cadcam manual

MERCHANT POLYTECHNIC COLLEGEMERCHANT POLYTECHNIC COLLEGE BASNABASNA

CERTIFICATE

CAD/CAM (M658) Lab Manual 1

This is certify thatMr/Miss._______________________________

Enroll. No. Of class 6 TH Mechanical

Has satisfactorily completed the his/her term work of

CAD/CAM.

Date of submission / /

Faculty/ Staff Head of Department

MERCHANT POLYTECHNIC COLLEGE BASNA


CAD/CAM

INDEX

Sr

No.Name of Experiment

Pag

e

no.

Dateof

Start

Dateof

Comp.

Comp

.

Sign

Marks/

Grade

1.TO STUDY ABOUT INTRODUCTION AND CONCEPT OF CAD/CAM

2.TO STUDY ABOUT COMPUTER HARDWARE ANDSOFTWARE

3.

TO STUDY ABOUT AUTOCAD

COMMAND AND ITS

APPLICATION

4.

TO STUDY ABOUT AUTOLISP

COMMANDS AND

PROGRAMMING.

5.TO STUDY ABOUT

INTRODUCTION OF PRO-E.

6.TO STUDY ABOUT CNC PART

PROGRAMMING.

7.

TO STUDY ABOUT

PROGRAMMING AND MISC.

FUNCTIONS

8.TO STUDY ABOUT “RECENT

TRENDS IN CAD/CAM”

Total Marks/ Grade:-

Signature of Faculty:-


1 INTRODUCTION AND CONCEPT OF CAD/CAMINTRODUCTION AND CONCEPT OF CAD/CAM

Objective: - Basic concepts of CAD/CAM

Learning:-

I. Era of cad/cam

II. Importance of cad/cam

III. Basic of cad/cam

INTRODUCTION :

Why Computer Aided Design?

Computer Aided Design (CAD) tools allow designers to spend their intellectual energy

on innovation instead of focusing their attention on the mechanics of designing. As idea

sere developed, designers must document and further develop them into fully market

able concepts. The more fluid the innovation process, the more readily innovative

designs can be achieved. CAD tools have relieved the burden of documenting a design

idea, and have gone further to provide automated calculations and analysis to allow the

designer to focus their attention on their designs. The ideal design tool must embed

significant industry knowledge and become a natural part of the innovation process,

enabling product advancements that were previously unachievable. In essence, what

would have taken a small army of assistants to retrieve information, perform

calculations and analyze designs should now be automated at the designer’s fingertips.

Computer Aided Design (CAD)

Can be defined as the use of computer systems to assist in the creation,

modification, analysis, and optimization of a design.

Computer Aided Manufacturing (CAM)

Can be define as the use of computer systems to plan, manage and control the

operation of a manufacturing plant through either direct or indirect computer interface

with the plants production resources

Definition of CAD/CAM: -


DATE: / / DATE: / /

CAD/CAD is a term which means computer aided design and computer aided

manufacturing. It is the technology concerned with the use of the digital computers to

perform certain function in the design & production.

DESIGNS STEPS & REASONS OF IMPLEMENTING CAD SYSTEM

The process of designing something is characterize by SHIGLEY as an interactive

procedure which consist of six identifiable steps or phases :

(1) Recognition of need : - It involves the realization by someone that a problem

exists for which some corrective action should be taken. This might be the

identification of some defect in a current machine design by an engineer or the

perception of a new product marketing opportunity by a sales person.

(2) Definition of the problem:- It involves a thorough specification of the item to be

designed. This specification includes physical & functional characteristics, cost,

quality & operating performance

(3) Synthesis: -Synthesis & analysis are closely related & highly iterative in the design

process.

(4) Analysis & Optimization: -A certain component or sub system of the overall system

is conceptualized by the designer, subjected to analysis, improved through this

analysis procedure, & redesigned.

(5) Evaluation: - It is concern with measuring the design against the specifications

established in the problem definition phase. This evaluation often requires the

fabrication & testing of a prototype model to assess operating performance, quality,

reliability, & other criteria.

(6) Presentation: - The final phase in the design process is the presentation of the

design .This includes documentation of the design process by means of drawings,

material specifications, assembly lists, & so on.


BENEFITS OF CAD/CAM

Improved engineering productivity

Shorter lead times

Reduced engineering personnel requirements

Customer modifications are easier to make

Faster response to requests for quotations

Avoidance of subcontracting to meet schedules

Minimized transcription errors

Improved accuracy of design

In analysis, easier recognition of component interactions

Provides better functional analysis to reduce prototype testing

Assistant in preparation of documentation

Designs have more standardization

Better designs provided

Improved productivity in tool design

Better knowledge of costs provided

FUNCTIONAL AREA OF CAD

Geometric modeling

Engineering analysis

Design review and evaluation

Automatic drafting

Part coding and classification


Objective: - Hardware and software used in cad/cam

Learning:-

I. Hardware and software information

II. Input and output devices

III. Hardware linked in cad/cam work-station

IV. Graphic packages and standard

INTRODUCTION :

In engineering practice, CAD/CAM has been utilized in different ways by different

people. Some utilize it to produce drawings and document designs. Others may employ

it as a visual tool by generating shaded images and animated displays. A third group

may perform engineering analysis of some sort on geometric models such as finite

element analysis. A forth group may use it to perform process planning and generate

NC part programs. Figure shows a flow chart of such cycle.

BLOCK DIAGRAM:

``


TO STUDY COMPUTER HARDWARE AND SOFTWARE TO STUDY COMPUTER HARDWARE AND SOFTWARE 2 2

DATE: / / DATE: / /

CLASSIFICATION OF CAD WORK STATION:

Low – end design work station

High – end design work station

FUNCTION OF CAD WORK STATION:

It coordinators with CPU.

It produces permanent graphic image of produces.

It provides numerical information about graphic images.

It connects computer commands into operating work.

It provides proper coordination between computer systems and users.

CONFIGURATION OF CAD WORK STATION:

SYSTEM PROCESSING UNIT:

Central Processor : PA – 8000

Clock frequency : 180 – 340 MHZ

No. of processors : 1 to 8

SPEC int 95 : 11.8

SPEC fp 95 : 20.2

SPEC int-base 95 : 10.8

SPEC fp-base 95 : 18.3

Linpack (100 * 100) complied : 158 MFLOPS

(With 177 + Oall + Oinline = daxpy)

Linpack (1000 * 1000) handcoded : 510 MFLOPS

(in PA-RISC 2.0 assembly code)

MEMORY MANAGEMENT UNIT:

Virtual memory address : 64 bit

Instruction TLB & data TLB : UNIFIED 96


PRIMARY CACHE:

Instruction cache size : 1 MB

Organization : Direct mapped

Bus width : 128 bit

Instruction cache bus peak performance : 2.88 GB / sec (16 bytes)

Data cache size : 1 MB

Organization : Direct mapped

Data cache bus peak performance : 2.88 GB / sec (16 bytes)

MP system bus : 64 data bits + 2 parity

Bus width : 960 MB / sec

(768 MB / sec peak sustained)

MAIN MEMORY:

Type : ECC DRAMS single bit correct

: Double – bit delta

: 60 ns 4Mbit, 16Mbit & 64Mbit

: DRAM Technology

Capacity : 128 MB – 3.75 GB (W / 64Mbit)

Main memory bus width : 128 data bits W / 16 check bits

Interleaving : up to 32 – way

Main memory bus peak performance : 960 MB / sec (64 – byte duration)

Memory options : 128MB-3.75GB in 32 MB, 64 MB,

124 MB or 256 MB increments

Memory expansion slots : 32, Configured in pairs

INPUT DEVICES:

These are the devices through which the user/operator communicates with the

computer for feeding it with the necessary information, both graphical and

alphanumerical as required. The various devices used are the following.


Keyboard

Mouse

Light pens

Joystick

Digitizer

(1) KEYBOARD:

Conventional keyboards are text only devices and from an essential and basic

input device. They are typically employed to create/edit programs or to perform word

processing functions. These keyboards have been modified to perform graphics tasks

by adding special function keys or attaching graphics input devices such as mice to

them.

How does the keyboard communicate with the CAD/CAM software or the main

application program? How is the software interrupted to receive the keyboard input?

Each input device, in general, is connected to the computer by means of registers

whose contents can be read by the computer.

(2) MOUSE:

The mouse was invented in the late 1960s as a location device but has only

recently become fairly popular due to its convenient use with icons and pop-up and pull-

down menus. Unlike the digitizing table, the mouse measures its relative movement

from its last position, rather than where it is in relation to some fixed surface. There are

two basic types of mouse available: mechanical and optical.

(3) LIGHT PEN:

The light pen is intrinsically a pointing or picking device that enables the user to

select a displayed graphics item on a screen by touching its surface in the vicinity of the

item. The light pen, however, does not typically have hardware for tracking, positioning,

or locating in comparison to a digitizing table and stylus. Instead, these functions are

performed by utilizing hardware capabilities of the graphics display at hand. Light pen

itself does not emit light but rather detects it from graphics item displayed on the screen.


Using the emitted light as an input, it sends an interrupt signal to the computer to

determine which item was seen by the pen.

(4) JOYSTICK:

The joystick can also be used to control the on-screen cursor movement as a

mouse dose. The joystick works by pushing its stick backward or to forward or to the left

or the right. A joystick may be equipped with a rotating knob on the top, which can be

used to enter a third axis value, thus the making a joystick a three dimensional input

device.

(5) DIGITIZER:

A digitizer is most widely used by CAD designers as an input medium. It is used

for converting the physical locations into co-ordinate values so that accurate transfer of

data can be achieved.

OUTPUT DEVICES :

Output devices form the other half of CAD/CAM workstation, the first being the

input devices. While CAD/CAM applications require the conventional output devices

such as alphanumeric (video) displays (terminals) and hard copyprinters, they require

output devices to display graphics to the user. Graphic displays or terminals which only

display information on a screen. Hard output devices refer to hardcopy printers and

plotters that can provide permanent copies of the displayed information.

HARDCOPY PRINTERS AND PLOTTERS:

Output devices of both printers and plotters are available to CAD/CAM systems

for purposes such as creating check plots for offline editing and producing final

drawings and documentation on paper. Relative to the drawing rate on screen, they are

slow. Printers usually provide hard copies of text as well as graphics. Hardcopy devices,

in general, employ one of two methods of plotting: vector or raster plotting. The two

methods are very close in concept to refresh and raster displays respectively.


PEN PLOTTERS:

There are two common types of conventional pen plotters: flat-bed and drum. In

the flat-bed plotters, the paper is stationary and the pen- holding mechanism can move

in two axes. In the drum plotter, the paper is attached to the drum that rotates back and

forth, there by providing moves in the transverse direction to provide movement along

the other axis.

ELECTROSTATIC PLOTTERS:

They are considered dot matrix or raster plotters. The image in vector form, as

lines, arcs, characters, and symbols, has to be converted in to raster-form and sorted.

Then these rows of dots can be printed across the width of the paper or plastics film as

it slowly moves through the plotter.

BLACK-AND-WHITE AND COLOR PRINTERS:

The major two types of black-and-white printers are dot matrix and laser printers.

Dot matrix printers are inexpensive but slow. The resolution is typically 75 dpi. It is

possible to obtain a resolution of 300 dpi from dot matrix printer. The laser printers are

also most popular printers.

The demand for color printers has increased since colour displays have become

affordable and popular. The major six types of color printers available are impact,

photographic, electro photographic, electrostatic, thermal transfer, and ink jet printers.

GRAPHICS DISPLAYS:

The graphics display of a workstation is considered its most important

component because the quality of the display image influences the perception of

generated design on the CAD/CAM system. In addition to viewing images, the graphic

display enables the user to communicate with the displayed image by adding, deleting,

blanking and moving graphics entities on the display screen.


GRAPHIC PACKAGES:

Graphics packages are one of following categories.

Paint program

Business program

Drafting program

Modeling (3D) program

Paint program requires following tools.

File handling

Drawing tools

Editing tools

Display control tools

Text creators

Printing features

Slide show

Animation features

Business graphic package includes following tools.

File handling

Graph making

Text entry

Printing

Drafting (2D) to modeling (3D) packages

Drawing facilities

Entity drawing

Editing command

Std. parts

Hatching

Dimensioning

Plotting


Configuration

Drawing interchange

GRAPHIC STANDARDS:

[1] GKS (Graphic kernel system):

FATURES OF G.K.S:

Independent of input output device.

Text is similar to English.

All facilities of display available.

Its graphic functions are 2D & 3D both.

[2] PHIGS (Programmer’s Hierarchical Interactive graphic Std.)

It is accepted by CAD vendors due to capability of 3D graphic work as well as

animation.

FEATURES OF PHIGS:

Very high interactivity.

Hierarchical structure of data.

Real time modification of graphic data.

Support for geometric animation.

Adaptability to distributed user environment.

[3] IGES (Initial Graphics Exchange Specification)

It works on the ‘Entity’ concept and entity is divided into three parts:

i. Geometry

ii. Anotation

iii. Structure

IGES file is divided into six sections;

1. FLAG: It is used to indicate the form in which the data is specified.

2. START: This contains information about man readable file and is used for post

processing of other application.

3. GLOBAL: This contains information about all details of product.

4. DIRECTORY ENTITY: This contains information about all details of product.

5. PARAMETER DATA: This contains the data associated with the entities.


6. TERMINATE: This contains the sub-totals of the records present in each of the earlier

sections.

CAD SOFTWARE:

There are mainly two parts of CAD software;

1. Operating system.

2. Application software.

Operating system connects uses two application software.

Application softwares are used for special work like;

Statistics / Data entry / Coupling

Drafting

Designing

Analysis

Report generation etc.

CAD softwares are like:

AUTO CAD

I-DEAS

PRO-E

CATIA

INVENTS

NASTRAN

UNIGRAPHICS


Objective: - Perform & study AutoCAD command and its application

Learning:-

I. AutoCAD profile/basic of AutoCAD

II. 2D & 3D command of AutoCAD

III. Achieve ability to draw design in 2D & 3D

INTRODUCTION:

When you start AutoCAD, the AutoCAD window opens. The window is your

design work space. It contains elements that you use to create your designs and to

receive information about them. The following discussion shows the main parts of the

AutoCAD window.

Menu Bar

Contains the default AutoCAD menus. Menus are defined by menu files that you

can modify or design on your own. The default menu file is acad.menu.

Standard Toolbar

Contains frequently used buttons such as Redo, Undo, and Zoom, as well as

Microsoft Office standard buttons such as Open, Save, Print, and Spell. Buttons with

small black triangles in the lower-right corner have flyouts containing tools that invoke

commands related to the first tool shown. Click and hold down the first button to display

the flyout.

Drawing File Icon

Represents a drawing file in AutoCAD. The drawing file icon is also displayed

next to options in dialog boxes that are saved in the drawing, instead of in each session

as in AutoCAD.


TO STUDY AUTOCAD COMMAND AND ITS APPLICATIONTO STUDY AUTOCAD COMMAND AND ITS APPLICATION 33 33

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Object Properties Toolbar

Sets object properties such as color, linetype, and lineweight and manage layers.

See "Using the Object Properties Toolbar."

Draw and Modify Toolbars

Provide access to common draw and modify commands. The Draw and Modify

toolbars are displayed when you start AutoCAD. These toolbars are docked on the left

side of the window. You can easily move toolbars and turn them on and off. See

"Working with Toolbars."

Drawing Area

Displays drawings. The drawing area size varies, depending on the size of the

AutoCAD window and on the number of other elements (such as toolbars and dialog

boxes) that are displayed.

Crosshairs

Identifies pick and drawing points within the drawing area. Use the crosshairs,

which are controlled by your pointing device, to locate points and select and draw

objects.

User Coordinate System (UCS) Icon

Shows the orientation of the drawing. AutoCAD drawings are superimposed on

an invisible grid, or coordinate system. Coordinate systems are based on X, Y, and (for

3D) Z coordinates. AutoCAD has a fixed world coordinate system (WCS) and a

movable user coordinate system (UCS). To help you visualize the UCS location and

orientation, a UCS icon is displayed in the lower-left corner of the drawing area.

Model Tab/ Layout Tabs

Switch your drawing between model (drawing) space and paper (layout) space.

You generally create your designs in model space, and then create layouts to plot and

print your drawing in paper space.

Command Window

Displays prompts and messages. In AutoCAD, you start commands in one of

three ways:


1. Choose an item from a menu or a shortcut menu.

2. Click a button on a toolbar.

3. Enter the command on the command line.

Status Bar

Displays the cursor coordinates in the lower-left corner. The status bar also

contains buttons that you can use to turn on common drawing aids. These include Snap

(Snap mode), Grid (drawing grid), Ortho (Ortho mode), Polar (polar tracking), Osnap

(object snaps), Otrack (object snap tracking), Lwt (line weight display), and Model

(model and paper space toggle).

DRAW COMMANDS:

Creates straight line segments :LINE

Creates an infinite line :CONS. -LINE

Creates multiple parallel lines :MULTI-LINE

Creates two-dimensional poly lines :POLYLINE

Creates an equilateral closed poly line :POLYGON

Draws a rectangular poly line :RECTANGLE

Creates an arc :ARC

Creates a circle :CIRCLE

Creates a quadratic or cubic spline (NURBS) curve :SPLINE

Creates an ellipse or an elliptical arc :ELLIPSE

Creates a block definition from objects you select :BLOCK

Creates a point object :POINT

Fills an enclosed area or selected objects with a hatch pattern :HATCH

Creates a region object from a selection set of existing objects :REGION

Creates multi line text :MULTI LINE TEXT

MODIFY COMMANDS:

Removes objects from a drawing :ERASE

Object Duplicates the objects you select :COPY

Creates a mirror image copy of objects :MIRROR

Creates concentric circles, parallel lines, and parallel curves :OFFSET


Creates multiple copies of objects in a pattern :ARRAY

Displaces objects a specified distance in a specified direction :MOVE

Moves objects about a base point :ROTATE

Enlarges or reduces objects equally in the X, Y, and Z directions :SCALE

Moves or stretches objects :STRETCH

Lengthens an object :LENGTHEN

Trims objects at a cutting edge defined by other objects :TRIM

Extends an object to meet another object :EXTEND

Erases parts of objects or splits an object in two :BREAK

Bevels the edges of objects :CHAMFER

Rounds and fillets the edges of objects :FILLET

Breaks a compound object into its component objects :EXPLODE

STANDARD COMMANDS:

Creates a new drawing file :NEW

Opens an existing drawing file :OPEN

Quickly saves the current drawing :SAVE

Plots a drawing to a plotting device or file :PLOT

Shows how the drawing will look when it is printed or plotted :PREVIEW

Finds, replaces, selects, or zooms to specified text :FIND

Copies objects to the Clipboard and erases the objects from the drawing :CUT

Copies objects to the Clipboard :COPY

Inserts data from the Clipboard :PASTE

Copies the properties from one object to one or more objects :MATCH

PROPERTIES

Reverses the most recent operation :UNDO

Reverses the effects of the previous UNDO or U command :REDO

Attaches a hyperlink to a graphical object or modifies an existing hyperlink

:HYPERLINK

Refreshes the display of all the view ports :REDRAW ALL

View ports Dialog Displays the View ports dialog :VIEW-PORTS

Controls the interactive viewing of objects in 3D :3D-ORBIT

Rea ltime Moves the drawing display in the current view port :PAN

Real time Zooms in real time :ZOOM


Zooms to display the previous view :ZOOM PREVIOUS

Runs AutoCAD Design Center :AUTOCAD DESIGN CENTER

Controls properties of existing objects :PROPERTIES

Provides an AutoCAD interface to external database tables :DB-CONNECT

Displays online help :HELP

DIMENSION COMMANDS:

Creates linear dimensions :DIM.LINEAR

Creates an aligned linear dimension :DIM.ALIGNED

Creates ordinate dimensions :DIM.ORDINATE

Creates radius dimensions for circles and arcs :DIM.RADIUS

Creates a diameter dimension for circles and arcs :DIM.DIAMETER

Creates an angular dimension :DIM.ANGULAR

Quickly create dimension arrangements :DIM.QUICK

Creates a linear, angular, or ordinate dimension from the baseline of the previous

dimension or a selected dimension :DIM.BASELINE

Creates a linear, angular, or ordinate dimension from the second extension line of the

previous dimension or a selected dimension :DIM.CONTINUE

Quickly creates a leader and leader annotation :QUICK LEADER

Creates geometric tolerances :TOLERANCE

Creates a center mark for circles and arcs :CENTER MARK

Edits dimensions :DIM.EDIT

Moves and rotates dimension text :DIM. TEXT EDIT

Creates and modifies dimension styles :DIM.STYLE

INQUIRY COMMANDS:

Measures the distance and angle between two points :DISTANCE

Calculates the area and perimeter of objects or of defined areas :AREA

Calculates and displays the mass properties of regions or solids :MASS-

PROPERTIES

Displays database information for selected objects :LIST

Displays the coordinate values of a location :LOCATE POINT


BLOCKS & ATTRIBUTES:

Saves a block definition in the current drawing or as a separate drawing file using a

dialog box. Saves a block definition in the current drawing using the command line

:BLOCK

Places a previously defined block or drawing in the current drawing :INSERT/MINSERT

The Write Block dialog box displays different default settings depending on whether

nothing is selected, a single block is selected, or objects other than blocks are selected.

For example, if you have a single block selected when you open the Write Block dialog

box, the Source radio button is set to Block. The following table lists other defaults

depending on the selection state of the current drawing :WRITE BLOCK

An ATTRIBUTE is informational text associated with a block. Use ATTEXT to extract

the data stored in the attribute into a file :ATTEXT

OBJECT SNAP COMMANDS:

Creates a temporary point used by Osnaps :TEMPORARY-

TRACK

Offsets from a temporary reference point :FROM

Snaps to the closest endpoint of an arc or a line :END POINT

Snaps to the midpoint of an arc or a line :MID POINT

Snaps to the intersection of a line, an arc, or a circle :INTERSECTION

Snaps to the apparent intersection of two objects :APPARENT-

INTERSECT

Snaps to the phantom extension of an arc or line :EXTENSION

Snaps to the center of an arc or a circle :CENTER

Snaps to a quadrant point of an arc or a circle :QUADRANT

Snaps to the tangent of an arc or a circle :TANGENT

Snaps to a point perpendicular to an arc, a line, or a circle :PERPENDICULAR

Snaps parallel to a specified line :PARALLEL

Snaps to a point object :NODE

Snaps to the insertion point of text, a block, a shape, or an attribute :INSERT

Snaps to the nearest point of an arc, a circle, a line, or a point :NEAREST


3D COMMANDS:

Solids:

Creates a three-dimensional solid box :BOX

Creates a three-dimensional solid sphere :SPHERE

Creates a three-dimensional solid cylinder :CYLINDER

Creates a three-dimensional solid cone :CONE

Creates a 3D solid with a sloped face tapering along the X axis :WEDGE

Creates a donut-shaped solid :TORUS

Creates unique solid primitives by extruding existing two-dimensional objects

:EXTRUDE

Creates a solid by revolving a two-dimensional object about an axis :REVOLVE

Slices a set of solids with a plane :SLICE

Uses the intersection of a plane and solids to create a region :SECTION

Creates a composite 3D solid from the common volume of two or more solids

:INTERFERE

Generates profiles and sections in viewports created with the SOLVIEW command

:SOLDRAW

Creates floating viewports using orthographic projection to lay out multi- and sectional

view drawings of 3D solid and body objects :SOLVIEW

Creates profile images of three-dimensional solids :SOLPROFILE

Solids editing commands:

Creates a composite region or solid by addition :UNION

Creates a composite region or solid by subtraction :SUBTRACT

Creates solids or regions from the intersection of solids or regions :INTERSECT

Extrudes selected faces on a solid object to a specified height or along a path

:SOLID EDIT FACE EXTRUDE

Moves selected faces on a solid object to a specified height or distance

:SOLID EDIT FACE

Equally offsets faces on a solid object by a specified distance or point

:SOLID EDIT FACE OFFSET

Deletes or removes faces, including fillets or chamfers on a solid object

:SOLID EDIT FACE DELETE


Rotates one or more faces on a solid object around a specified axis

:SOLID EDIT FACE ROTATE

Tapers faces on a solid object with a specified angle :SOLID EDIT FACE TAPER

Copies faces on a solid object as a region :SOLID EDIT FACE COPY

Changes the color of individual faces on a solid object :SOLID EDIT FACE COLOR

Copies 3D edges on a solid object as an arc, circle, ellipse, line, or spline

:SOLID EDIT EDGE COPY

Changes the color of individual edges on a solid object

:SOLID EDIT EDGE COLOR

Imprints geometry on a face of a solid object :SOLID EDIT BODY IMPRINT

Removes all redundant edges and vertices on a solid object

:SOLID EDIT BODY CLEAN

Separates 3D solid objects with disjointed volumes into independent 3D solid objects

:SOLID EDIT BODY SEPARATE

Creates a hollow, thin wall with a specified thickness on a solid object

:SOLID EDIT BODY SHELL

Validates a 3D solid object as a valid ACIS solid :SOLID EDIT BODY CHECK

Surfaces commands:

Creates solid-filled polygons :2D SOLID

Creates a three-dimensional face :3D FACE

Creates a three-dimensional box polygon mesh :BOX

Creates a right-angle wedge-shaped polygon mesh with the sloped face tapering along

the X axis :WEDGE

Creates a pyramid or a tetrahedron :PYRAMID

Creates a cone-shaped polygon mesh :CONE

Creates a spherical polygon mesh :SPHERE

Creates the upper half of a spherical polygon mesh :DOME

Creates the lower half of a spherical polygon mesh :DISH

Creates a toroidal polygon mesh that is parallel to the XY plane of the current UCS

:TORUS

Changes the visibility of three-dimensional face edges :EDGE

Creates a free-form polygon mesh :3D MESH

Creates a revolved surface about a selected axis :REVOLVED

SURFACE


Creates a tabulated surface from a path curve and a direction vector: TABULATED

SURFACE

Creates a ruled surface between two curves :RULED SURFACE

Creates a three-dimensional polygon mesh :EDGE SURFACE

UCS & VIEW COMMANDS:

Manages user coordinate systems :UCS

Manages defined user coordinate systems :UCS MANAGE

Restores the previous UCS :UCS PREVIOUS

Sets the UCS to the World Coordinate System :UCS WORLD

Defines a new coordinate system based on a selected object :UCS OBJECT

Defines a new coordinate system based on a selected face :UCS FACE

Establishes a new coordinate system with the XY plane parallel to the screen

:UCS VIEW

Defines a new UCS by shifting the origin :UCS ORIGIN

Defines a UCS using a positive Z axis extrusion method :UCS Z AXIS

Specifies the new UCS origin and the direction of the X and Y axes :UCS 3 POINT

Rotates the current UCS about the X axis :UCS X AXIS

Rotates the current UCS about the Y axis :UCS Y AXIS

Rotates the current UCS about the Z axis :UCS Z AXIS

Applies current UCS to a selected viewport :UCS APPLY

Creates and restores views :VIEW

Sets the view point to top :TOP VIEW

Sets the view point to bottom :BOTTOM VIEW

Sets the view point to left :LEFT VIEW

Sets the view point to right :RIGHT VIEW

Sets the view point to front :FRONT VIEW

Sets the view point to back :BACK VIEW

Sets the view point to southwest isometric :SW ISO VIEW

Sets the view point to southeast isometric :SE ISO VIEW

Sets the view point to northeast isometric :NE ISO VIEW

Sets the view point to northwest isometric :NW ISO VIEW

Allows you to set a different camera and target location :CAMERA


Objective: - Perform & study auto-lisp command and programming

Learning:-

I. Knowing auto-lisp

II. Command of auto-lisp

III. Programming for command

INTRODUCTION

Auto LISP is a programming language designed for extending and customizing

AutoCAD functionality. It is based on the LISP programming language, whose origins

date back to the late 1950s. LISP was originally designed for use in Artificial Intelligence

(AI) applications, and is still the basis for many AI applications.

AutoCAD introduced Auto LISP as an application programming interface (API) in

Release 2.1, in the mid-1980s. LISP was chosen as the initial AutoCAD API because it

was uniquely suited for the unstructured design process of AutoCAD projects, which

involved repeatedly trying different solutions to design problems.

Visual LISP (VLISP) is a software tool designed to expedite Auto LISP program

development. The VLISP integrated development environment (IDE) provides features

to help ease the tasks of source-code creation and modification, program testing, and

debugging. In addition, VLISP provides a vehicle for delivering standalone applications

written in Auto LISP.

In the past, developing Auto LISP programs for AutoCAD meant supplying your

own text editor for writing code, then loading the code into AutoCAD and running it.

Debugging your program meant adding statements to print the contents of variables at

strategic points in your program. You had to figure out where in your program to do this,

and what variables you needed to look at. If you discovered you still didn't have enough

information to determine the error, you had to go back and change the code again by


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adding more debugging points. And finally, when you got the program to work correctly,

you needed to either comment out or remove the debugging code you added.

The Visual LISP (VLISP) interactive development environment runs in a separate

set of windows from the rest of AutoCAD. You must explicitly start VLISP to work in the

interactive development environment.

STARTING THE VLISP

To start Visual LISP

1 Start AutoCAD.

2 Choose Tools AutoLISP Visual LISP Editor from the AutoCAD menu, or enter the

following at the Command prompt: vlisp

VLISP SCREEN INFORMATION

The areas shown in the VLISP screen are as follows:

Menu

You can issue VLISP commands by choosing from the various menu items. If

you highlight an item on a menu, VLISP displays a brief description of the command's

function in the status bar at the bottom of the screen.

Toolbars

Click toolbar buttons to issue VLISP commands quickly. There are five toolbars

Debug, Edit, Find, Inspect, and Run each representing a distinct functional group of

VLISP commands. (In the figure shown on this page, the toolbars are adjacent to one

another, each toolbar beginning with an icon ( ). You can execute many, but not all,

menu commands from the toolbars. If you move your mouse pointer over a toolbar

button and leave it there for a couple of seconds, VLISP displays a tooltip indicating the

function of the button. A more descriptive explanation appears in the status bar at the

bottom of the VLISP screen.

Console Window

This is a separate, scrollable window within the main VLISP window. In the

Console window, you can type AutoLISP commands, similar to the way you do in the


AutoCAD Command window. You can also issue many Visual LISP commands from

this window, instead of using the menu or toolbars.

Status Bar

The information displayed in the status bar located at the bottom of the screen

varies according to what you are doing in VLISP.

You may also see a minimized Trace window. During startup, this window

contains informational messages about the current release of VLISP, and may contain

additional information if VLISP encounters errors during startup.

LOADIND AND RUNNING VLISP PROGRAM

To load and run a program in a Visual LISP text editor window

Make sure the text editor window containing the drawline.lsp program is active. If you

are not sure whether the window is active, click anywhere in the window to activate it.

Choose the Load Active Edit Window button from the Run toolbar, or choose Tools

Load Text in Editor from the VLISP menu.

VLISP responds by displaying a message in the Console window indicating it has

loaded the program.

Run the drawline function from the Console prompt by entering the function name in

parentheses, then pressing ENTER: _$ (drawline)

The drawline function will ask you to specify two points, and will then draw a straight

line between those points.

Respond to the prompts by specifying points in the graphics window or on the

Command line.

IMPORTANT FUNCTIONS

(add) Returns the sum of all numbers (+ [number number] ...)

(subtract) Subtracts the second and following numbers from the first and returns the

difference (– [number number] ...)

(multiply) Returns the product of all numbers

(* [number number] ...)

(divide) Divides the first number by the product of the remaining numbers and returns

the quotient


(/ [number number] ...)

(equal to) Compares arguments for numerical equality

(= numstr [numstr] ...)

(not equal to) Compares arguments for numerical inequality

(/= numstr [numstr] ...)

(less/greater than) Returns T if each argument is numerically less/greater than the

argument to its right, and returns nil otherwise

(< >numstr [numstr] ...)

(increment) Increments a number by 1

(1+ number)

(decrement) Decrements a number by 1

(1– number)

Returns the absolute value of a number

(abs number)

Converts a string into a real number

(atof string)

Returns the third element of a list

(caddr list)

Returns the second element of a list

(cadr list)

Returns the first element of a list

(car list)

Returns a list containing all but the first element of the specified list

(cdr list)

Defines a function

(defun sym ([arguments] [/ variables...]) expr...)

Pauses for user input of an angle, and returns that angle in radians

(getangle [pt] [msg])

Pauses for user input of a rectangle's second corner

(getcorner pt [msg])

Pauses for user input of a distance

(getdist [pt] [msg])

Pauses for user input of a point, and returns that point

(getpoint [pt] [msg])


Takes any number of expressions, and combines them into one list

(list [expr...])

Returns the largest of the numbers given

(max [number number...])

Returns the smallest of the numbers given

(min [number number...])

Prints an expression to the command line, or writes an expression to an open file

(print [expr [file-desc]])

Sets the value of a symbol or symbols to associated expressions

(setq sym expr [sym expr]...)


Objective: - Study & performing pro-e

Learning:-

I. Introduce to pro-e

II. Command of pro-e

III. Design different module in pro-e

INTRODUCTION

Following are the important features of Pro – E.

Protrusion Feature

Hole Feature

Round Feature

Chamfer Feature

Rib Feature

Shell Feature

Pipe Feature

PROTRUSION FEATURE

Protrusion is the method of adding a solid material.It can add material in a void or on

An existing solid. Pro/engineer provides the following basic method of adding material

to a model.

Extrude – creates a solid feature by extruding a section normal to the section plane.

Revolve - creates a solid feature by revolving a section about an axis.

Sweep - creates a solid feature by sweeping a section about a trajectory.

Blend - creates a solid feature by blending various cross sections at various level.

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 Diameter 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 it 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, surfaces

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 reference

geometry and on your need to customize the default round geometry supplied 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

are two types of chamfer.

1. Edge

2. Corner

Edge: An Edge Chamfer removes a flat section of material from a selected edge to

create a beveled surface between the two original surfaces common to that edge. One

can select multiple edges to create an edge chamfer.

45 x d: this option is used to create a chamfer that is at angle of 45 degrees to both

surfaces & 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 chamfers only on

an edge formed by the inter section of two perpendicular surfaces.

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.

d1 x d2: Creates a chamfer at a distance d1 from the selected edge along one surface

and a distance d2 from the selected edge along the other surface. the system displays

both distances their respective surfaces when you modify the chamfer.

Ang x d: Creates a chamfer at a distance d from the selected edge 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 or 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 create a thin wall or we to

support to `surfaces. The Rib is used to increase the strength of the part. You always

ketch a rib from a side view it grows symmetrically about the sketching plane.

Straight Rib: Ribs that are not created on through/Axis datum planes are extruded

symmetrically about the sketching plane. You must skill sketch the Ribs 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.

Pro/Engineer adds all material in the direction of the arrow. if an incorrect 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 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, 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 creation is very

important when you use shell.

After involving this command Pro/Engineer Displays the feature creation dialog box. if

desired, select the optional element spec thick to specify thickness individually.

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. After the

pipe feature has been created, you can determine its length by using info from the

toolbar, before you start to create a pipe feature. Reference datum points must already

exist.


Objective: - Perform & study CNC

Learning:-

I. Introduce NC & CNC

II. Designation of different motion

III. Knowing of codes

NC SYSTEM

Flexible automation is implemented in machine tools in the form of digital control.

The programs are in binary, in numerical form; strictly speaking alphanumeric. This

instructions when read by the system, regulate the various slides of the machine tool to

enable the tool/tools to shape the objects to required profiles by positional and/or

continues control. Such systems are known as numerical control (NC) system.

CLASSIFICATION OF NC MACHINE

It is convenient though not necessary in the context of the standard, to classify

the NC machines in the following groups.

Group I: Machine tools with rotating tools (i.e. spindle with cutting power). These

machines may have vertical spindle, e.g. vertical knee mill, drilling machines, profiling

and contour mill, vertical boring mill, tapping machines, etc. These may be grouped as

(a). Those with horizontal spindles are the horizontal boring machines, horizontal

spindle machining centers etc. The machines grouped in (a) could be single column (a-

i) or gantry tube I (a-ii)

Group II: Machine tools with rotating work pieces (i.e. spindle generates a surface of

revolution) e.g. lathes, grinding machines, etc.

Group III: Machine tools with non-rotating work pieces and non-rotating tools (i.e. no

spindle) e.g. shaper, planer.


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Group IV: Machines other than machine tools, like NC drafting machine etc.

DESIGNATING THE MOTIONS AND AXIS:

The guiding coordinate system for designating the axes is the conventional

mathematical right-hand coordinate system. Some possible dispositions of these

coordinates are shown in Fig. One could use his right hand to get to these alternative

relative positions of the same right-hand coordinate system.

First of all, Z-motion shall be designated. This shall be followed by X and Y

motions respectively.

Z-MOTION

Location: Z-axis motion is either along the spindle axis or parallel to the spindle axis

(of I and II machine groups). In case of machine groups III and IV it is recognized as the


one perpendicular to the work holding surface which may or may not be passing

through the controlled point (i.e. cutting tool tip or drafting machine pen tip).

Direction : The principle for the machines of groups I and II where drilling type motion

can be performed is that for moving a drill into the work piece the cutting tool should

move in the negative (-) z direction.

For other machines the positive (+) z motion increases the clearance between

the work surface and the tool holder (or a pen holder in the case of the drafting

machine)

When there are several spindles and slide ways, in such cases, one of the

spindles, preferably perpendicular to the work holding surface may be chosen as the

principal spindle. The primary z motion is then near to the primary spindle. The tool

motions of other spindle quills or other slides, which are termed as secondary and

tertiary motions.

X – MOTION

The X-Motion is principal motion in the positioning plane of the cutting tool or the

work piece.

Location: It is perpendicular to the axis and should be horizontal and parallel to the

work holding surface wherever possible.

Direction: Fro group (a-i) machines, when looking from the principal tool spindle to the

column the positive (+) X is to the RIGHT.

For Gantry profiler when looking from the principal spindle to the left hand gantry

support the positive (+) X is to the Right.

For Horizontal boring machine when looking from the principal tool spindle

towards the work piece the positive (+) X is to the RIGHT.

For Turret Lathe it is radial and parallel to the cross slide, X is positive (+) when

the tool recedes from the axis of rotation of the work pieces.


For Shaper and Drafting Machine the x-axis is parallel to the positive (+) in the

principle direction of movement (or cutting) of the guided point (or the cutting tool)

Y – MOTION

It is designation is derived from the already recognized Z and X axes. It is

perpendicular to both X and Z axes and + Y is in the direction which completes with +X

and +Z motions a right hand Cartesian coordinate system. In Figs this has been

demonstrated in the columns under coordinate system Y. The first two columns under Z

and X show the designation of Z and X axes as per the principles mentioned earlier.

The column under coordinate system shows the relevant right hand coordinate system.

From the third column the Y axis designation is derived and is mentioned in column

under Y.

ROTARY MOTIONS

Location: These motions are located about the axis parallel to X, Y and Z respectively.

If, in addition to the above mentioned primary rotary motions, there exist secondary

rotary motions, whether parallel or not to A, B and C those should be designated as D

and E.

Direction: Positive (+) A,B and C are in the directions which advance right and screws

in the positive (+) X, Y and Z directions respectively.

In Fig the fingers of the right hand point towards the positive directions of the

rotary motions. All the above mentioned motions, viz X,Y,Z : U,V,W : P, Q,R : A,B,C

and D, E are with reference to a point, movement of which is being controlled. This

point is mostly the tip of the cutting tool. Many times the tool point may not be moving in

some direction e.g. the quill of the spindle of a vertical milling machine is moving in Z-

direction but not in X and Y directions. In such cases the work surface is generally

moved in a direction opposite to the one intended for the tool e.g. table of the milling

machine holding the work piece may be moved in -X and -Y directions. Such

movements of machine elements say - X and -Y are denoted as +X’ and +Y’

respectively. Primed letters can thus be used for all the above mentioned motions to

indicate the corresponding reversed directions for moving work surfaces. This is shown

in Fig. The various illustrations of the machines indicate the motions using primed as


well as unprimed letters it can be observed that +X’, +U’, +Z’ etc. all indicate those

motions of the slides which result in positive movement of the tool.

OBJECTVIES OF AXIS DESIGNATION:

The conventional mathematical right hand coordinate system is in general known

and well understood. The machine movements designated as above permit the part

programmer to assume safely that the tool moves relative to the right hand coordinate

system of a stationery work piece. The programmer can thus imagine to be sitting on a

tool and describe all the machining operations without having to know whether the tool

approaches the work piece or the work piece approaches the tool. He thus uses only

the unprimed letters for the intended motions. For example in Fig. on a Vertical Milling

Machine, For a moving a tool (say a drill) from position P to Position Q, the part

programmer specifies the movement from coordinates (5,7,6) to (8,6,5). The actual

motions which take place on the machine tool are :

Movement of Quill (Z): 5-6: - 1 i.e. the tool tip comes down one unit.

Movement of table (X’): 8-5 = +3 i.e. Table moves left by 3 units, and

(Y’) 6-7 = -1 i.e . . . . Table moves towards the column of the

mill by one unit.

STRUCTURE OF CNC PART PROGRAMMING

There are many codes specifying the particular area of instruction required to

control the machine tool. The tool path of C.N.C machine is then described in machines

codes, which usually take the structure of –

N-G-X-Y-Z-I-J-K-F-S-T-M-EOB

Where,

N = sequence number.

G = preparatory function – ISO codes.

XYZ = dimension words – in mm or inch.

IJK = dimensions words for arc and circle – in mm or inch.

F = feed rate.

S = spindle speed – revolution/min.

T = tool selection.


M = miscellaneous function – ISO codes.

EOB = End of block.

1.”N”: The sequence number is designated by the address character ”N” and three

numeric digits. The word indicates the start of specific sequences of operation. It is the

first word for the programming sequence in the block.

2. “G”: The preparatory function is designated by the character “G” and two numeric

digits. This word immediately follows the sequence number word. The “G” word prepare

numeric control unit for specific mode of operation.

3. “XYZ”: These addresses signify axis motion in accordance with the designated axis

motion of machine tools. These address could be supplement by “W, A, B, etc” if the

machines have extra axis of motion. XYZ are three axes. C.N.C can have up to six axis.

4.”IJK”: These addresses are used when employing circular interpolation to specify the

center of the program arc, I, J, and K which are equivalent to X, Y, and Z but with

reference to the start point.

5. “F”: The feed rate for slide displacement is expressed in mm/min and is a three digit

number is prefixed by the letter “F”.

6.”S”: The spindle speed is expressed in rev/min and is a four digit number prefixed to

the letter “S”.

7. “T”: The tool function is designated by the letter “T” and maximum of five numeric

digit. This word immediately follows the spindle speed word. Tool function code to

identify the tool to be used or loaded if at a tool change.

8. “M”: The miscellaneous function is designated by the letter “M” and two numeric

digits. These functions are a family of instruction that cause the starting stopping or

setting of a variety of machines function. Some M- functions have been standardized by

popular usage and others have special significance for individual machines.


CANNED CYCLES

It will be noticed in some machining operations that some preliminary

movements have to take place before the actual machining operation starts. For

example, in the

operation of drilling, the tool has to first approach the position of actual drilling since

invariably the tool will be at some other position before the drilling operation. So the

required motions would be the movement of the work piece in the XY plane till the point

has been approached and then the tool will move down till it is in the proximity of the

work piece and then moves further at the desired feed rate. After the drilling operation is

over, the tool retracts well above the work piece and if another hole is to be drilled,

instructions described earlier will be repeated. In case of NC programming, these

operations can be grouped and made available by use of preparatory functions called

canned cycles or fixed cycles. Similar facilities are also available for the operation of

milling, tapping and boring. A typical assigning of he codes for these cycles are as. “

G 78, G 79 - Mill

G 81-Drill

G 82- Drill Dwell

G 84- Tap

G 85- Ream

G 86- Bore

G 78 and G 79 for milling, operate in the following way:

The table feed in the X and / or Y direction till the start point of the milling profile

is approached. Then the tool moves rapidly in the Z direction up to a plane called R

plane at the fastest feed rate. Then the remaining travel, in the Z axis at the appropriate

feed rate, takes place till the total depth is milled.

G 81 for drilling cycle starts with rapid movement in the X and / or Y direction.

After positioning in the XY plane, rapid movement in the Z direction up to R plane takes

places followed by further motion at appropriate feed rate till the required depth is

obtained, then the tool rapidly retracts to the R plane.

G 82 for dwell cycle is similar to G 81 except that spindle direction reverses when

the tool retracts.


G 84 for tap cycle is also similar to G 81 except that spindle direction reverses

when the tool retracts.

G 85 for ream cycle is identical to G 81 except that the return is at the feed rate.

G 86 for bore cycle is similar to G 81 except that there is dwell for 2s when full depth is

reached and the spindle stops rotating and then rapid return to R plane and the spindle

starts rotating again.

The R plane refers to the rapid plane which is kept 1 to 2 mm above the surface

of the part since all the operations prior to actual machining and reaching R plane and

also tool retraction (after the operation) up to R plane take place at the highest feed rate

possible on the machine, a large saving in cycle time is possible when cutting is taking

place in air (idle operation).

G 80 for canceling cycle. All the cycles described above would continue to take

place again and again at newer coordinate positions given. This saves lot of time in the

programming, tape preparation and reading of the tape. However if the cycle in

operation has to be terminated then a preparatory code G 80 is necessary to be given.

The statement, in program, for the same would read as follows:

PARAMETRIC SUBROUTINES

It is quite evident that one of the major expenses in NC manufacturing is the cost

of programming and therefore it must be the endeavor of the people involved that ways

and means must be adopted by which is cost could be kept to a minimum. In fact, costs

under this head have been the main reason for many a manufacturers to decide

against use of NC machines. We are already familiar with the use of canned cycles

which enable quite a good saving in programming time and length and thereby the

reduction in processing time and chances of error occurring due to largeness of data.

However, these are fixed cycles which means that it needs to be specified in the

program as many times as the operation needs to be repeated besides the data for the

operation.


However, canned cycles are more of the fixed type. These do not offer

optimization in programming because these are designed for the general situation.

Programming costs can be reduced considerably if the time involved is decreased. By

using canned cycles which the programmer writes himself.

This can be done by storing a number of part program blocks more appropriately

called subroutines, in the controller and call them for action by the main program. For

example, referring to fig 6.17 pertaining to a turning operation on a lathe, the subroutine

will be as follows:

G 25 (start of subroutine)

$L (identification number)

N 1001 G 01 X - 7500 FO S 400 M03

N 1002 G 95 Z - 255000 F 250 (feed in mm / rev.)

N 1003 X 2500 Z 2500

N 1004 Z 252500 F 0

L 00

G 26 (end of Subroutine)

Step N 1001 through 1004 represent blocks of information pertaining to moves 1

through 4 in the figure.

The main program will be

N 01 G 90

N 02 G 01 X 22500 Z 405000 F 0

N 03 G 91

N 04 L 1101 - enter subroutine 11

N 05 G 90 - enter main program

N 06 G 00 X 37500 Z 405000 FO

Steps NO2 and N06 represent operation reaching the starting point while N04

leads to calling the subroutine L 11 and run it one (01) time and the subroutine is

searched and acted upon and when finished returns to main program at block N 05 and

continues. If this routine is required again, it can be called similarly, However this cycle

is for fixed dimensions since in this case all values are assigned in the subroutine.


If the repetitive subroutine mode is used, it will be more beneficial since it will

eliminate many steps in programming e.g. if it is mentioned “N 04 L 11 04” in the main

program, then the subroutine L 11 will be repeated four times. This is really useful since

it will give a series of cuts. In the first run of the subroutine, the tool feed will be 7.5 mm

and retract 2.5mm, in the second run 5.00mm of metal will be removed and soon. This

procedure not only reduces the programming time but also the length of the program

considerably.

The most important aspect of parametric subroutine is that it allows the

programmer to make his own canned cycles What is done is that the common

sequence of motion of the components on the machine tool are decided and the

subroutine is written without the dimensions. For example, in lathe operations, the

common moves are longitudinal, transverse motions and other important parameters for

any components are put in the main part program in the block which calls the

subroutine. This is similar to tool length / radius compensation, discussed earlier, for

example, the subroutine will be. :

G 25

$ L 11

N 1001 G 91

N 1002 G 01 X ; -01; F; 03

N 1003 Z ; -04

N 1004 X; 01 F 0

N 1005 Z; 04

N 1006 L 00

G 26

The call block in the main part program will be

N 04 L 11 04 ; 7500 ; 2500 ; 250 ; 250000

The value of X, Y, and F were not given in the subroutine while a number was assigned

to them e.g. 01 and 02 for X, 03 for feed rate and 04 for Z. The call block assigns values

to the parameters in the subroutine as X = 7.5 mm, X = depth of cut 2.5; F = 2.5 mm

per revolution (feed rate) and Z = 250 mm. The cut made will be as shown in fig.. Thus

by one subroutine and one call block, a series of cuts can be made. By giving tow

values of X in one block, incremental motion is given in sequence


Thus it can be seen that parametric subroutine is really useful for roughing outs,

thread cutting, keyway milling, drilling etc., where a sequence of motions is involved. By

allowing subroutines with large number of parameters, concept of ‘family of parts’ of GT

programming can be evolved.

To make the use of NC highly productive, one must endeavor to improve on

programming as far as possible with the aim of reducing the length of program and

requirement of skill. Parametric subroutine offers these advantages to a large extent.

Use of such techniques consequently reduces costs, programming errors and most

important of all increases programming flexibility.


Objective: - Perform & study programming and miscellaneous function

Learning:-

I. G & M codes

II. CNC programming basic, structure, standard

III. Programming

LIST OF G CODES

SR.NO. CODE FUNCTION

1. G00 RAPID POSITIONING2. G01 LINEAR INTERPOLATION3. G02 CLOCKWISE CIRCULAR INTERPOLATION4.

G03COUNTER CLOCKWISE CIRCULAR INTERPOLATION

5. G04 DWELL IN SECONDS6. G20 INCH PROGRAMMING7. G21 METRIC PROGRAMMING8. G28 AUTO. RETURN TO REF. POINT9 G32 THREAD CUTTING CYCLE

10. G70 FINISHING CYCLE11. G71 STOCK REMOVAL IN TURNING12. G72 STOCK REMOVAL IN FACING13. G73 PATTERN REPEATING CYCLE14. G74 PECK DRILLING CANNED CYCLE15. G90 DIAMETER CUTTING CYCLE16. G92 THREADING CANNED CYCLE17. G96 CONSTANT SURFACE SPEED ON18. G97 CONSTANT SURFACE SPEED OFF

LIST OF M-CODES

Sr. No. CODE FUNCTION1. M01 OPTIONAL PROGRAM STOP2. M02 PROGRAM END


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3. M03 SPINDLE START CLOCKWISE4. M04 SPINDLE START ANTICLOCKWISE5. M05 SPINDLE STOP6. M07 COOLANT NO. 1 ON7. M08 COOLANT NO. 2 ON8. M09 COOLANTS OFF9. M13 SPINDLE CLOCKWISE & COOLANT ON10 M14 SPINDLE ANTI-CLOCKWISE & COOLANT ON9. M30 PROGRAM END & REWIND

10. M98 START OF SUBROUTINE11. M99 END OF SUBROUTINE

Characteristics of the CNC Machine

Work part machining on CNC machine requires controllable &

adjustable infeed axes which are run by Stepper motors independent of

each other. The above figure shows the X & Z axes along with their

directions of movement.

CNC Programming Basics

A CNC program comprises a series of commands with which the CNC Machine

tool is instructed to manufacture a certain profile.

For each machining process on a CNC machine, the CNC program has a command

with relevant information. These commands consist of letters, numbers & characters.

CNC Programming Standards (ISO)

The ISO- Norm 6983 is for standardizing the CNC programming of machines.

This is however limited to standardizing certain commands as well the general structure

of a CNC program. CNC manufacturers have considerable liberty for incorporating their


own CNC commands in their control. Sequentially the general structure of a CNC

program according to ISO 6983 is illustrated.

Structure of a CNC Program

The first line of the CNC program contains the program name (ex.G02- dia 25).

This name can contain alphanumerical or numerical characters. A CNC program

consists of a sequence of blocks. They contain the relevant geometric & technical

information that the CNC control requires for each machining step. The program end is

commanded with M30 or M02.The comments are also allowed within the program for

identifying an operation. These however must be set in brackets.

Structure of a Program Block

Every CNC block consists of a block number as well as specific control

character, which inform the CNC Control about the necessary action to be performed.

Structure of a Program Word

A word consists of a address letters & a number with a plus or minus sign. The definition & sequence are designated in the programming instructions of the CNC control system.


Block number N :

The block number is the first word in a block. The block number has no influence

on the execution of the individual blocks since they are invoked following the order in

which they were entered into the control.

G – Function :

ogether with the words for the co-ordinates. This word essentially determines the

geometrical part of the CNC program. It consists of the address letter G & a 2 digit

code.

Co-ordinates X & Z :

The co-ordinates X, Z defines the target points that are needed to travel.

Interpolation parameters I & K :

The interpolation parameters I, K are used to define the center of a circle for

circular movements.


Feed F :

The speed at which the tool is to be moved is programmed with the function F.

This value in entered in mm/min.

Spindle Speed S :

The function S is for entering the spindle speed. It can be directly programmed in rotations perMinute

.

G & M CODES IN DETAIL

Part Programming codes that are available with this machine are according to

the latest ISO standards and adopted by the Industrial CNC controller manufacturers

worldwide. Following G, M, F, T, S commands are included in this controller.

G - CODES

G00 - RAPID TRAVERSE ( Rapid Positioning )


This motion type is used to command motion at the machine's fastest possible

rate. It is used to minimize non-productive time during the machining cycle. Common

uses for rapid motion include positioning the tool to and from cutting positions, moving

to clear clamps and other obstructions, and in general, any non-cutting motion during

the program.

The command almost all CNC machines use to initiate rapid motion is G00.

Within the G00 command, the end point for the motion is given. The G00 command

moves the tool to the position in the work piece coordinate system with an absolute or

incremental format at a rapid traverse rate.

In the Absolute format command, Coordinate value of the end point is

programmed. In Incremental format command, the distance the tool is to be moved is

programmed.

In this case last command for respective axis will be considered. I.e. X command

will be ignored and U command will be executed. No Feedrate (F Word) is required to

be programmed as it is taken from internally set values.

Format : G00 X __ Z __

NOTE: The rapid traverse rate in the G00 command is set internally for each axis drive.

In the Positioning mode actuated by G00, the tool is accelerated to a predetermined

speed at the start of block and it is then decelerated at the end of the block.

G01 - LINEAR INTERPOLATION

A G01 word is commonly used to specify straight line motion. This is the most

common code used for almost all the cutting operations. In this code single axis

(individual) as well as double axis movement is possible. Double axis movement is used

for taper turning operation. The G01 command moves the tool to the position in the

work piece coordinate system with an absolute or incremental format at a programmed

feed rate in the straight line.

In the Absolute format command, Coordinate value of the end point is

programmed. In Incremental format command the distance the tool is to be moved is

programmed.

The tool moves from the current position at the specified feed rate (F) to the final

position .The tool path is a direct straight line joining current position to final position.

This code is useful for OD/ID/face turning, also for taper turning.


Format: G01 X__ Z__ F__

Here F is feed rate (tool movement speed) given in mm/min. As this code is used

for cutting operation the value of F is very less that has to be decided according to the

material of job.

G02 - CIRCULAR INTERPOLATION (CLOCKWISE)

The G02 command is utilized to move the tool in the circular arc profile. With

G02 the movement will be in the Clockwise direction. The movement taken will be at

the programmed feed rate.

Format : G02 X__ Z__ I__ K__ F__

G02 X__ Z__ R__ F__

Here in first syntax,

I = Distance between start point & center point of arc along X-axis.

K= Distance between start point & center point of arc along Z-axis.

& in second syntax

R = Radius of the arc.

G03 - CIRCULAR INTERPOLATION (ANTI-CLOCKWISE)

The G03 command is used to move the tool in the anti circular arc profile. The

movement taken will be at the programmed feed rate.


Format: G03 X__ Z__ I__ K__ F__ G03 X__ Z__ R__ F__

Here,

I = Distance between start point & center point of arc along X-axis.

K= Distance between start point& center point of arc along Z-axis.

G04 - PROGRAMMED DWELL

G04 Command will delay the execution of next block by given time.

Format: G04 X__ G04 U__

X & U specifies dwell in seconds.

This code is used mainly after the spindle ON command, as the spindle will require

some time to reach to the specified speed, before that the cutting operation should not

start.

G20 - INCH PROGRAMMING

This is the modal command which commands the controller that the

dimensions specified in blocks following the current block is in the INCH system.


Format: G20

G21 - METRIC PROGRAMMING

This is the modal command which commands the controller that the dimensions

specified in blocks following the current block is in the METRIC system. I.e.in millimeter

format. METRIC format is the default format of dimensioning.

Format: G21

NOTE: The definition of dimensioning system is to be done only once in the part

program in first block. If it is specified more than one time the preprocessor will invoke

the ERROR ALARM showing that this is the violation of programming code. It is not

possible to switch from G20 to G21 in the program.

G28 - AUTO. RETURN TO REF. POINT

This command will move the tool to the specified reference point. In this command the

Tool movement will be rapid.

Format : G28 U___ W___

No Feedrate (F Word) is required to be programmed as it is taken from internally

set values.

G70 - FINISHING CYCLE

After roughing operation this cycle is used to achieve the final dimensions.

Finish allowance has to be kept before starting this cycle. The tool path is same as the

roughing operation.

Format : G70 P __ Q __

Here,

P= starting block of the roughing cycle.

Q= end block of roughing cycle.


This cycle is used after G71,G72 & G73 codes. The finishing allowances values are

taken from the above codes.

G71 – STOCK REMOVAL IN TURNING

This code is used to do turning as well as taper operation. The program by this

code becomes very simple. You will have to write the program for the final profile &

when the program is executed the depth of cut is taken in X – direction. The total profile

is achieved in steps, decided by depth of cut. Please refer the example given after the

syntax.

Format: G71 U (d) R (e)G71 P__ Q__ U (u) W(w) F__

Here,

U (d) = Depth of Cut

R (e) = Escaping amount (After depth of cut, this is the return path

For the tool in X + Direction)

P = Starting block no. of the program for the required shape

Q = Final block no. of the program for the required shape

U (u) = Finishing allowance in X direction.

W (w) = Finishing allowance in Z direction.

F = Feed-rate for cutting.


G72 – STOCK REMOVAL IN FACING

This cycle is same as G71. The only difference is that the cutting operation is

done parallel to X axis i.e. the depth of cut is in Z direction.

Format: G72 W (d) R (e)

G71 P__ Q__ U (u) W (w) F__


Here,

W (d) = Depth of Cut (For trainer machine it is 1mm).

R (e) = Escaping amount (After depth of cut, this is the return path

For the tool in X + Direction)







G73 PATTERN REPEATING CYCLE:

This cycle allows cutting a fixed pattern repeatedly, with a pattern being

displaced bit by bit.

Format : G73 U(i) W(k) R(d)

G73 P__ Q__ U(u) W(w) F__

Where,

U(i) = Distance of relief in X direction

This U(i) = (Job. Diameter – Min. Diameter in the program) / 2

W(k) = Distance of relief in Z direction

R(d) = No.of divisions for the pattern.

This R = (U(i) / Max. Depth of Cut) + 1







G74-PECK DRILLING CYCLE

This cycle is designed for deep hole drilling .The drill entering the work piece by

a predetermined amount then backing off by another set amount to provide breaking &

allowing chips to clear the drill flutes.


Format : G74 X__ Z__ Q__ R__ F__

Where,

X&Z = Final respective coordinates

Q = Depth of cut.

R = Return amount.

F = Feed in mm/min


G90 –Diameter Cutting Cycle:

This cycle is used to reduce the diameter of the job. In this cycle the tool will be

back to the starting position after cutting the diameter. In this machine the depth of cut

is 1mm. So if you want to reduce the diameter of the job from 22mm to 18 mm you will

have to use 4 G90 codes.

Format: G90 X___ Z___ F__


G92 -THREAD CUTTING CANNED CYCLE:

This canned cycle is suitable for External thread cutting operation. This cycle is same to

that of G32 except that in G92 the tool is returned to the starting position.

Format: G92 X___ Z___ F__

Where,

X = Threading diameter.

Z = Thread length.

F = Thread Pitch.

NOTE:

While the execution of thread cutting cycle, Spindle Speed is nonprogrammable,

Controller will automatically adjust it to proper value and after completing the threading

operation the original Spindle Speed will be restored.


G96 - CONSTANT SURFACE SPEED ON:

G97 - CONSTANT SURFACE SPEED OFF_:

With this command active the constant surface speed can be achieved while

cutting operation takes place. This is the modal command and will not have any effect

on the spindle speed while thread cutting operation.

Format: G96 S__

G97

Where,

S = Surface speed in meter/min.

G97= this command will cancel the Constant surface speed option set by the G96

Command.


M – CODES

M00 – PROGRAM HAULT

This command is useful to check the job in between the program. With this

command the axis & the spindle will be stopped. After checking the job parameters rest

program will be executed by pressing the ENTER key. The spindle will be automatically

started with the previous speed.

Format: M00

M01 - OPTIONAL PROGRAM STOP:

The M01 is used to STOP the Operation in Auto Mode. This code is only

effective when the Optional Stop is enabled. This can be set from Setup menu.

Format: M01


In this case auto. Mode Operation will be stopped. User can continue the

Operation after pressing the <Enter> Key.

M02 - PROGRAM END:

The M02 is used to END the Operation in Auto Mode. After a block specifying the

end of program is executed, control returns to the start of program.

Format: M02

M03 - SPINDLE ON CLOCKWISE

This command is used to start the Spindle in Clockwise Direction. Spindle speed

can be specified with this command as follows,

Format : M03 S__

In this case spindle will start rotating in Clockwise direction with S speed in rpm.

Speed of rotation is specified in S word (i.e. S600). But S word is not mandatory. If not

specified, default maximum speed set internally is used for operation.

M04 - SPINDLE ON ANTICLOCKWISE:

This command is used to start the Spindle in anticlockwise Direction.

Format: M04 S__

In this case spindle will start rotating in anticlockwise direction with the S speed.

M05 - SPINDLE STOP:

This command is used to STOP the Spindle rotation.

Format: M05

Spindle rotation can also be stopped by M30 command.

M08 - COOLANT ON:


This command is used to ON the Coolant Pump provided. If two pumps are

provided, M08 command will start the Pump

Format: M08

M09 - COOLANT PUMP OFF:

This command is used to STOP the Coolant Pumps. If both pumps are ON, M09

command will STOP the Pump.

Format: M09

Coolant Pumps can also be stopped by M30 command.

M13 – SPINDLE CLOCKWISE & COOLANT ON:

This command is used to move the spindle in clockwise direction & coolant ON.

Format: M13 S__

S = spindle speed in rpm.

M14 – SPINDLE ANTICLOCKWISE & COOLANT ON

This command is used to move the spindle in anticlockwise direction & coolant

ON.

Format: M14 S__

S = spindle speed in rpm.

M30 - END OF PROGRAM:

M30 command must be the last command in the program. This command

indicates the END OF PROGRAM. If not specified, ERROR ALARM will be displayed.

The M30 command will stop all the Auxiliary functions like, Spindle & Coolant. After

the execution of this command program will be reset to first Block.

M98 – SUBROUTINE CALL:

M99 - END OF SUBROUTINE:


When a program contains certain fixed sequences or frequently repeated

patterns, these sequences or patterns may be entered into memory as a subprogram to

simplify programming. A subprogram can call another subprogram .When the main

program call a subprogram; it is regarded as a one-loop subprogram call.

When a command calling a subprogram is encountered in the main program control is

passed to the subprogram. And control returns to the main program when returning

command is encountered in the program.

Format : M98 P__ R__

M99

Where,

P = subroutine repetitions.

R = subroutine label (alphabetical as well as numerical).


Objective: - Study recently trends in cad/cam

Learning:-

I. Numerical control system

II. Flexible manufacturing system

III. Robotics

IV. Computer integrated manufacturing

INTRODUCTION:

Following are the important trends in CAD/CAM:

1. ADAPTIVE CONTROL IN CAM

2. DIRECT NUMERICAL CONTROL (DNC)

3. FLEXIBLE MAUFACTURING SYSTEM (FMS)

4. ROBOTICS


STUDY ABOUT “RECENT TRENDS IN CAD/CAM”

PROGRAMMING.

STUDY ABOUT “RECENT TRENDS IN CAD/CAM”

PROGRAMMING.

8 8

DATE: / / DATE: / /

5. COMPUTER INTEGRETED MANUFACTURING (CIM)

ADAPTIVE CONTROL IN CAM:

This is a control system in which output process variable is measured and by

using this output feed and/or speed is controlled so that maximum output can be

achieved and process efficiency can be increased.

Following can be considered as a output process variable;

- Spindle deflection or force

- Torque

- Cutting temperature

- Vibration amplitude etc.

Types of adaptive control:

Adaptive Control with Constraint (ACC)

Adaptive Control Optimization (ACO)

DIRECT NUMERICAL CONTROL (DNC):

DNC may be defined as a system connecting a group of numerically controlled

machines to a common computer memory for part program storage, distribution of

machine data. Provision of collection, display or editing of part programs, operation

instruction or data related to the NC processor are also available.

Component of DNC system:

1. Central computer

2. Bulk memory

3. Telecommunication line

4. Machine tools

Advantage of DNC system:

1. All machines can be controlled at a time.

2. Calculation speed is high.

3. Central computer can be placed at any place.

4. Tape and tape reader is not required.


5. Post processing facilities are available.

6. Ideal time can be reduced.

7. Inventory control and scheduling is possible.

FLEXIBLE MAUFACTURING SYSTEM (FMS):

Flexible manufacturing system can be defined as a set of machines in which

parts are automatically transferred under computer form one machine to another for

processing. Flexible system is one, which is able to respond to change components of

FMS like;

Machine tools

Handling system

Tool system

Transport system

Monitoring system

Planning system

CAD/CAM

Component of FMS:

1. Hardware:

It contains CNC Machine tools, Material handling system, Automatic storage and

retrieval system, Coolant system, Tooling system Co-ordinate measuring machines,

Computer hardware etc.

2. Software:

NC programming, CMM programming, Software tooling information etc.

Types of FMS:

1. Flexible Manufacturing Module (FMM)

2. Flexible Manufacturing Cell (FMC)

3. Flexible Manufacturing Group (FMG)

4. Flexible Fabrication – Machining Assembly System (FFMAS)

Advantage of FMS:

1. Operation control

2. Reduction in direct labour cost

3. Increasing utilization factor

4. Reduction in inventory


5. Wide range processing.

Application of FMS:

All manufacturing process like; sheet metal work, forging, assemble, inspection

and quality control etc.

ROBOTICS:

An industrial robot is defined as a reprogrammable, multi functional manipulator,

designed to move the material, parts or specialized device through variable

programmed motions for the performance of variety of tasks.

Types of joints for robots:

1. Linear joint (L – joint)

2. Orthogonal joint (O – joint)

3. Rotational joint (R – joint)

4. Twisting joint (T – joint)

5. Revolving joint (V – joint)

Robot configuration:

1. Polar configuration

2. Cylindrical

3. Cartesian

4. Joint arm robot

5. SCARA (Selective Compliance Assembly Robot Arm)

Application of Robot:

Arc welding, spray painting, Material handling, Mobile robot etc.

COMPUTER INTEGRETED MANUFACTURING (CIM):

CIM is recent technology being tried in advanced countries and it comprises a

combination of software and hardware for product design, production, planning,

production control etc.

Area of CIM:

1. Marketing


2. Product design

3. Planning

4. Product purchasing

5. Manufacturing engineering

6. Inventory control

7. Ware housing

8. Finance

9. Information management

Advantage of CIM:

1. Renewable flexibility for manufacturing diverse components in the same setup easy

and quick manipulation of software.

2. High production rate.

3. Reduction in lead time.

4. Integrating and fine tuning of all factory functions.


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