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M-658
CAD/CAM
LABORATORY MANUAL

SHRI B.S. PATEL POLYTECHNIC

GANPAT VIDYANAGAR,
KHERVAPrepared By
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Kalpesh P. Patel(M.E.Mech.)
u Certificate v
This is to certify that Shree ___________________________
Reg. No._________ has satisfactory completed the term work
within four walls of Shree B. S. Patel Polytechnic, Ganpat
Vidhyanagar.

INDEX
PRA. NO. PRATICAL AIM DATE SIGN

1 INTRODUCTION & TRENDS IN CAD/CAM

2 STUDY ABOUT HARDWAE IN COMPUTE SYSTEM

3 INTRODUCTION TO DIFFRENT FEATURES OF PRO/ENGINEER

4 INTRODUCTION DIFFRENT COMMANDS OF AUTOCAD

5 TO STUDY NC, CNC AND DNC MACHINES AND PREPARE A
PART PROGRAM FOR GIVEN COMPONENT

6 TO PREPARE PART PROGRAM FOR GIVEN COMPONENT USING

MASTER-CAM SOFTWARE
7 STUDY ABOUT RECENT TRENDS IN CAD/CAM
8 TO STUDY AUTOLISP & PREPARE PROGRAM TO DRAFT GIVEN
FIGURE USING AUTOLIPS

HEAD OF DEPARTMENT TEACHER’S SIGN

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u PRACTICAL: 1
_______
DATE: v
AIM: INTRODUCTION & TRENDS IN CAD/CAM.

OBJECTIVES: To know:
Ø The different types of CAD/CAM Software.
Ø General requirement for CAD Work Station.
Ø Different between Modeling & Drafting.
Ø Different types of Modeling.
Ø Feature highlight of
· Pro/ENGINEER
· IDEAS
· CATIA.

INTRODUCTION WITH DIFFERENT TERMS

[1] CAD: Computer Aided Designing.
v Cad Can Be Defined As The Use Of Computer Systems To Assist In The Cre-
ation, Modification, Analysis Or Optimization Of Design.
v The Computer System consists of hardware & software to perform the specialized
design function required by particular User.
v The hardware includes: monitor. One or more graphics display terminals. Key-
board & other related equipments.
v The software includes application & program.
v Examples of application:
· Analysis Of Components
· Animation of components
· Heat transfer calculation

[2] CAM: Computer Aided manufacturing

v Cam Can Be Defined As The use of computer system to plan, Manage &
control the operations of a manufacturing plant through Direct or indirect
computer interface with the plant productions Resources.
v Depend on application classified in two ways.
1. Computer Monitoring And Control
In These Application Computer Is Directly Connected To
Manufacturing Process For Controlling The Parts.
2. Manufacturing Support Application.
v In This Application Human Being Are Present For, Input The Computer Program
Or Interpret Computer Program And Implications If Required.

[3] CADD: Compute Aided Drafting And Design

v In Modern Cad System, You Can Do Drafting So WhenEver You Can Draw Only Sketch-
ing Then This Type Software Used.

w [4] CAE: Computer Aided Engineering.

[5] CIE: Computer Integrated Engineering.
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u [6] CIM: Computer Integrated Manufacturing.

[7] CAI: Computer Aided Inspection.

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[8] FMS: Flexible manufacturing system.

[9] FMC: Flexible manufacturing Cell.

[10] CAPP: Computer Aided Process Planning.

CAD SOFTWARE CAM SOFTWARE

Þ AutoCAD. Þ Master Cam.

Þ Pro/ENGINEER. Þ Smart Cam.
Þ I - DEAS Þ Any Cam.
Þ Catia. Þ Cam-400.
Þ 3D Max. Þ I-DEAS: GNC.
Þ Solid Edge. Þ Pro: Manufacturing.
Þ AutoDesk Inventor. Þ Work: NC.
Þ Mechanical Desktop.

GENERAL REQUIRMENT FORCAD WORK STATION

Þ Pentium –IV Processor.

Þ 1.5 GHZ Processing Speed.
Þ Intel 845 Chipset Mother Board.
Þ 1.44 MB Floppy Disk Drive.
Þ 20 GB Hard Disk Drive.
Þ Designer ATX Cabinet.
Þ 15” Flat Color Monitor.
Þ 132 Keys Multimedia Keyboard.
Þ Logitech 3-buttons Mouse.
Þ 64 MB Graphics Card.
Þ 52 x CD Rom Drive.
Þ 56.6 Kbps: Internal Modem.
Þ Two Speakers.
Þ Head Phone With Microphone.

MODELING

Þ The Terms Modeling Refers To 3D Representations of Any Objects.

Þ In Modeling , One Can Done Drafting, Modeling & Analysis.
Þ Generally, Software Used
· Pro/ENGINER.
· I-DEAS.

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· Catia.
Þ One Can See All The Principle View In Modeling.
Þ One Can Easily Understand The Drawing.
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DRAFTING

Þ The Terms Drafting Refers To 2 Dimensional Drawing Sketch Only.

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Þ When Your Weight edge On Only Drafting Then Used The Software.
Þ Generally software used : AutoCAD.
Þ You Can See Only One View At One Time.
Þ One can not easily understand the drawing as compare to modeling.

DIFFERENT TYPE OF MODELING

Þ There Are Three Types Of Geometrical Modeling Techniques Used.

1. Wire Frame Modeling.
2. Surface Modeling.
3. Solid Modeling.

1.Wire Frame Modeling

In Wire Frame Points, Lines, Circles And Curves In 3d Representation de-
scribe Modeling An Object.

2.Surface Modeling
In Surface Modeling An Object Is Described By Surface Entities Such As B-
Spline Surface, Bezier Patches, Coons Patches, Ferguson Surface Etc.

3.Solid Modeling

ü Solid Modeling Is A Complete Representation Of Surface Model Where

Object Is Described By The Solid Entities Such As Block, Cone, Wedge,
Cylinder, Sphere, Etc.
ü A Solid Model Will Have The Necessary Physical Material Property Such
As Mass Density And Other Design Data Related With An Object.
ü A Solid Model Can Be Compared With An Actual Or Existing Object.
ü It Can Be Rotated Easily To Visualize The Object In Computer Monitor
Screen.

F EATURE HIGHLIGHTS OF PRO/ENGINEER

Þ Draw 3 Dimensional Drawing.
Þ Find Out The Area & Volume.
Þ If You Know The Material Then Find Out The Weight Of Component.
Þ One Can Do Structural Analysis.
Þ One Can Do Thermal Analysis.
Þ One Can Do Flow Analysis.
Þ One Can Do Motion Analysis.
Þ One Can Do Sheet Metal Design.
Þ One Can Do Electromagnetic Analysis.

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Þ One Can Do Mould Design In Foundry.
Þ One Can Also Do A Piping Design.
Þ One Can Do Programming With NC Or CNC Machine.
u F EATURE HIGHLIGHTS OF I-DEAS
Þ It’s A One Type Of Cad Software.
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Þ Developed By (SDRC)
Static Dynamic Research Center.
Þ Distributor In India……..Uni-Graphics. Ex. In Motion Analysis, The Driver
Sit Of Tata-Indica Made in I-DEAS.
Þ Icon Based User Interface.
Þ Drafting Done Very Easily.
Þ Less Use Of Key Board.
Þ One Can Do Texture Mapping Vary Easily.
Þ Only One Click Of The Mouse We Can See Different Ortho Graphics View.
Þ With Help Of “ Mechanism Module” It Can Done Interference And Analysis.
Þ One Can Do Exploded View And Make Manual.
Þ One Can Prepare Bill Of Material Automatically.
Þ One Can Do Modeling Of The Complicated Surface.
Þ One Can Obtain Output In IGES And DXF Format.
Þ One Can Give Different Colors In Different Parts.

F EATURE HIGHLIGHTS OF CATIA

Þ Most Powerful Software Of CAD/CAM/CAE In 21st Century.
Þ Any Type Of Solution Like…
Product Design And Manufacturing,
Fabrication And Assembly,
Electrical And Electronics Item,
Sheet Metal Designing,
Mould Designing,
Þ Use In…..
Automobile Industries,
Textile And Agriculture Industries,
Paper Manufacturing Industries,
Ship Manufacturing Industries,
Modeling Of Passenger Car, Racing Car, Truck, And Motor Cycle.
Þ Used With Well known Companies…
Motorola Buying Ferrari
Ford Toyota General Motors
Mahindra & Mahindra

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u PRACTICAL: 2
AIM: STUDY ABOUT HARDWARE IN COMPUTER SYSTEM.
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DATE: _______

INTRODUCTION:

There are two basic components in CAD System, They are:

(1) Computer Hardware
(2) Computer Software

Hardware consists of the graphic workstations, graphic input device like mouse, key-
board & digitizer. And output devices like plotter & printers.

V WORKSTATIONS: -
Workstations are typically divided into two broad categories low end & high end.

V WORKSTATIONS CONTAINS: -
a) Graphical Terminal – RGB Monitor
b) Operator Input devices
c) Output Devices like Plotters, Printers
d) CPU (Central Processing Unit) which is based on RISC (Reduced Instruction
Set Computing Microprocessor Cache Memory)
E) Secondary Storage

V ID E O O U T P U T

E TH E R N E T

C P U S E R IA L P O R T
B O A R D P A R A LLE L P O

R G B A U D IO
M O N IT O R
S C S I

G R A P H IC S
B O A R D

B L O C K D IA G R A M

Q COMPUTER: -
1) Personal Computer
2) Mini Computer
3) Mainframe Computer
4) Super Computer

q Work Stations: -
1. Low End Workstation: -
Ø Generally consist of personal computers incorporating hard disk. Appropriate soft-
ware & special hardware like graphic accelerator cards to these for boosting per-
formance.

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Ø Advantage of being able to run a substantial amount of software such as program
for drafting, analysis, spreadsheets & word processing.
2. High End Workstation: -
Contain more powerful processors.
u Ø High-resolution graphic display of 1024
Ø RAM 256 MB & Hard disk 12 GB.
Ø Used for analysis and for graphics.
x 800 pixels or more.
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DISKS, TAPES STORAG

GRAPHIC
PLOTTERS PASSIVE COMPUTER
HARD GRAPHIC NETWORK CALCULATI
COPIES

COMMAND ALPHANUMERICAL GRAP

MESSEGES SCREENS, DIAL
KEYBOARDS

CAD HARDWARE CLASSIFICA

A] GRAPHICS TERMINALS: -
CAD System generally uses three types of graphic terminals: -
1. Direct Beam Refresh
2. Direct View Storage Tube (DVST)
3. Raster Scan (Digital TV)

§ Direct Beam Refresh: -

Ø Electron Beam is deflected directly to trace the image on the screen in a
continuous sweep similar to approach used in oscilloscopes.
Ø After the beam generates the complete image it is repeatedly refreshed.
Ø Having high brightness & excellent resolution.
Ø Colour capability is inferior to raster scan.

§ Direct View Storage Tube (DVST): -

Ø DVST uses stroke-writing method. DVST
having storage tube so that image
becomes steady on screen.
Ø New line can be added to improve picture
quality.
Ø Storage tube is comparatively having less cost. Stroke Writing
Ø Graphical & Textual data contains up to higher numbers.
Ø If the picture can be regenerated then only change can be seen on screen.

§ Raster Scan: -
Ø Electron beam moves in a zigzag path on
screen.
Ø It is a point-plotting device. If a line to be
drawn, it can be approximated by a series of
dots close to the path of the line.
Ø Raster scan require higher computer memory.

Raster Scan

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u 2] OPERATOR INPUT DEVICE: -
§ Keyboard: -
Ø Keyboard interacts with the computer on a software & hardware level.
Ø Four keys are required for all directional movements.
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§ Light Pens: -
Ø Light pen is shaped like a pen with wire connected to it to interact directly with the
CRT Display.
Ø This device can be used for positioning a cursor as well as pointing to & selecting
from menu.

Ø Light pen consists of stylus containing a photocell.

§ Touch Screens: -
Ø Simply touching CRT Display with one’s figure uses them.
Ø Two types of touch screen Mechanical type & Optical touch screen.
§ Joy Sticks: -
Ø Joystick is a potentiometric device that contains sets of variable resistors, which
feed signals.
Joystick devices are normally set so that side-to-side movement produces change in
X-coordinates & front to back movement produce change in Y-direction.

Joystick
Trackball

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board
Mouse
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Digitizer on digitizer
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Ø
§ Track Balls: -
Ball must be rolled with figures on the palm of the hand. v
Cursor moves in the direction of roll at rate corresponding to rotational speed.
§ Mouse: -
Ø Generally Used
Ø Mouse can be moved around by the operator on any flat surface to provide
graphic input.
Ø Mouse is available as mechanical or optical graphic input device.
§ Digitizer: -
Ø These are used together with a movable stylus.
Ø They are used to enter drawing into computer graphic system by taping
drawing to the surface of
digitizer.
§ Thumb Wheel: -
Ø Two of them are provided for X &
Y of cursor.

[3] OUTPUT DEVICE: -

Plotter: - A thumbwheel input

device
Ø It can be classified as pen plotters & electrostatic plotters.
Ø Pen plotters are uses 1,4,8, or more different colours pen.
Ø Electrostatic are faster but no colour variety.
Ø High-resolution dots/mm.
Printers: -
§ Impact Printers: -
Ø These use small hammers or print head containing small pins to strike a rib-
bon to form dot matrix image.

Dot Matrix Printer

Ø Colours are introduced through the use of multiple ribbons or single ribbon
with different colours.
§ Electrostatic Printer: -
Ø Costly & require frequent maintenance.

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Ø Operating cost is high.
§ Inkjet Printers: -
Ø Produce image by fine droplets of ink.
Lesser Printers: -One of the latest output devices.
u Ø High speed.
Ø High resolution.
ØHigh quality of output.
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Inkjet Printer

Flat bed plot-

ter line diagram

Drum type plotter

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u PRACTICAL: 3
AIM: INTRODUCTIO
INTRODUCTIONNTOD
TO IFFERENT FEA
DIFFERENT TURES O
FEATURES F
OF
DATE: __________ v
PRO/ENGINEER.
PRO/ENGINEER.

OBJECTIVES: To know:

Ø Protrusion Feature
Ø Hole Feature
Ø Round Feature
Ø Chamfer Feature
Ø Rib Feature
Ø Shell Feature
Ø Pipe Feature

PROTRUSION FEATURE

Protrusion Is The Method Of Adding A Solid Material. I.e. It Can Add Material In A Void Or On
An Existing Solid. Pro/Engineer Provides The Following Basic Methods Of Adding Material To A
Model.

1) Extrude - Creates A Solid Feature By Extruding A Section Normal To The Section

Plane.
2) Revolve - Creates A Solid Feature By Revolving A Section About An Axis.
3) Sweep - Creates A Solid Feature By Sweeping A Section About A Trajectory.
4) Blend - Creates A Solid Feature By Blending Various Cross Sections At Various
Level.

[1] Extrude:
§ Solid: This Type Needs Closed Non-Self Intersecting Cross Section For De-
fining A Protrusion. It Adds Material By Using The Cross – Sectional Area.
§ Thin: This Type Needs Either Closed Or Open Non – Self Intersecting Cross
Section For Defining Protrusion. It Converts The Boundary Of The Section As
A Thin Constant Thickness Solid.
§ Extrusion Insert > Protrusion > Extrusion Feature > Create > Solid > Protru-
sion > Extrusion

Extrusion Is The Method Of Defining A Volume By Extruding The Sketched Cross

Section Along An Axis Normal To The Section Plane. To Define Extrusion First You Should
Define The Sketch Plane In Which You Want To Draw The Cross Section, And Then You
Have To Define The Direction Of Extrusion And The Amount Of Extrusion By Various
Options.

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v Attribute types
§ One Side: Adds The Material In One Side Of The Cross-Section Only.
§ Both Side: Adds the material on both sides of the cross-section.
Defining sketching plane.
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v Extrusion depth: This Determines The Depth Of Extrusion. It Can Be Defined By
Any One Of The Following Options:
§ Blind
§ 2side Blind
§ Through Next
§ Through All
§ Through Until
§ Unto Pnt/Vtx
§ Up To Curve
§ Up To Surface

§ 1 Side Blind: By This Method You Can Directly Specify The Depth Of Ex-
trusion As A numerical Value. If You Have Selected The Extrusion As Both
Sided, Then The Depth Is Taken As Total Depth Of The Feature. (I.E.,
Keeps Your Section Plane As Mid-Plane Of your Feature).
§ 2side Blind : This Method Is Available Only For Extrusion In Both Sides. In
This Method You Can Specify Different Depths For Each Side As A Nu-
merical Value.
§ Through Next :This Method Extrudes The Feature Up To The Next Inter-
secting Face Of The Part, In The Extrusion Direction. This Method Is Not
Available For The Base Part.(I.E., The Very First Solid Feature).
§ Through All: This Method Extrudes The Feature Up To The Other Bound-
ing Face Of The Part, In The Extrusion Direction. This Method Is Not Avail-
able For The Base Part.
§ Through Until: This Method Extrudes The Feature Up To The Selected
Face Plane Of The Part. The Termination Plant Should Intersect With The
Feature.
§ Up To Pnt/Vtx : This Method Extrudes The Feature Up To The Selected
Point Or Vertex Of The Part. Point And Vertex Can Be Any Where In The
Model. Pro/ENGINEER Projects The Point On The Axis Of Extrusion And
Extrudes The Feature Up To The Projected Point.
§ Up To Curve: This Method Extrudes The Feature Up To The selected curve
or edge of the part. The curve or edge should be parallel to the sketching
plan.
§ Up To Surface: This Method Extrudes The Feature Up To The Through
Until Method. Here You Can Even Specify A Non Intersecting Face As The
Terminating Surface.

[2] Revolve:
Insert > Protrusion > Revolve
Feature > Create > Solid > Protrusion > Revolve

Revolve Is The Method Of Defining A Volume By Revolving The Cross Section

Along An Axis Lying In The Section Plane. To Define Revolution First You Should

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Define The Sketch Plane, In Which You Want To Draw The Cross Section And Revo-
lution Axis. Then You Have To Define The Direction Of Revolution And The Amount Of
Revolution By Various Options. Similar To Extrusion You Can Define The Attribute
Type As Solid Or Thin And Also You Can Revolve The Component At One Side Or
Both Sides.
u § Sketching The Section
§ To Create A Revolved Section, Create A Centerline And The
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Cross Section That Will Be Revolved About That Centerline.
§ Rev To (Angle Of Revolution)

Angle Of Revolution Can Be Defined By One Of The Following Ways,

§ Variable
§ 90
§ 180
§ 270
§ 360
§ Up To Pnt/Vtx
§ Up To Plane

§ Variable: Variable Potion Allows You To Specify Revolution Angle Less Than
360 Degree. You Can Change This Value In Feature Directly By Modifying
The Dimension.
§ Preset Angles 90,180,270,360 :Selecting preset angle will not allow you to
edit the value using modify method. You can change this value only by rede-
fining the feature.
§ Up to Pnt/Vtx :Revolves The Cross Section Up To The Specified Point Or
Vertex In The Part, In The Specified Revolution Direction.
§ Up to Surface: Revolves The Cross Section Up To The Specified Planer
Face Or Datum Plane. Specified Termination Plane Must Pass Through The
Axis Of Revolution. You Have To Specify The Stop Side For Terminating The
Feature.

[3] Sweep:
Feature > create > solid > protrusion > sweep

Sweeping Is The Method Of Defining A Volume By Sweeping The Sketched

Cross-Section Along A Trajectory, Normal To The Section Plane. To Define Sweep
Feature, First You Should Define The Tr9ajectory And The Cross Section. The Tra-
jectory Can Be Defined By Using The Existing Curve/Edge Or Create A New Trajec-
tory By Sketching.

§ Trajectory: Trajectory Is The Path Along Which The Cross Section Is Going Be
Swept. Pro/Engineer Allows You To Define A Trajectory In Two Ways. Sketch-
ing The Trajectory Or Selecting An Existing Trajectory.
§ Sketching The Trajectory: One Can Define A Sketching Plane And Sketch The
Trajectory At The Time Of Creation. Pro/Engineer Will Not Allow Self Inter-
secting And Broken Sketching As Trajectories.
§ Selecting The Trajectory: You Can Select An Existing Edge Or Datum Curve
As Your Trajectory. The Trajectory Should Be Planer. To Select You Can Use

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Any Of The Following Options.
§ Close Trajectory: For closed trajectory, you can specify either as add-inn face
or no inn face.
Add Inn Faces: For Open Sections, Adds Top And Bottom Faces To Close The
Swept Solid. The Resulting Feature Consists Of Surfaces Created By
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§
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Sweeping The Section And Has Two Planner Surfaces That Cap The Open Ends.
No Inn Faces :Sweeps The Section Along The Path But Does Not Add Top And
Bottom Faces.
§ Open Trajectory :If The Trajectory Is Open. And If The Swept Feature Touches
Existing Part Geometry, You Can Either Merge The Ends Or Keep It Free.
§ Merge end: Merge The Ends Of The Swept Feature, It Possible, With The Adjacent
Solid. To Do This, The Sweep Endpoint Must Be Attached To Part Geometry.
§ Free Ends: free ends options will not merge the swept end to adjacent geometry.
§ Sketching Cross Section: After Defining Trajectory You Have To Sketch The Cross
Section. Sketch Plane Will Be Aligned Automatically According To Your Trajectory
And Start Point.

[4] Blend:
Insert > Protrusion > Blend
Feature > Create > Solid > Protrusion > Blend

Blending Is The Method Of Defining A Volume By Connecting Of At least Two

Planner Sections Together At Their Edges With Transactional Surfaces.

Blend Types
§ Parallel: Parallel Option Allow You To Sketch All The Blend Sections In A Single
Sketchplane. Later Pro/Engineer Allows You To Specify The Normal Distance Be-
tween Each Of The Sections.
§ Rotational :Each Blend Section Is Sketched Indevidually And Aligned Using The
Coordinate System Of The Section. The Blend Sections Are Rotated About The Y-
Axis, Up To A Maximum Of 120 Degree.
§ General: The Section Of A General Blend Can Be Rotated About And Translated
Along X,Y And Z Axes. Each Section Is Sketched Individually And Aligned Using
The Coordinate System Of The Section.

Blend attributes
§ Smooth Blend: Creates a Smooth Blend By Connecting Vertices Of Diff. Sub
section With Smooth Curves. Edges Of The Section Are Connecting With
Spline Surfaces.
§ Straight Blend: Creates a Straight Blend By Connecting Vertices Of Diff. Sub
section With straight lines. Edges of the sections are connected with ruled
sur faces.
§ Open: Creates an open solid shape.
§ Closed: Creates a closed solid blend.

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§ Depth: Defines The Depths Of Subsection From The Previous Subsection In
The Depth Direction.
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HOLE FEATURE:
Insert > Hole
Feature > Create > Solid > Hole
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When you invoke this command pro/engineer displays the hole dialog box.

Hole Type
§ Straight Hole: Straight Hole Is An Extruded Cut With A Circular Section. The Diam-
eter Of The Hole Is Constant. It Begins At The Placement Surface And Extends To
The Specified End Surface Or User Defined Depth.

§ Sketched Hole: A Sketched Hole Is Created By Sketching A Section For Revolution

In Sketcher Mode And Placing The Into The Part. Sketched Holes Are Always Blind
And One-Sided. A Tapered Hole Could Be Created As A Sketched Hole.

§ Standard Hole: Standard Hole Is The Combination Of The Sketched And Extruded
Feature. It Is Based On Industries Standard Fastener Tables. You Can Calculate
Either The Tapered Or The Clearance Diameter Appropriate To The Selected Faster.
You Can Use System-Supplied Standard Lookup Tables For These Diameters Or
Create Your Own.

ROUND FEATURE:
Insert > Round
Feature > Create > Solid > Round

In Pro/Engineer Round Option Is Used To Create A Filleting Between Surfaces Or

In Place Of A Middle Surface. Surfaces Can Be Pro/Engineer Zero Thickness Quilts, Sur-
faces And Surfaces Of Solid Models.

Simple & Advance Rounds You Can Create Two Different Types Of Round Simple
And Advanced. The Type Of Round You Create Depend On The Complexity Of The Ref-
erence Geometry And On Your Need To Customize The Default Round Geometry Sup-
plied By The System.

Generally, After You Specify The Placement References And Radius Of The Round,
The System Generates The Default Round Geometry By Using Some Default Attributes.
The System Normally Terminates The Round Geometry Whenever It Encounters Non-
Tangents Edges.

CHAMFER FEATURE:
Insert > Chamfer
Feature > Create > Solid > Chamfer

In Pro/ENGINEER chamfer command is used to create a beveled surface. There

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are two types of chamfer.
§ 1.Edge
§ 2.Corner
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Edge: An Edge Chamfer Removes A Flat Section Of Material From A
Selected Edge To Create A Beveled Surface Between The Two Origi-
nal Surfaces Common To That Edge. One can select multiple edges
to create an edge chamfer

o 45 x d. This Option Is Used To Create A Chamfer That Is At

Angle Of 45 Degrees To Both Surfaces & A Distance d From The
Edge Along Each Surface. The Dimension Appears As”45 x d” , But
You Can Modify The Distance, D Only. You Can Create 45 x d Cham-
fers Only On An Edge Formed By The Inter Section Of Two Perpen-
dicular Surfaces.

o d x d:Creates A Chamfer That Is At A Distance d From The

Edge Along Each Surface. If You Modify The Chamfer, The System
Displays The Distance As The Only Dimension.

o d1 x d2 :Creates A Chamfer At A Distance d1 From The

Selectedvedge Along One Surface And A Distance d2 From The Se-
lected Edge Along The Other Surface. The System Displays Both Dis-
tances Along Their Respectives Surfaces When You Modify The Cham-
fer.
o Ang x d:Creates A Chamfer At A Distance d From The
Selectedvedge Along One adjacent Surface, at a specified angle to
that surface. The System Displays Both values as dimensions when
you modify the chamfer.you can use this option between two planer
surfaces only.

§ Corner: A Corner Chamfer Removes Material From The Corner Of

A Part. In The Next Step Is You Have To Select The Corner And The Edges.
Pro/ENGINEER Displays The Pick/Enter Menu, Which Allows You To Specify
The Location Of The Chamfer Vertex On The High Lighted Edge.

RIB FEATURE
Insert > Rib
Feature > Create > Solid > Rib

A Rib Is A Special Type Of Protrusion Designed To Created A Thin Wall Or Web To

Support To Surfaces. The Rib Is Used To Increase The Strength Of The Part. You Always
Sketch A Rib From A Side View And It Grows Symmetrically About The Sketching Plane.

§ Straight Rib: Ribs That Are Not Created On Through/Axis Datum Planes Are Ex-
truded Symmetrically About The Sketching Plane. You Must Skill Sketch The Ribs

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As Open Sections.

Because You Are Sketching An Open Section Pro/Engineer May Be Uncertain

About The Side To Which The Rib Is Used To Be Added. This System Displays The
Direction Menu After The Rib Section Has Been Regenerated.
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Pro/Engineer Adds All Material In The Direction Of The Arrow. If An Incor-
rect Choice Is Made, Modify The Arrow Direction Using The Feat Menu Option
Redefine.

§ Rotational Ribs: You Can Create Rotational Ribs On Through/Axis Datum

Planes. You Can Sketch The Rib To The Silhouette Of The Parent Feature. To
Create The Solid Geometry, Pro/Engineer Revolves The Section About The Axis
Of The Parent, Making A Wedge That Is Symmetrical About The Sketching Plane.
Pro/Engineer Then Trims The Wedge With Two Planes Parallel To The Sketching
Surface, The Distance Between These Planes Corresponds To The Thickness Of
The Rib. You Can Place A Rotational Rib Only On Any Surface Of Revolution.
Note That The Angled Surface Of The Rib Is Conical, Not Planer.

SHELL FEATURE:
Insert > Shell
Feature > Create > Solid > Shell

The Shell Option Removes A Surface Or Surfaces From The Solid Then Hollows
Out The Inside Of The Solid, Leaving A Shell Of A Specified Wall Thickness.

When Pro/Engineer Makes The Shall, All The Features That Ware Added To The
Solid Before You Chose Shell Are Hollowed Out. Therefore, The Order Of Feature Cre-
ation Is Very Important When You Use Shell.

After Involving This Command Pro/Engineer Displays The Feature Creation Dia-
log Box. If Desired, Select The Optional Element Spec Thick To Specify Thickness Indi-
vidually.]

PIPE FEATURE:
Insert > Pipe
Feature > Create > Solid > Pipe

This Pipe Feature Is Three Dimensional Centerline That Represents The Centerline
Of A Pipe.

Given The Diameter Of A Pipe, A Pipe Connects Selected Datum Points Either
With A Combination Of Straight Lines And Arcs Of Specified Bend Radius Or A Spline.

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After The Pipe Feature Has Been Created, You Can Determine It’s Length By
Using Info From The Toolbar, Before You Start To Create A Pipe Feature, Reference
Datum Points Must Already Exist.
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AIM
PRACTICAL: 4
AIM:INTRODUCTION TO DIFFERENT COMMANDS OF AUTOCAD
DATE: __________ v
V INTRODUCTION: Auto Computer Added Drafting.
Ø It’s Drafting Software.
Ø Not Design Software.
Ø First Time Established & Developed By AutoDesk Inc. Company
Ø Latest Software Is Mechanical Desktop 5.0

V COMMANDS:
1.Units: To Set The Units Of The Drawing. Ex. Measurement Of Length, Angle.
2.Limits: To Set & Control The Limits Of The Drawing. You Can See The L.L.C. &
U.R.C. On Screen By Using Grid Command.
3.Grid: Display A Dot-Gnd On Current Viewpoint & To Set Spacing Size Of Dot-Grid.
4.Snap: On: You Can Move Curser On Dot-Grid Only.
Off: You Can Move Curser Anywhere On Screen.
Adv: While Drawing An Object You Select A Reference Point. With The
Help Of Snap Command You Can Not Requires A Ref Point To Draw An
Object.
5.Point Style: To Draw A Different Style Of Point.
6.Line: To Draw A Line Either Single Or Series Of Lines Segment End To End.
Esc: To Exit From Command.
To Go Outside Of Command.
7.Zoom: To Increase Or Decrease The Apparent Size Of An Object In The Current
viewpoint.
Ø Real Time: Zoom In Real Time
Ø Previous: To Display Previous View.
Ø Window: Zoom To Display The Generating Portion Of The Drawing
Ø Scale: Zoom With A Specified Scale Factor.
Ø Center: Display A Window Specified By A Center Point & Height.
Ø In: Increase The A.S.O. Object In C.V.Point.
Ø Out: Decrease The A.S.O. Object In C.V.Point.
Ø All: Zoom To Display The Entire Drawing In Current Viewpoint.
Ø Extant: Zoom To Display The Drawing Extent.

8.Ray: Creates A Semi-Infinite Lines Commonly Used As A Construction Line. Ray

Has A Finite Starting Point & Extends To Infinite In Only One Direction.
9.Construction Line: Create Infinite Lines, Which Is Commonly Used As A Con-
struction Lines. C Line Has A Finite Starting Point & Extends To Infinite In Both direction.

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10.Multi Lines: Multiple Parallel Lines Are Called Multi Lines. To Draw More Than
One Lines.
11.Poly lines: To Draw A Poly Line. Draw An Object By Line & Poly Line, Then
Select Line Do Not Select Whole Object & in Poly Line Select Whole Object.
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17. Spline: Creates A Quadratic A Or Cubic Spline Curve.
18. Ellipse: To Draw An Ellipse.
19. Hatch: Filled An Enclose Area Or Selected Object With A Hatch Pattern.
20. Boundary: Creates A Region Or A Poly Line From An Enclosed Area.
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21. Block: To Insert Block In Present View.
22. Point: Options
Single Point
Multiple Point
Divide, Measure
Note: Both Are Used To Draw Equal Parts Or Lines.
23. Text: To Write Single Line Or Multi Lines Text.
Dimension

DIMENSION
24. Quick Dim. : To Draw Any Dimension Quickly.
25. Liner:Create A Liner Dimension.
26. Aligned: Create An Aligned.
27. Ordinate: Create Ordinate Dimension. (To Give Value Of X & Y Coordi
nate)
28. Radius: Create Radius Dimension For Circles & Arcs.
29. Diameter: Create Diameter For Circles & Areas.
30. Angular: Create An Angular Dimension.
31. Baseline: Create Liner, Angular, Ordinate Dimension From The Baseline
Of Previous
32. Continuous: Create A Liner, Angular & Ordinate Dimension From The
Second Extension Line Of The Previous Dimension.
33. Leader: Quickly Create A Leader & Leader Annotation.
34. Center Mark: Create A Center Mark Of Circle & Areas.
35. Oblique: Make The Extension Line Of Linear Dimension Oblique.
36. Style: Create & Modify Dimension Style.
37. Over Ride: Over Ride Dimension Style Variable.
38. Update: Update Dimension So That Use The Most Current Dimension
Style Sating.
39. Dimension Edit & Text Edit: To Modify Dimension & Text.

MODIFY
MOD
40. Property: Control The Property Of The Existing Object.
We Can Change By The Table.
41. Match Property: Copies The Properties From One Object Another & More Object.
42. Hatch: Modify An Existing Hatch Object
43. Poly Line: Edit Poly Line & Time Dimension Poly Line.

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44. Spline: Edit A Spline Object.
45. Multi Line: To Draw More Then One Line.
46. Text: Edit Text & Attribute Definition.
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47. Eraser: Remove Object From A Drawing.
48. Copy: Duplicate The Object You Select.
49. Mirror: Create A Mirror Image Copy Of Object
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50. Offset: Create Parallel Lines, Parallel Curves & Consent Circles. Off Set Only A
Single Line If Line Is Multiple Than Pewit Command Used.
51. Array: Create Multiple Copies Of An Object In A Pattern. Both In Rectangle & Polar.
52. Move: Displaces The Object Of A Specified Distance In A Specified Direction.
53. Rotate: Move Object About Base Point
54. Scale: Enlarge Or Reduce Object Equally In X, Y, Z Direction.
55. Stretch: Move Or Stretch Object
56. Lengthen: Lengthen An Object
57. Trim: Trim Objects Of A Cutting Edge Defined By Other Object.
58. Extend: Extend An Object To Meet Another Object.
59. Break: Erase Part Of Object Or Splits An Object In Two Parts.
60. Fillet: Rounds And Fillets The Edge Of The Selected Object.
61. Explore: Break A Compound Object In To its Component Object.

Format
62. Layer: Manage Layer & Layer Properties.
63. Color: set The Color For New Object.
64. Line Type: Create Loads And Sets The Line Type.
65. Line Weight: Set Current Line Weight & its Units.
66. Text Style: create And Modify The Names Style & Set Current In Your Drawing.
67. Dim. Style: create And Modify The Dimension Style.
68. Plot Style: Create And Modify Plot Style For New Object.
69. Multilane Style: To Draw A Multiple Parallel Line This Command Use.
70. Thickness: set The Current 3d Thickness.
71. Rename: Change Name At Selected Object.

TOOLS
72. Spelling: Check The Spelling In The Drawing.
73. Inquiry: To Measure The Distance & Area & Volume.
74. Drafting Setting: Specify Setting For Snap Mode, Grid, Polar & Object Snap
Tracking.

View
75. Re Draw: Refresh The Display Of The All Viewpoints.
76. Region: regenerate The Drawing & Refresh The Current View Point.
77. Regional: Regenerate The Drawing & Refresh The All View Point

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78.
79.
Pan: Move The Drawing Display In The Current Viewpoint
Arial view: Open The Arial View.
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80. Toolbar: Display, Hide & Customizes The Toolbar
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81. Hide: Regenerate A Three Dimensional Model With Hidden Line.
82. Shade: To Give Shade Of Three Dimensional Drawing.
83. Block: Create A Block Definition From Object You Select.
84. W Block: Write Object Or Block To A New Drawing File.
85. Pewit: Convert Different lines in to plotline.

-:FUNCTIONAL KEYS:-
F1: For Help
F2: To Toggle Drawing Mode To Text Mode & Text Mode To Drawing Mode.
F3: Snap On/Off.
Permanent Setting Of Curser For Further Editing
Note: - Use Right Side Click Always.
F4: Table On/Off.
F5: To Toggle Is Plane Top
“ “ “ Right
“ “ “ Left
F6: Coordinate On/Off [X & Y Coordinate]
F7: Grid On/Off.
F8: Ortho On/09off. (To Draw Straight & Zigzag Line)
F9: Snap On/Off.

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u PRACTICAL: 5 DATE: __________ v
AIM: - TO STUDY NC, CNC AND DNC MACHINES AND PREPARE PART PRO-
GRAM FOR GIVEN COMPONENT.
INTRODUCTION: -

Automation and mass production are associated with advancement in

technology. In the mass production units since the quantity of item required is
very high with little or no variety, special purpose machines, automatic ma-
chines or transfer lines, have been used. However, for job or batch produc-
tion, general-purpose machines are being used due to large variety of compo-
nents and machines are continuously demand of products. In the conventional
general-purpose machines, the skilled operator is responsible for many inputs
to the machine. The operator, in addition to physical work of handling the
machine, has to do lot of information processing like reading the drawing and
checking dimensions. AS the degree of complexity of the component increases
and the tolerances become closer, the time to produce the component also
increases. Since the process is operator dependent, the mistakes on the part of
operator due to inattention and tiredness, result in production of defective
components.

To overcome these problems of job and batch production, several improve-

ments have been made in the conventional machines by reducing the
manual control elements. For small batch production, copying the machines
have been used. In the copying machines, also called tracer-controlled ma-
chines, a model or template called master is first manufactured and used
with copying attachment. A tracer or stylus scans the model and the motion
of the tracer is transmitted to the cutting tool by means of servomechanism.
The main disadvantage of the copying method is the time spent on produc-
ing master, as the master is made without automation and it has to be pro-
duced to a high degree of accuracy. A more flexible system, widely used, is
the automatic lathe machine. Pairs of micro switches and stoppers establish
the set up of the required dimensions of the parts. This sequence-controlled
machine is quite flexible but the main disadvantage is that the setting of the
limit switches and stoppers. Also, since the number of limit switches and
stoppers is limited, the maximum number of programmed operations on a
part is also limited. These problems of automation of medium and small
volume production have been overcome by numerically controlled machine
tools where the machining operations/processes are controlled with the help
of instructions given to the machine tool in a coded form. The simplest

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definition of numerical control (NC) is “A system in which the actions are
controlled by direct insertion of numerical data at some point. The system
must automatically interpret at least some portion of this data”.
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[1] NC MACHINES:-
MACHINES:-
The control systems and machine tools in numerically controlled machine
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tools have varying complexities and capabilities. In the initial stages, the NC ma-
chine tools had NC systems added to the machine but only to control the position
of the work piece relative to the cutting tool. The operator had to select the cutting
tools, speed and feeds etc. In the next stage, the capabilities of the machine tools
improved and in addition to maintaining cutter/work piece relationship, the mate-
rial removal was also controlled by the numerical control system. The instructions
to the NC machines are fed through an external medium i.e. paper tape or magnetic
tape. The information read from the tape is stored into the memory of the control
system called ‘buffer storage’ and is processed by the machine step by step. So
when the machine is working on one instruction block, the next block is read from
the tape and stored in the memory of the machine control system. Since the part
cannot be produced without a tape being run through the machine, these machines
are also called tape-controlled machines. The tape has to be run repeatedly de-
pending on the number components to be produced. Also if there is even a minor
change in the design of the component, the tape has to be discarded and new tape
with changed programme has to be produced.
[2] CNC MACHINES:
MACHINES:
In case of computer numerical control machine tools, a dedicated computer is
used to perform all the basic NC function. The complete part programme to produce a
component is input and stored in the computer memory and the information for each
operation is fed to the machine tools i.e. motors, etc. the part programmes can be stored
in the memory of the computer and used in future. The conventional NC machine tools
are not much in use these days. CNC machine tools are widely used due to many
controlled features available in CNC machine tools are:

The part program can be input to the controller unit through keyboard or the tape
reader in the control unit can read the paper tape.

The part program once entered into the computer memory can be used again and
again.

The part program can be edited and optimized at the machine tool itself. If there
is any change in the design of the component, the part programme can be changed
according to the requirements.

The input information can be reduced to a great extent with the use of special
sub-programme developed for repetitive machining sequences. For common opera-
tions such as drilling holes on a pitch circle, special cycle programmes can be built and
stored in the computer memory. These sub-programmes or sub-routines can be re-

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trieved and used any number of times within a part programme; only certain parameters
have to be specified and the computer control carries out the necessary calculations and
subsequent actions.
u The CNC machines have the facility for proving the part programme
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without actually running it on the machine tool. The control system pro-
cesses the part programme and the movement of the cutting tool in each
operation is shown on the monitor screen. The shape of the component that
will be produced after machining is shown on the screen without actual
machining taking place.
CNC controlled unit allows compensation for any changes in the
dimensions of the cutting tool. When a part programme is written, part
programmer has a particular type and size of cutting tool in mind. But
while actually using the part programme on the machine tool that particu-
lar cutter may not available. CNC control system allows the compensa-
tions to be made for difference between the programmed cutter and the
actual cutter used. With the CNC control systems, it is possible to obtain
information on the machine utilization, which is useful to the manage-
ment. The control system can provide the information such as number of
components produced, time per component, time for setting up a job, time
for which machine has not been working and fault diagnosis, etc.
ADVANT
ADV AGES O
ANTA F CNC MA
OF CHINES:
MACHINES:
• Reduced Lead Time:
The time between the receipt of a design drawing by the production
engineer and manufacturing getting ready to start production on the shop
floor, including the time needed for planning, design and manufacture of
jigs, etc. is called lead time. Since special jigs and fixtures are often en-
tirely eliminated in CNC machines, the whole of the time needed for their
design and manufacture is saved. Consider the position of two manufac-
turers; one equipped with conventional machines and the other with CNC
machines tools. For job requiring special jigs and fixtures and cutting tolls,
the manufacturing unit with conventional machines will have to spend con-
siderable time in design and manufacture of special tooling taking up the
production of components whereas the unit with CNC machines can start
production within a short period of the work being planned and material
being available.
• Elimination of Operator Errors:
The machine is controlled by programme of instructions stored in
the memory of the computer. The programme is checked before it goes to
the machine so no errors will occur in the job. Fatigue, boredom or inatten-
tion by an operator will not affect the quality or duration of the machining.
• Operator Activity:
The operator is relieved of tasks readily performed by the machine and is
free to attend to matters for which his skills and abilities are essential.
Presetting of tools, setting of components and preparation and planning
of future jobs fall into this category. It is possible for two workstations to

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be prepared on a single machine table, even with small batches. Two

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setting positions are used, and the can set up one station while machin-
ing takes place at the other. The two jobs need not be identical. Also it is
possible for one operator to attend to more than one CNC machine at a
time.
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• Lower Labor Cost:
Actual cutting time in the CNC machine is more than conventional machines
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since the setting time, etc are lower. Also one operator can run two or more machines
or multiple pallet machines are used resulting in reduced labor cost.

• Smaller Batches:
By the use of pre-setting tooling and pre-setting techniques, downtime be-
tween batches is kept at a minimum. Periodic machining time of small batches is
found to be economical and brings about a rapid stock turnover. Larger storage fa-
cilities for work-in-progress are required. Machining centers eliminate some of the
set-ups needed for successive operations on one job and time spent in waiting until
each machine for successive operations are free. The components circulate round the
machine shop in a shorter period, inter-departmental transport costs are saved and “
Progress Chasing “ is reduced.

• Longer Tool Life:

Tools can be used at optimum speeds and feeds because the part programme
controls these functions. The operator can override programmed speeds and feeds if
difficulty in machining is encountered.

• Elimination of Special Jigs and Fixtures:

Standard locating fixtures are often not used on CNC machines, and cost of
special jigs and fixtures is frequently eliminated. The capital cost of jig storage facili-
ties is also reduced. The storage of a part programme is very simple matter, it may be
kept for many years and the manufacture of spare parts, repeat orders or replace-
ments is made much more convenient.

• Flexibility in Changes of Component Design:

Re-programming and altering the concerned instructions can readily accom-
modate the modification or changes in component design. These are no jigs and
fixture to be altered; hence, savings are affected in time and cost.

• Reduced Inspection:
The time spent on inspection and in waiting for inspection to begin is greatly
reduced. Normally it is necessary to inspect the first component only. If there is any
difference in the dimensions of the machined component, the programme is checked
and corrected, if needed.

• Less Scrap:
Since the operator errors are eliminated; a proven part programme results in an
accurate component. However, tool settings, as in a boring bar, do not come under
the control of the part programme and periodic checks must be made to ensure that

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the settings remain correct. Drill or tap breakages are not unknown, but since the
tools are operating under controlled optimum condition, the incidence of breakages
should be very small.
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• Accurate Costing and Scheduling:
In CNC machines, the time taken in machining is predictable, consistentv
and results in a greater accuracy in estimating and more consistency in costing.
Consistent operations enable the accurate compilation of shop loading schedules
and thus results in a balanced loading and a more predictable output.

v DISADVANTAGES OF CNC MACHINES:

• Higher Investment Cost:

CNC machine tools represent a more sophisticated and complex technol-
ogy This technology costs more to buy than its non-CNC counterpart. The higher
cost requires manufacturing management to use these machines more aggressively
than ordinary equipment. High machine utilization is essential in order to get rea-
sonable returns on investment. Machine shops must operate their CNC machines
two or three shifts per day to achieve this high utilization

• Higher maintenance Cost:

Because CNC is a more complex technology and machines are used harder,
the maintenance problem becomes more acute.

• Costlier CNC personnel:

Certain aspects of CNC machine operations require a higher skill level than
conventional operations. Part programming and CNC maintenance are two areas
where personnel with the required skill are in short supply. The problems of find-
ing, hiring and training these people must be considered a disadvantage to the
CNC shop.

• Planned Support Facility

Since most of the preparatory work for CNC operations is done away from
the machine, planned support facilities will be essential e.g. part programming,
tape preparations and tool pre-setting are fundamental services that must be con-
sidered, However, the advantages of CNC systems outweigh the disadvantages
considerably and the CNC machines have been widely accepted by the industry.
CNC is being used in drilling, turning, boring, milling and grinding machines. In
addition to the metal removing operations, CNC is used on machines like pipe
bending, coil winding, flame cutting, welding, wire-cut EDM and many other ar-
eas.

v PARTS SUITABLE FOR CNC MACHINES:

Ø The number of operations per component is large.
Ø Operations are very complex.
Ø Size of batches is medium.
Ø Batches are often repeated.
Ø Labor cost for the component is high.
Ø The component requires suitable tooling.
Ø Components require 100% inspection.
Ø Set-up and inspection times are high.

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Ø Ratio of cutting time to non-cutting time is high.
Ø A large variety of components are produced.
Ø The component requires highly skilled operator.
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[3] DIRE
DIRECT NUMERICAL CO
IRECT NTR
CONTROL:
NTROL:
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Direct Numerical Control (DNC) is a manufacturing system in which a large
number of machines are controlled by a computer through direct connections. All the
machines are linked to a mainframe computer, which sends information to individual
machines as and when required. The part programmes for all the components, which are
to be manufactured on the machines in DNC system, are stored in the memory of the
computer. When a machine needs control commands, the computer communicates them
immediately. There are two alternative system configurations for linking the computer
with machine tools. In the first configuration the main computer is directly linked to the
machine and only minimum facilities are provided at each machine tool so that each
machining operation can be completed. In this system there could be delays at the main
computer in providing details to the machine tool, while it is processing some other
information. In the second configuration, the main computer is connected to machine
tool through a mini computer called satellite computer. The main computer stores the
part programmes for all the components to be machined on a particular machine The
satellite computer receives and stores the part programmes. The satellite computer then
controls the machine tool operation. The advantage of this system is that the machines
can be used independent of the main computer, as the main computer is not actively
involved in the operation of the machine tool.

v CONFIGURA
CONFIGURATIO
NFIGURATIONO
TION F THE CNC SYSTEM:
OF

Figure 1 shows a schematic diagram of the working principle of a

CNC machine.

w [Figure 1: Schematic diagram of a CNC machine tool]

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A CNC system basically consists of the following:
Ø Central processing unit (CPU)
Ø Servo-control unit
Ø Operator control panel
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Ø Machine control panel
Ø Other peripheral devices
Ø Programmable logic controller

(1) Central Processing Unit (CPU):

The CPU is the heart and brain of a CNC system. It accepts the information
stored in the memory as part program. This data is decoded and transformed into
specific position control and velocity control signals. It also oversees the movement
of the control axis or spindle and whenever this does not match with the programmed
values, a corrective action is taken.

All the compensations required for machine accuracies (like lead screw pitch
error, tool wear out, backlash, etc.) are calculated by the CPU depending upon the
corresponding inputs. Made available to the system. The same will be taken care of
during the generation of control signals for the axis movement. Also, some basic
safety checks are built into the system through this unit and the CPU unit will pro-
vide continuous necessary corrective actions. Whenever the situation goes beyond
control of the CPU it takes the final action of shutting down the system and in turn
the machine.

Speed Control Unit:

This unit acts in unison with the CPU for the movement of the machine axes.
The CPU sends the control signals generated for the movement of the axis to the
servo-control unit and the servo-control unit converts these signals into a suitable
digital or analog signal to be fed to a servo-drive for machine tool axis movement.
This also checks whether machine tool axis movement is at the same speed as di-
rected by the CPU. In case any safety conditions related to the axis are overruled
during movement or otherwise they are reported to the CPU for corrective action.

(2) Servo-control Units:

The decoded position and velocity control signals generated by the CPU for
the axis movement forms the input to the servo-control unit. This unit in turn gener-
ates suitable signals as command values. The servo-drive unit, which is interfaced
with the axes, converts the command values and the spindle motors.

The servo-control unit receives the position feedback signals for the actual
movement of the machine tool axes from the feedback devices (like linear scales,
rotary encoders, resolves, etc.). The velocity feedbacks are generally obtained

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through tachogenerators. The feedback signals are passed on to the CPU for fur-
ther processing. Thus, the servo-control unit performs the data communication
between the machine tool and the CPU.
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Servo-drives:
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As shown in Fig. 1, the servo-drive receives signals from the CNC system and trans-
forms it into actual movement on the machine. The actual rate of movement and direc-
tion depend upon the command signal from the CNC system. There are various types of
servo-drives, viz., dc drives, ac drives and stepper motor drives. A servo-drive consists
of two parts, namely, the motor and the electronics for driving the motor.

(3) Operator Control Panel:

The operator control panel provides the user interface to facilitate a two-way
communication between the user, CNC system and the machine tool. This consists of
two parts:
Ø Video display unit
Ø Keyboard

Video Display Unit (VDU)

The VDU displays the status of the various parameters of the CNC System and
the machine tool. It displays all current information such as:
ü Complete information on the block currently being executed.
ü Actual position value, set or actual difference, current feed rate, spindle speed.
ü Active G functions, miscellaneous functions.
ü Main program number, subroutine number.
ü Display of all entered data, user programs, user data, machine data etc.
ü Alarm messages in plain text.
ü Soft key designations

Keyboard

A keyboard is provided for the following purposes:

ü Editing of part programs, tool data, and machine parameters.
ü Selection of different pages for viewing.
ü Selection of operating modes: e.g. Manual data input, jog etc.

(4) Machine Control Panel (MCP):

It is the direct interface between the operator and the CNC system, enabling the
operation of the machine through the CNC system. During program execution, the CNC
controls the axis motion, spindle function or tool function on a machine tool, depending
upon the part program stored in the memory. Prior to the starting of the machining
process, machine should first be prepared with some specific tasks like,
ü Establishing a correct reference point.
ü Loading the system memory with the required part program.
Loading and checking of tool offsets, zero offsets, etc. For these tasks, the system

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must be operated in a specific operating mode so that these preparatory functions can
be established.
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v Classifications of CNC machines according to control systems:
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(1) Open-loop Control System:
Machine tool controls in which there is no provision to compare the actual position of
the cutting tool or work piece with the input command value, are called open-loop
systems. In the open-loop control system, the electric motor continues to run until the
absence of power, from input command signal, indicates that the programmed location
has been attained There is no monitoring of the actual displacement of the machine
slide. In the open-loop control system, the control may indicate a movement of 50mm
whereas actually the slide may have moved only 49.8 mm. Fig.2 (a) shows the block-
diagram of an open-loop control system.

[Figure 2(a) Block diagram of an open-loop system]

In open-loop control system the actual displacement of the slide may vary
with change in external conditions and due to the wear of components of the drive
mechanism i.e. backlash errors in lead screw, etc. Since there is no provision of
feedback in the control system periodical adjustments are required to compensate
for the changes due to various factors. Although open-loop systems are less accu-
rate compared to a closed loop system, these are adequate for many applications.
Open-loop systems are less expensive than closed-loop systems due to the ab-
sence of monitoring devices and their maintenance is not complicated.

(II) Closed-loop Control System:

In a closed-loop control system the actual output from the system i.e. actual
displacement of the machine slide, is compared with the input signal. The
closed loop control systems are characterized by the presence of feedback de-
vices in the system. In the closed-loop control system the displacement can be
achieved to a very high degree of accuracy because a measuring or monitoring
device is used to determine the displacement of the slide.

w [Figure 2(b) Block diagram of a closed-loop system]

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The feedback from the monitoring device is then compared with the input signal
and the slide position is regulated by the servo system until it agrees with the
desired position. Fig. 2(b) shows a closed loop control system with a provision for
feedback the displacement of position of machining slide. In order to measure the
speed of the motor and compare the actual speed with the programmed speed, a
velocity feedback system is added to the system.
Specifications of a CNC System:
1. Number of controlled axes Two/Four/Eight, etc.
2. Interpolation Linear/circular/parabolic or cubic/cylindrical
3. Resolution Input resolution (feedback)
Programming resolution
4. Feed rate Feed/min
Feed/revolution
5. Rapid traverse rate Feed rate override
Feed per minute
6. Operating modes Manual / Automatic / MDI(editing) /input /
Output / Machine data
Set-up/Incremental, etc.
7. Type of feedback Digital (rotary encoders with train of pulses)
Analog (transducers, etc.)
Both
8. Part program handling Number of characters which can be stored
Part program input devices
Output devices
Editing of part program
9. Part programming Through MDI
Graphic simulation
Blue print programming
Background editing
Menu driven programming
Conversational programming
10. Compensations Backlash
Lead screw pitch error
Temperature
Cutter radius compensation
Tool length compensation
11.Programmable logic controller Built-in (integrated)/External
Type of communication with NC
Number of inputs, outputs, timers, counters and flags
User memory
Program organization
Programming Languages
12. Thread cutting/ Tapping Types of threads that can be cut
13. Spindle control Analog/Digital control

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Spindle orientation
Spindle speed overrides
RPM/min; constant surface speed
u14. Other features Inch/metric switchover
Polar coordinate inputs
Mirror imaging
Scaling
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Coordinate rotation .system
Custom macros
Built-in fixed cycles
Background communication
Safe zone programming
Built-in diagnostics, safety functions, etc.
Number of universal interfaces
Number of active serial interfaces
Direct numerical control interface

q EXERCISE:
PREPARATION OF CNC PROGRAM FOR FOLLOWING COMPONENT. (INCREMENTAL
& ABSOLUTE MODE):

READ ME:
Note-1: Consider cutter radius compensation, which is stored under address
D01. Machining is done in clockwise direction from point A. Z=0 at surface of work
piece. Initially tool is 10 mm. above work piece. Depth of cut is 3 mm.
Note-2: To Prepare a CNC Program for above component in given “A4” size

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blank page & also enclose in the file.
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u PRACTICAL: 6 DATE: __________ v
AIM: TO PREPARE PART PROGRAM FOR GIVEN COMPONENT USING MASTER-
CAM SOFTWARE.

INTRODUCTION:

MASTER-Cam is a powerful, versatile CAD/CAM software design to help us to

produce high quality parts faster and with great accuracy. MASTER-CAM system pro-
vides the CAD/CAM tools to significantly improved lead-time, part quality and machining
flexibility.
CNC software offers complete CAD/CAM solution for 2 through 5-axis milling, turn-
ing, wire EDM, 3-D design, drafting and surface modeling. CNC software continually up-
dates and expands its products.

VARIOUS MODULES AVAILABLE WITH MASTER-CAM:

1. MASTER-CAM MILL LEVEL-1

CAD/CAM system for 2-1/2 axis machining and design
v Contouring and drilling
v Improved pocketing including zigzag, spiral and one-way cutting.
v Tapered wall pocketing with tapered islands of different heights.

2. MASTER-CAM MILL LEVEL -2

CAD/CAM system for 3- axis machining and design
v Tool path projection on to planes, cones. Spheres, cylinders and more
v Ruled, swept and surface of revolution.
v Single-surface roughing finishing and flow line machining.

3. MASTER-CAM MILL LEVEL-3

CAD/CAM system for 2-throught 5-axis machining and design.
v Multi surface roughing and finishing, including NURBS surfaces.
v Constant Z-level roughing
v Containment machining
v 3-D tool path projection on to surfaces

4. MASTER-CAM DESIGN
Powerful 3-D CAD software integrated into most MASTER CAM products.
v Advance geometry creation including NURBS curves and surfaces.
v 2-D and 3-D dimensioning
v Surface extension, blending, filleting & trimming and splitting.

w x
5. MASTER-CAM LATHE
CNC programming system for turning
v Roughing, finishing, grooving, boring and drilling
Editable tool and materials libraries
u
v Automatic tool compensation
v Rough to an outside boundary (casting)

6. MASTER-CAM WIRE
v
CAD/CAM system for wire EDM
v 2 - and 4 - axis wire path creation
v Automatic or manual synchronization
v Automatic corner filleting and skim cuts.
v 4 - axis surface finish by chorale deviation or step size.

7. DATA TRANSLATORS
Powerful bi-directional data translators for IGES, DXF, CADE, STL, VDA and ASCII
format

8. POST-PROCESSOR
v Hundreds of library and custom post-processors are available for virtually any ma-
chine and control

9. MASTER-CAM Draft
Basic CAD package gives you 3-D design and drafting capabilities.
v 2-D and 3-D geometry creation
v Dimensioning in any view, including isometric
v Dynamic rotation, panning and zooming
v Bi-directional data translators included

PREPARATION OF PART PROGRAM FOR POCKETIN OPERATION

w (Depth of pocket is 10mm.)

x
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O0000
(PROGRAM NAME - PART)
(DATE=DD-MM-YY - 19-09-03
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N178Y71.205
N180X94.75
N182Y74.75
v
TIME=HH:MM - 21:28) N184X90.
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N208X81.25Y32.079Z-6.356R6.
N118X89.38Y37.689Z.012R6.
N210X87.25Y38.079Z-6.849R6.
N120X93.25Y32.079Z-.368R6.
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N122X87.25Y26.079Z-.862R6.
N214X93.25Y32.079Z-7.343R6.
N124X85.12Y26.47Z-.976R6.
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N218X85.12Y26.47Z-7.951R6.
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N222X87.25Y38.079Z-8.825R6.
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N226X93.25Y32.079Z-9.319R6.
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N158Y35.863 N250X80.25
N160X80.25 N252Y57.068
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N170Y57.068 N262X94.75
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N282X36.146Y91.662Z.012R6.
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N288X28.013Y82.838Z-.976R6.
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N506X6.75Y32.079Z-8.705R6.
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w x
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w x
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w x
u PRACTICAL: 7 DATE: __________ v
AIM: STUDY ABOUT RECENT TRENDS IN CAD/CAM.
OBJECTIVES: To study about:
1. ROBOTICS
2. FMS - Flexible Manufacturing System
3. DNC – Direct Numerical Control
4. CIM – Computer Integrated Manufacturing

[1] Robotics: -

“An Industrial Robot is a reprogramable multifunctional, manipulator, designed

to move the materials, parts, tools, or special device through variable programmed
motions for the performance of a variety of tasks.

v Robot is made from Links & Joints as below: -

1. Linear Joint (L Joint)

2. Orthogonal Joint (O Joint)
3. Rotational Joint (R Joint)
4. Twisting Joint (T Joint)
Revolving Joint (V Joint)

w x
u v

v Robot Configurations: -
1. Polar Configuration
2. Cylindrical Configuration
3. Cartesian Configuration
4. Jointed Arm Robot
5. SCARA (Selective Compliance Assembly Robot Arm)

w x
u v

v Applications of Robots: -
1. It relieves man form hazardous or fatiguing tasks.
2. It brings improvement in product consistency & quality.
3. It offers opportunities for multi machine manning for multi shift operation & for
wholly unmanned production.
4. In countries short of labor, it brings in saving from labor reductions. It increases
the output without increasing the labor force.
5. Robotics will lead the way into areas of technology where man has not entered so
far.
6. Mobile robots with moving arms & wide sensing power will find more application.

[2] FMS – Flexible Manufacturing System: -

Flexible Manufacturing System could be defined as a set of machines in which
parts are automatically transferred under computer control form one machine to another
for processing. Flexible System is one, which is able to respond to change components
of FMS: -
ü Machine tools
ü Handling System
ü Tool System
ü Transport System
ü Monitoring System
ü Planning System
ü CAD/CAM

v Contains of FMS: -
1. Hardware: - CNC machine tools, material handling equipments, central chip re-

w computer hardware.
x
moval system, coolant system, tooling system, co-ordinate measuring machines

2. Software: - NC Programmers, traffic management software tooling information,

CMM Programmers.
u 1.
2.
v Types of FMS: -
Flexible Manufacturing Module (FMM)
Flexible Manufacturing Cell (FMC)
v
3. Flexible Manufacturing Group (FMG)
4. Flexible Fabrication – Machining Assembly System (FFMAS)

v Advantages of FMS: -
1. Operation Control
2. Reduction in direct labor cost
3. Increasing in utilization factor
4. Reduction in inventory
5. Wide range processing

v Application of FMS: -
1. Sheet metal press working
2. Forging
3. For assemble parts
4. For automatic inspection
5. For sheet, cast iron, aluminum parts

..
[3] DNC – Direct Numerical Control: -
DNC may be defined as a system connecting a group of numerically con-
trolled machines to a common computer memory for part program storage, distri-
bution of machine data. Provision for collection, display, or editing of part pro-
grams, operation instruction or data related to the NC Processor are also avail-
able.

v Classification of DNC System: -

1. Central Computer

w x
2. Bulk Memory
3. Telecommunication Lines
4. Machine Tools
u 1.
2.
v Advantages: -
All machines can be controlled at a time.
Its calculation speed is high.
v
3. Central computer can be placed at any place.
4. Tape & Tape reader not required.
5. Post Processing facilities are available.
6. Ideal time can be reduced.
7. Inventory control & scheduling is possible.

[4] CIM – Computer Integrated Manufacturing: -

CIM is recent technology being tried in advanced countries & it comprises a
combination of software & hardware for product design, production planning, produc-
tion control, production planning, production control, production equipments & produc-
tion processes.

v CIM includes following area: -

1. Marketing
2. Product design
3. Planning
4. Product purchasing
5. Manufacturing engineering
6. Inventor control
7. Ware housing
8. Finance
9. Information management

w x
u v

v Advantages of CIM: -
1. Renewable flexibility for manufacturing diverse components in the same
setup easy & quick manipulation of soft ware.
2. High rates of production with consistent high quality.
3. Uninterrupted production with negligible supervision or hands on work.
4. Economical production even where product demand is only moderate in
volume.
5. Drastic reduction in lead-time.
Integrating and fine-tuning of all factory functions such as raw and semi
finished materials flow, tooling, metal writing inspection etc.

w x
u v

w x
u v

w x
u v

w x
u PRACTICAL: 8 DATE: __________ v
AIM
AIM: TO STUDY AUTO LISP & PREPARE PROGRAM TO DRAFT GIVEN FIG-
URE USING AUTOLISP.

v What is Auto Lisp?

Auto Lisp is a programming language developed by AutoDesk that is designed to
assist the user in increasing productivity by simplifying multiple step task into routing
that require single command to execute. It is integrated with Auto CAD drawing environ-
ment. It is used extensively in filled of research & development as well as being the
industry standard for development of artificial intelligence.

V LIST OF AUTO LISP MATHS FUNCTIONS: -

(+ Number Number)add,
(- Number Number) subtract,
(* Number Number) multiply,
(/ Number Number) divide,
(max Number Number…) find largest no
(min Number Number) find smallest no
(rem Number Number) find reminder
(abs Number) gives absolute value
th
(exp n ) e raised nth power
(expt number nth) number raised to
(fix real) convert real to integer
(float integer) convert integer to real
(ged integer integer) find greatest common denominder
(sqrt number) find greatest square root of no

The value can be stored in variable by using setq function.

(setq variable name value)
Example:
(setq length 20)
To retrieve the value form variable (“!”) expression is used.
Example:
! length will show 20 on command prompt.

v Functions used to allow: -

Graphic Input
Get Point Allows key or more entry of point values.
Get Corner Allows selection of opposite corner of window requires & point value
defining first corner of window. The selected opposite corner de-
fines window.

w x
Get Angle Allows key or mouse entry of angle base on Auto CAD Compass ori
entation on angles (in radian)
Get Dist Allows key or mouse entry of distance.
u
v Data types in Auto Lisp: -

1. Integer: It is a number without decimal point. It stores value between (-32768 to +32767)
v
2. Real Numbers: It is a number with decimal point ex 12.5

3. String: It is used to write a quote in Auto Lisp String is written in double quotation. Ex (str “B S
Patel Polytechnic”)

4. List: When data elements are written in parenthesis, it is called list. Ex (12 14.2 18.7)

5. File descriptor: It is used to read & write file form disk.

6. Entity name: Every object in Auto CAD is determined by alphanumerical identification code.
Which is used in processing of that object in Auto Lisp. Ex <entity name 1005a>

7. Selection set: When many objects are to be processed together it is determined by selection
set.
Ex <selection set : 1 >

v Storing & Running program in Auto Lisp: -

Ø Program is written in ASCII (American Standard Code for Information Institute) with the help of
Notepad or WordPad then it is stored with LSP extension.

Ø Once the Auto Lisp program has been saved, it must be loaded into AutoCAD’s memory so that
it can be executed at any time. This can be done with Auto Lisp LOAD function when program is
loaded; each expression is checked for errors.
Syntax: (Load “File Name”)
Example: (Load “Test”)

Ø It program does not contain any error then result of last expression will be return to command
prompt.

v Example of Program for given figure: -

(DEFUN C: Y5 ( )
(SETQ RADI1 (/ (*90 PI) 180))

w x
; *******TAKES THE INPUT FROM THE USER*******
(INITGET 7)
u v
(SETQ SP1 (GETPOINT “/N PLEASE PICK THE FIRST POINT SP1:”))
(INTIGET 7)
(SETQ (GETDIST SO1 “/N PLEASE ENTER THE LENGTH OF THE
SQUARE:”))
(SETQ TP (/(* L L) 2))
(SETQ LENG ( / (SQRT TP) 4))
(SETQ P2 (POLOR SP1 0 L)
P4 (POLAR SP1 RADI1 L)
P3 (POLAR P4 0 L)
M1 (POLAR P4 0 ( / L 2 )
M2 (POLAR SP1 0 ( / L 2 )
M4 (POLAR P2 RADI1 ( / L 2 )
M (POLAR P4 0 ( / L 2 )
T1 (INTERS SP1 P3 P2 M4)
T2 (INTERS M1 P3 P2 P4)
T3 (INTERS M3 P2 SP1 P3)
T4 (INTERS M4 P3 P2 P4)
); SETQ ENDS
; ******* DRAWS NECESSARY DRAWING ******
(COMMAND “LINE” SP1 P2 P3 P4 “C”)
(COMMAND “CIRCLE” “3P” M1 T1 T2)
(COMMAND “CIRCLE” “3P” M2 T2 T3)
(COMMAND “CIRCLE” “3P” M3 T3 T4)
(COMMAND “CIRCLE” “3P” M4 T4 T1)
); DEFUN ENDS

INPUT:

PICK FIRST POINT SP1 = SELECT ANY POINT ON DRAWING AREA

ENTER THE LENGTH L OF SQUARE =100

OUTPUT

w x
u v

w x
u v

w x
u v

w x