ME2309 CAD CAM Lab Manual

ME2309 CAD / CAM Lab

Ex. No.

Date of the Experiment

Mechanical Engineering

Name of the Experiment

2013-2014

Date of Submission

Staff Sign.

CAD LAB

CAM LAB

St.Joseph’s College of Engineering/St.Joseph’s Institute of Technology 1

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ME2309


2013-2014

CAD/CAM LAB

TPC 0032

3D GEOMETRIC MODELING Creation of 3D Models - Wire Frame, Surface, Solid modeling Techniques Using CAD Packages – CSG, B-Rep Approaches in Solid Modeling - Feature Based Modeling Technique – Assembly – Detailing - Exposure to Industrial Components – Application of GD&T STL FILE GENERATION – REVERSE ENGINEERING Manual CNC Part Programming Manual CNC Part Programming Using Standard G and M Codes - Tool Path Simulation – Exposure to Various Standard Control Systems- Machining simple components by Using CNC machines. COMPUTER AIDED PART PROGRAMMING CL Data Generation by Using CAM Software– Post Process Generation for Different Control System – Machining of Computer Generated Part Program by Using Machining Center and Turning Center. STUDY OF EXPERIMENTS Multi-axial Machining in CNC Machining Center –EDM – EDM Wire Cut - Rapid Prototyping TOTAL: 45 PERIODS CONTENTS Sl.No 1 2 3 4 5 6 7 8 9 10 11 12

Name of the Experiment Introduction to CAD 3D Modeling of Screw Jack 3D Modeling of Plummer Block 3D Modeling of Flanged Coupling 3D Modeling of Universal Coupling Introduction to CAM Taper Turning Multiple Turning Turning and Drilling Multiple Threading Linear & Circular Interpolation Viva Questions

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Expt .No:

Date: INTRODUCTION TO CAD Computer-aided design is essentially based on a versatile and powerful technique called computer graphics, which basically means the criterion and manipulation of pictures on a display device with the aid of a computer. Computer graphics originated at the Massachusetts institute of technology (MIT) in 1950when the first computer-driven display, linked to a Whirlwind 1 computer, and was used to generate some pictures. The first important step forward in computer graphics came in 1963 when a system called SKETCHPAD was demonstrated at the Lincoln Laboratory of MIT. This system consists of a cathode ray tube (CRT) driven by TX2 computer. The CRT had a keyboard and a light pen. Pictures could be drawn on the screen and then manipulated interactively by the user via the light pen. Computer Aided Design is the process of developing and using computer assisted design tools in the design process. The advent of computers has contributed to significant advance in calculation, data handling and utilization applications. The ability to use the computers in these application areas enhances the capability of the design team significantly. Drafting and geometric modeling play significant roles in CAD. The module therefore concentrates on the general design process with specific consideration to drafting and geometric modeling. Three different CAD systems are referred to in the module. The syllabus includes: historical development, the design process, traditional drawing practice and the development of the CAD industry, system hardware, computers micros to mainframes, output devices, storage, workstations, networked systems, examples of CAD systems; simple entity descriptions: points, lines, arcs, made-edge lists, free-form curves, free-form surfaces; transformations: pan, rotate and scale, 3D transformations, observer angles, perspective, depth cueing; geometric modeling: wire frame modelers, surface modelers, solid modelers (CSG and B- rep), hidden line removal and mass properties; user interface: input devices, menus, graphics interface language, parametric. ROLE OF COMPUTERS IN DESIGN As manual design process has several risk factors including human fatigue and the evaluation of design based on his previous experience. With the advent of computer and the development in the field of computer graphics, various design & manufacturing process takes place new faster rate with minimum or optimum error. The below figure shown the implementation of computer in design: Implementation of computer in the design stage becomes the subset of design process. Once the conceptual design materializes in the designer mind the geometric model starts by the appropriate CAD software. The choice of geometric model to CAD is analogous to the choice. The various design related tasks which are performed by a modern computer-aided design system can be grouped into four functional areas: 1. Geometric Modelling 2. Engineering Anlaysis 3. Design review and evaluation 4. Automated drafting.


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INTRODUCTION TO CATIA V5


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Result: Viva Questions: 1. What do you meant by CAD? 2. States some of the commonly used CAD software’s? 3. How CAD software’s are classified? 4. What are the advantages of CAD software’s? 5. What do you meant by GUI?


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Expt .No:


2013-2014

Date:

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SCREW JACK Aim: To create a 3D view of the Screw Jack model using a computer package. Software Used: CATIA V5. Plotter: HP design Jet 10PS. Commands Used: Line, Circle, Trim, Symmetry, Pad, Pocket, Shaft, Groove, Hole, Rib, Slot, Loft, Dimension, Print, etc. Description: Screw jack is a manually operated device. It is used to lift automobile vehicles and any heavy objects through a small height by applying small effort. The effort is given by a tummy bar. One type of screw jack is shown in the figure. It consists of a cast iron body, with a circular base which provides a larger bearing area. A gun metal nut tight fitted at the top of the body. A mild steel, square threaded screw spindle is screwed through the GM Nut. The head of the screw spindle has holes to insert the tummy bar. A load bearing cup is mounted at the top of the screw spindle. The cup is loosely held in position by a washer and CSK screw so that when the spindle is rotated cup moves only up and down but will not rotate. Procedure:


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Result: Inference:

Viva Questions: 1. 2. 3. 4. 5. 6. 7.

Differentiate First angle & third angle Projection? What is meant by Assembly Drawing? Differentiate orthographic and isometric projections? What is expansion of CATIA? What is parametric modeling? In CATIA V5, you can a hexagon using Rectangle tool. (T/F) To scale the sketched elements, select them and then choose the Translate Tool from the Transformation toolbar. (T/F)

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Date:

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PLUMMER BLOCK (PEDESTAL BEARING) Aim: To create a 3D view of the Plummer Block model using a computer package. Software Used: CATIA V5. Plotter: HP design Jet 10PS. Commands Used: Line, Circle, Trim, Symmetry, Pad, Pocket, Shaft, Groove, Hole, Rib, Slot, Loft, Dimension, Print, etc. Description: It is a split type of journal bearing to support horizontal shafts. It is used for supporting shafts which run at high speed. It consists of a cast iron block, brasses and a cast iron cup. The brasses (bush) are provided in between the block and cup and fastened by using two square headed bolts and lock nuts. The block has hole. The bottom brass has a snug. It seats on the snug hole provided in the block. This arrangement is to prevent the rotation of the bush. Collars provided at the both end of the brasses prevent axial movement of the brasses. Procedure:


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Result: Inference: Viva Questions: 1. How many Modules are in CATIA? 2. What are the types of Assembly design in CATIA? 3. What are the types of drafting techniques in CATIA? 4. What is work bench in CATIA? 5. What are the features in the Part Design workbench in CATIA? 6. You can also draw an arc, while working with the Profile tool. (T/F) 7. You can, draw the key profile in the Sketcher workbench of CATIA V5. (T/F)


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2013-2014 Date:

FLANGED COUPLING Aim: To create a 3D view of the Flanged Coupling model using a computer package. Software Used: CATIA V5. Plotter: HP design Jet 10PS. Commands Used: Line, Circle, Trim, Symmetry, Pad, Pocket, Shaft, Groove, Hole, Rib, Slot, Loft, Dimension, Print, etc. Description: Shaft couplings are used for transmitting rotary motion directly from one shaft to another. They may be classified as (1) Rigid coupling (2) Loose coupling and (3) Flexible coupling. Flanged coupling is a rigid coupling. This is a standard form of coupling and is extensively used. It consist of two cast iron flanges, keyed to the ends of two shafts and fastened together by means of a number of tight fitting bolts. Sunk taper keys of rectangular or square cross section are commonly used for the purpose. For ensuring correct alignment one of the shafts is extended so that its end partly enters the flange keyed to the other shaft. Now the axis of the two shafts will be in straight live. Procedure:


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Result: Inference:

Viva Questions: 1. What are the tools in the Sketcher Based Feature Tool bar? 2. What are the tools in the Dress-Up Feature Tool bar? 3. What are the tools in the Transformation Feature Tool bar? 4. How you can modify the setting in CATIA? 5. What are types of Constrains? 6. You can invoke the Pad tool first and then draw the sketch. (T/F) 7. You can also Pan the view of the model using CATIA Compass. (T/F) 8. You can also Rotate the view of the model using CATIA Compass. (T/F)

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UNIVERSAL COUPLING Aim: To create a 3D view of the Universal Coupling model using a computer package. Software Used: CATIA V5. Plotter: HP design Jet 10PS. Command Used: Line, Circle, Trim, Symmetry, Pad, Pocket, Shaft, Groove, Hole, Rib, Slot, Loft, Dimension, Print, etc. Description: When two shafts are at some inclination to one another, universal coupling is used to connect these shafts. The angle between the two shafts is usually less than 30. The angle between the two shafts may be varied even when they are in motion. It is used in automobile propeller shaft, differential, and milling machine etc. In this coupling, there are two forks keyed to the shafts. The forks are connected to a central cross piece by using pins. The axis of pins will be at right angle to each other. Procedure:


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Expt .No:

Date: Assembled View of Universal Coupling

Details Item No. 1 2 3 4 5 6 7

Description Fork Centre Shaft Parallel Key Pin Collar Taper pin

Quantity 2 1 2 2 2 2 2

Result: Inference: Viva Questions: 1. What are tools in the Geometric Constrains Toolbar? 2. What are tools in the Assembly Constrains Toolbar? 3. What is use of OFFSET command? 4. What is use of ARRAY command? 5. What is the difference between TRIM and BREAK command? 6. What is the difference between FILLET and CHAMFER command?


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INTRODUCTION TO CAM Aim: To study the different operations in CAM. Part programming fundamentals NC procedure The following are the basic steps in NC procedure  Process planning  Part programming  Part program entry  Proving the part programs  Production In detail, Process planning The part programmer will often carryout the task of process planning. Process planning is the procedure of deciding what operations are to be done on the component, in what order, and with what tooling and work holding facilities. Procedure  Receive the part drawing .from the part drawing information, check suitability of part to be machined against the machine capacity.  Determine a method of driving the component (chuck type, chuck size, type of jaw, collet size, face driver etc.,) and the method of machining.  Determine the tooling required to suit the method of machining and utilize as much as possible the tools which are permanently in the turret set upon the machine.  Determine the order of machining and the tooling stations.  Determine planned stops (cycle interrupt procedure, incorporating block delete codes) for checking dimensional sizes where required by operator.  Determine the cutting speeds based on  Component material, method of driving, rigidity of component.  The tooling selected for roughing and finishing.  Determine the depth of cut and feeds for roughing operations based on –horsepower available for cutting and rigidity of the part.  Determine the surface finish requirements the cutter nose radius most suited for finishing operations and determine feed rates.  Allocate tool offsets as required.  Complete planning sheet. Part programming  After completing the planning sheet, draw the component showing the cutter paths (a simple sketch sufficient for simple components).  Select a component datum and carryout the necessary calculations at slopes and arcs.  Prepare tooling layout sheet showing tools to be used in the program and indicate the station number for each tool.  Indicate the ordering code for each tool and the grade and type of inserts to be used.  Write the part program according to the sequence of operations. Manual programming In this method the necessary program information is taken directly from the work piece drawing and set down in the form of program blocks which are then input into the control system (possibly by punched tape). We speak of manual programming, for example, if programming is carried out in the programming language of the CNC system (i.e., a control plane followed


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established standards) – regardless of whether such programming is carried out in the workshop or in the planning department. Manual programming is suitable only to develop part programs for 2D and 2-1/1 D surface machining. NC program BUILD UP In a NC program, the machining steps for producing a part on the machine tool are laid down in a form that the control system can understand. A program is composed of several blocks. A block is a collection of NC words .A NC word is a collection of address letter and a sequence of numbers. Address characters as per DIN 66025 Character Meaning A Rotation about X-axis B

Rotation about Y-axis

C

Rotation about Z-axis

D&E F G H I J K L M N O P,Q,R S T U,V,W X Y Z

Rotation about additional axes Feed Preparatory function, identifying the action to be executed Unassigned Interpolation parameter , thread pitch parallel to X-axis Thread pitch parallel to Y-axis Thread pitch parallel to Z-axis Unassigned Auxiliary function Block number Not used Thread movement parallel to X, Y, Z axes respectively. P & Q are also used as parameters in cycles. Spindle speed Tool Second movement parallel to Z,Y,Z axes respectively Movement in X-axis Movement in Y-axis Movement in Z-axis

All the NC words may not be used on every CNC machine. Using these words as an example, the composition of a block is assembled as follows N G X Z F S T M ; In the programming language of a CNC control system, the manufacturer specifies  What instructions can be programmed  What supplementary functions are possible in conjunction with the individual instruction  Of what letters and number sequences the instruction and supplementary functions are formed.


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PART PROGRAM FORMATS

The order in which these words appear in a block of instructions is called the format. Basically there are two types of format:  Fixed block format -Fixed Sequential format (fixed block) -Tab sequential Format (Fixed Block)  Word address format(Variable block) 1) Fixed block format a) Fixed Sequential Format Every instruction contains all the words in the same sequence irrespective of the words being the same as in the previous blocks. Hence the identifying address letter need not be provided. For example, if some coordinate values (ie...X, Y, Z coordinates) remain constant from one block to next block these values have to be specified in the next block also. the data must be input in a specified sequence and characters within each word must be of the same length. Example: N010 G00 X10 Z0 F60 S800 EOB N020 G01 X20 Z0 F60 S800 EOB b) Tab Sequential Format The words in each instruction/block are always provided in the same sequence but each word is preceded by the TAB Character. If instructions remain unchanged in the succeeding blocks, the instructions need not be repeated but the TAB character must be punched. Here also the identifying letter address need not be employed. Example: N010 G00 X10 TAB Z0 TAB F60 TAB S800 EOB N020 G01 X20 EOB 2. Word access format Each word is precedes and identified by its letter address. This format enables instructions which remain unchanged from the preceding block, to be omitted from succeeding blocks. This system speeds programming, and the tape lengths are considerably reduced. This is the format adopted by most CNC machine control units. Detailed format classification is provided by the control system manufacturer. Miscellaneous Codes and Preparatory Codes for CNC Lathe a) Miscellaneous Functions (M codes) M Codes are instructions describing Miscellaneous Functions like calling of tool, spindle rotation, coolant on, etc. M Codes M00 Program Stop M02 Optional Stop M03 Spindle Forward (CW) M04 Spindle Reverse (CCW) M05 Spindle Stop M06 Tool Change M08 Coolant On M09 Coolant Off M10 Vice Open M11 Vice Close M62 Output 1 On M63 Output 2 On M64 Output 1 Off M67 Wait Input 1 On M76 Wait Input 1 Off M77 Wait Input 2 Off


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ME2309 CAD / CAM Lab M98 M99


2013-2014

Sub Program Call Sub Program Exit

b) Preparatory Functions (G Codes) A 2-Digit Number following address G determines the meaning of the command of the block concerned. The G codes are divided into the following two types: Types Meaning One Short G The G Code is effective only at the block in which it is specified Codes Model G Codes The G Code is effective until another G Codes in the same group is commanded

NOTES ON G CODES Maximum spindle speed setting (50) is valid when the constant surface speed control (option) is provided. The G codes are marked * are set when the power is turned on. The G codes in groups 00 are not modal. They are effective only in block in which they are specified. A number of G codes can be specified in a block even if they do not belong to the same group. When a number of G codes of the same group are specified, the G code specified last is effective. All the G codes may not apply to each machine.


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G Codes G Codes

Group

Function

G00 G01 G02 G03

1 1 1 1

Positioning (Rapid Traverse) Linear interpolation(Feed) Circular Interpolation(CW) Circular Interpolation(CCW)

G04

0

Dwell

G20 G21

6 6

Inch Data Input Metric Data Input

G28

9

Reference Point return

G32

1

Thread Cutting

G40 G41 G42

7 7 7

Tool Nose Radius Compensation cancel Tool Nose Radius Compensation left Tool Nose Radius Compensation right

G50

0

Work Co-ord. Change/Max.Spindle speed setting

G70 G71

4 4

Finishing cycle Stock removal in turning

G72 G73 G74 G75 G76

0 0 0 0 0

Stock removal in Facing Pattern repeating Peck drilling in Z axis Grooving in X axis Thread cutting cycle

G90 G92 G94

1 1 1

Cutting cycle A Thread cutting cycle Cutting cycle B

G96 G97 G98 G99

2 2 11 11

Constant surface speed control Constant surface speed control cancel Feed per minute Feed per revolution

Result:

Viva Questions: 1.Define CAM. 2.Define NC program. 3.How do the composition of a block is assembled? 4. What is a format? 5.What are the types of part program format? Expt .No:

Date: TAPER TURNING


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Aim: To write manual part programming using G & M codes, simulate & machining the given component as shown in the figure in a CNC lathe trainer. Materials Required: Aluminium billet 32mm diameter and 70mm length. Tools Used: Single point cutting tool of radius 2mm, Allen key, chuck key. Machine Details: CNC Machine : XL TURN; CONTROLLER : FANUC; Tool Setting Procedure: In order to guide the tool to exactly where the workpiece, is present we need to do a toll setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in the controller pad of the CNC machine. Tool can made to move by also operating the 4 way movement cursor if axis movement is not desired. Program: [BILLET X32 Z70; G21 G98; G28 U0 W0; M06 T01; M03 S1500; G00 X33 Z1; G90 X32 Z-60 F50; X31; X30; G00 X31 Z1; G90 X30 Z-6 F50; X29; X28; X27; X26; X25; X24; X23; X22; X21; X20; G00 X31 Z-5; G90 X30 Z-21 R0 F30; X30 R-0.5; X30 R-1; X30 R-1.5; Expt .No: Date: TAPER TURNING


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X30 R-2; X30 R-2.5; X30 R-3;


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X30 R-3.5; X30 R-4; X30 R-4.5; X30 R-5; G00 X31 Z1; G01 X30; G01 Z-39; G90 X30 Z-54 R0 F30; X29 R0.5; X28 R1; X27 R1.5; X26 R2; X25 R2.5; X24 R3; X23 R3.5; X22 R4; X21 R4.5; X20 R5; G00 X31 Z-54; G90 X30 Z-60 F50; X27; X26; X25; X24; X23; X22; X21; X20; G28 U0 W0; M05; M30; Result: Inference: Viva Questions: 1.What is a fixed sequential format? 2.what is Tab sequential format? 3.What are M codes? 4.What is word access format? 5.What does CNC stand for?

Expt .No:

Date: MULTIPLE TURNING


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Date: MULTIPLE TURNING

Aim:


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To write manual part programming using G & M codes, simulate & machining the given component as shown in the figure in a CNC lathe trainer. Materials Required: Aluminium billet 32mm diameter and 70mm length. Tools Used: Single point cutting tool of radius 2mm, Allen key, chuck key. Machine Details: CNC Machine : XL TURN; CONTROLLER : FANUC; Tool Setting Procedure: In order to guide the tool to exactly where the workpiece, is present we need to do a toll setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in the controller pad of the CNC machine. Tool can made to move by also operating the 4 way movement cursor if axis movement is not desired. Program: [BILLET X32 Z70; G21 G98; M06 T07; G28U0 W0; M03 S1500; G00 X33 Z1; G71 U0 R1; G71 P1 Q2 U0.1 W0.1 F50; N1 G01 X20; G01 Z0; G01 X22 Z-2; G01 X22 Z-15; G02 X27 Z-22 R10; G01 X27 Z-32; G03 X32 Z-39 R10; N2 G01 X32 Z-39; G28 U0 W0; M06 T15; M03 S1500; G00 X33 Z0; G70 P1 Q2 F30; G28 U0 W0; M05; M30; Result: Inference: Viva Questions: 1.What does M00 specify? 2.what does M02 specify? 3.what does M98 specify? 4.what does M08 specify?

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Date:

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TURNING & DRILLING

Expt .No:

Date: TURNING & DRILLING

Aim:


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To write manual part programming using G & M codes, simulate & machining the given component as shown in the figure in a CNC lathe trainer. Materials Required: Aluminium billet 32mm diameter and 70mm length. Tools Used: Single point cutting tool of radius 2mm, Allen key, chuck key. Machine Details: CNC Machine : XL TURN; CONTROLLER : FANUC; Tool Setting Procedure: In order to guide the tool to exactly where the workpiece, is present we need to do a toll setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in the controller pad of the CNC machine. Tool can made to move by also operating the 4 way movement cursor if axis movement is not desired. Program: [BILLET X32 Z70; G21 G98; G28 U0 W0; M06 T01; M03 S1500; G00 X33 Z1; G94 X0 Z-.5 F50; Z-1; G90 X32 Z-50 F50; X31; X30; X29; X28; X27; X26; X25; G90 X24 Z-25; X23; X22; X21; X20; G28 U0 W0; M06 T04; M03 S1000; G00 X0 Z1; G74 R1; G74 X0 Z-20 Q1000 F30; G28 U0 W0; M05;


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M09; M30; Result: Inference: Viva Questions: 1. What are preparatory functions? 2.What isone short G codes? 3.What are Model G codes? 4.What does G00 specify? 5.What does G74 specify?

Expt .No:

Date: MULTIPLE THREADING

Aim:


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To write manual part programming using G & M codes, simulate & machining the given component as shown in the figure in a CNC lathe trainer. Materials Required: Aluminium billet 32mm diameter and 70mm length. Tools Used: Single point cutting tool of radius 2mm, Allen key, chuck key. Machine Details: CNC Machine : XL TURN; CONTROLLER : FANUC; Tool Setting Procedure: In order to guide the tool to exactly where the workpiece, is present we need to do a toll setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in the controller pad of the CNC machine. Tool can made to move by also operating the 4 way movement cursor if axis movement is not desired. Program: [BILLET X32 Z70; G21 G98; G28 U0 W0; M06 T01; M03 S1500; G00 X33 Z1; G90 X33 Z-40 F50; X32; X31; X30; X29; X28; X27; X26; X25; G90 X25 Z-20 F50; X24; X23; X22; X21; X20; X19; X18; X17; X16; X15; X14; X13; X12; G01 X11 Z0; G01 X12 Z-1; Expt .No:

Date: MULTIPLE THREADING


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G28 U0 W0; M06 T08; M03 S1500;


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G01 X13 Z1; G76 P031560 Q200 R0.15; G76 X9.853 Z-15 P1075 Q250 F1.75; G28 U0 W0; M05; M30; Result: Inference: Viva Questions: 1.what is the G code for thread cutting cycle? 2.What is the G code for feed per minute? 3. what does G50 specify? 4.What does G32 specify? 5.What is the G code for Grooving in x axis?

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Date:

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LINEAR & CIRCULAR INTERPOLATION

Expt .No:

Date: LINEAR & CIRCULAR INTERPOLATION

Aim: To write manual part programming using G & M codes, simulate & machining the given component as shown in figure in the CNC milling trainer.


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Materials Required: Aluminium billet 10010010mm. Tools Used: Milling cutter 6mm diameter. Machine Details: CNC Machine : XL MILL; CONTROLLER : FANUC; Tool Setting Procedure: In order to guide the tool to exactly where the workpiece, is present we need to do a toll setting procedure. In tool setting, we control the movement of tool by the 4 axis movement present in the controller pad of the CNC machine. Tool can made to move by also operating the 4 way movement cursor if axis movement is not desired. Program: [BILLET X100 Y100 Z10; [TOOL DEF T01 D06; [EDGE MOVE X-50 Y-50; G21 G94; G91 G28 Z0; G28 X0 Y0; M06 T01; M03 S1500; G90 G00 X-22.5 Y-37.5 Z5; G01 Z-1 F50; G01 X22.5 Y-37.5; G02 X37.5 Y-22.5 R15; G01 X37.5 Y22.5; G03 X22.5 Y37.5 R15 ; G01 X-22.5 Y37.5 ; G02 X-37.5 Y22.5 R15 ; G01 X-37.5 Y-22.5 ; G02 X-22.5 Y-37.5 R15 ; G00 Z5 ; G91 G28 Z0 ; M05 ; M30 ; Result: Inference: Viva Questions: 1.What is linear interpolation? 2.what is circular interpolation? 3.What does M05 specify? 4.What does M30 specify?


ISO9001:2008

ME2309 CAD CAM Lab Manual

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