integration
OBJECTIVE
To understand the automatic part program generations for Machining & Turning Centre using
Pro/Manufacturing.
THEORY
The integration of CAD and CAM has resulted in a paradigm shift in the methodology of NC
programming. Today it is possible not only to generate CNC program required to
manufacture a component directly from the CAD model but also design and model the
fixturing set up, design the blank, process plan, select optimum process parameters, and
simulate the machining operations on the CAD/CAM workstations to ensure that the program
is capable of producing acceptable components. Today the geometry of the component can
directly be obtained from the 3-D CAD model. CAM software can create the NC program
from the geometry data.
There are several popular CAM packages available today. Some of them are listed below:
The steps involved in the part program development using CAM software are described in the
next section. The starting point of CAM is the CAD file. A common approach is the program
creation carried out using solid models or surface models. Data for program creation can also
be obtained from SAT (ACIS solids), IGES, VDA, DXF, CADL, STL and ASCII file using
suitable translators.
1. Create a manufacturing model from the design model and the work piece.
2. Set up the tool database. Tools must be defined before an operation is performed. Tool
libraries can be created and retrieved for a manufacturing operation. Alternatively, they
also can be created at the time of defining the manufacturing operation.
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
3. Select the set up for the machining operation. A component may require more than one
set up to complete the machining operation.
4. Fixtures are necessary at each set up. Fixtures can be displayed along with the work
piece. This is to ensure that the path of the tools does not interfere with the tools.
Standard fixture elements can be created as a library of parts and assembled before the
manufacturing operation is commenced. These are also available as standard libraries.
5. Create a machinability database. Parameters like spindle speed and feed rate can be
selected from the machinability database.
6. Create the manufacturing operations to generate the Cutter Location (CL) data. As each
manufacturing operation takes place, material is removed from the work piece to simulate
the actual manufacturing operation. This simulation is enhanced by the tool path being
displayed for each operation.
QUESTIONS
1. Develop the part program using CAM software for the pocket milling operation on a
machining centre. Create your own geometric model and give the detailed procedure
along with your assumptions.
2. Simulate the above part program on CNC milling & give comments on it.
3. Enlist and explain the activities & benefits of CAD/CAM integration in manufacturing.
REFERENCES
Practical No. 6
STUDY OF TOOLPATHS FOR MILLING AND TURNING
AIM
To study various tool paths during milling and turning operations.
THEORY
Here types of various toolpaths are to be studied along with their use.
QUESTIONS
2. For exercises of practical no. 3 generate toolpaths and part program using CAM
simulation software and compare the program with the manual part program stating
conclusion.
Practical No. 7
RAPID PROTOTYPING
AIM:
To study about rapid prototyping.
OBJECTIVE:
1. To understand the scope and utility of rapid prototyping.
2. To study various processes of rapid prototyping.
THEORY:
QUESTIONS:
REFERENCES:
Practical No. 8
FMS – INTRODUCTION & SYSTEM ELEMENTS
AIM
THEORY
The concept of FMS was born in London in the 1960s when David Williamson, a research
and development engineer, came up with both the name and the concept. At the time he was
thinking of a Flexible Machine System, and it was in a machine shop that the first FMS was
installed. This concept of decentralized computer control of machine tools, combined with
idea of using machine tools for 24 Hrs per day, was the beginning of the FMS.
PROCESSING EQUIPMENTS
Turning Centers:
Increased and improved machine tool technology has taken the NC lathe beyond the scope of
conventional turning operations. Approaching the flexibility of machining centers, a new
array of NC turning center features and options has emerged that extends the turning center’s
capabilities far beyond its earlier predecessors.
Machining Centers:
Machining centers originated out of their capability to perform variety of machining
operations on a work piece by changing their own cutting tools. Thus began with tool change
system, later many other features and capabilities are added.
Machining just like turning centers, are classified as Vertical or Horizontal centers.
Vertical Machining Centers:
Widely accepted and used for flat parts where 3-axis machining is required on a single part
face such as in mold and die work.
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Robot:
A robot is an automatic, servo-controlled, freely programmable, multipurpose manipulator
with several areas, for handling of work piece, tools or special devices. Variably programmed
operations make the execution of a multiplicity of tasks possible
QUESTIONS
1 Describe with sketch working of AGVs used in FMS stating advantages, limitations and
safety measures.
2 State the functions and benefits of Robot in FMS.
3 Describe types of AS/RS used in FMS. And how the success of AS/RS is measured?
4 What is Palletizing? Discuss its importance in FMS.
5 Describe conveyor and Pallet floating systems used in FMS.
6 Explain in brief Tool management in FMS
REFERENCES
1. Flexible Manufacturing Cells & System by Luggen
2. CAD/CAM – Principles & Applications by P.N. Rao
3. CAD/CAM/CIM by P. Radhakrishnan, S. Subramanyam
Practical No. 9
GROUP TECHNOLOGY – MATRIX FORMATION
ALGORITHMS
AIM
To study the Group Technology
OBJECTIVES
1. To study different types of coding systems, coding structures and their applications.
2. To generate the codes using particular coding system for the given part.
THEORY
Definition of GT (Group Technology)
“A manufacturing philosophy in which similar parts are identified and grouped
together to take advantage of their similarities in manufacturing and design.”
Similarities in Design and Manufacturing
Design Attributes
Part Configuration (round, prismatic), Dimensional envelope (ratio - length / diameter),
Surface integrity, Material type, Raw material state
Manufacturing Attributes
Operations, Batch sizes, Machine and cutting tools, Processing times
Part Family
“A collection of parts which are similar either because they possess similarities in
geometric shape and size, or because similar processing steps are used in their manufacture.”
Part families are a central feature of group technology.
There are always differences among parts in a family but the similarities are close enough
that the parts can be grouped into the same family.
Coding and Classification of Parts
Coding: Assignment of a symbol (or a set of symbols) to represent information
Classification: A protocol that is used to separate a large group of objects into separate sub-
groups.
Therefore, we first estimate (or survey) all possible different shapes we may be dealing with.
Next, we identify some "features" that define something distinguishing about the shape of a
part.
Coding structures
(a) Hierarchical Structure (Tree Structure) (Monocode)
(b) Chain Structure (Polycode)
(c) Hybrid Structure
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
Applications of GT
1. Design
2. Machine Selection
3. Factory layout and work-flow planning
4. Fixture Design
CHAROTAR UNIVERSITY OF SCIENCE & TECHNOLOGY
FACULTY OF TECHNOLOGY AND ENGINEERING
CHAMOS Matrusanstha Department of Mechanical Engineering
5. Automobile Manufacturing
QUESTIONS
1. State the need of a structure and explain the types of structure used in coding stating
illustrations and applications. Explain the types of structure used in OPITZ, CODE and
MICLASS coding systems.
2. Explain the clustering by Bond Energy algorithm for part family formation with the help
of appropriate illustration.
3. Apply the Rank Order Clustering technique to the part-machine incidence matrix in the
following table to identify logical part families and machine groups. Parts are identified
by letters and machines are identified numerically.
Parts
Machines A B C D E F G H I
1 1 1
2 1 1
3 1 1 1
4 1 1 1
5 1 1
6 1 1
7 1 1
8 1 1
REFERENCES
Practical No. 10
CIM – EMERGING TECHNOLOGIES
AIM
To study the various emerging technologies in CIM environment, its application and scope.
THEORY
The point is, we have the best machine tools we can get with today’s technologies. Now, we
are going to add something to them that will not try to make the machines better but will try
to make the parts better.
The area where technology is emerging are electronic materials, surface transportation,
system management, intelligent process equipments, expert systems, micro & nano
manufacturing, vision systems, high performance materials, ceramics, composites,
aeronautics etc. Several of these areas are directly or indirectly affect the CIM, its
development. And they are undoubtedly helps the manufacturer to achieve CIM.
Expert Systems
It is a branch of computer based artificial intelligence. It provides the services of the experts
at shop floor in the absence of the human experts. The system may be interfaced to the end
users or to an array of sensors and effectors to communicate with the plants and processes.
Advantages
1 Captures the expertise of the employees who may not be there tomorrow due to job
change, retirement or death
2 Synergetic effect with the knowledge of several experts
3 Resulting decisions are consistent
4 Knowledge can be updated, revised and improved
5 Knowledge can be shared and used when an expert is busy or not available.
Computer vision
It is called as machine vision. It is defined as a system for automatic acquisition and analysis
of the image to obtain desired data for interpreting or controlling the activities. In a broader
sense, the term is applied to a wide range of the non-contact electro-optical sensing
techniques from simple triangulation, profiling to a 3D object recognition technique.
QUESTIONS
1 Describe the process for implementing CIMS stating an illustration.
2 Discuss the application of computer vision in CIMS.
3 Discuss need and importance of shop floor data collection system. What are their
functions?
4 Explain AI based scheduling in CIM environment.
5 Discuss the area where expert systems are applicable.