Cam Lab 12k708

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BANNARI AMMAN INSTITUTE OF TECHNOLOGYSATHYAMANGALAM 638 401DEPARTMENT OF MECHATRONICS ENGINEERINGLAB MANUAL

12K708

CAM LABORATORY

S7 MECHATRONICS

Year of Release: 2015BANNARI AMMAN INSTITUTE OF TECHNOLOGYSATHYAMANGALAM 638 401DEPARTMENT OF MECHATRONICS ENGINEERING LAB MANUAL

12K708

CAM LABORATORY

S7 MECHATRONICS

Prepared byApproved byName of the Faculty Name of the HOD with Signature with Signature( K M Nithish Kumar) Dr. K P Arulshri

Year of Release: 2015R 2012: Lab Code: 12K708 Lab Name: CAM LaboratoryList the Experiments as per the syllabus1. Generation of CNC program for CNC lathe using linear and circular interpolation2. CNC programming of facing and step turning operations for the given diagram3. CNC program generation for a cylindrical model whose diameter is continuously varying throughout its length.4. Simulation of thread cutting operation in a CNC simulation software5. Exercise on grooving cycle6. Drilling and boring cycle operation in a CNC lathe7. Generation of CNC program for CNC milling using linear and circular interpolation8. CNC program generation of contour milling operation for the given diagram9. Simulation of drilling operation of CNC milling in a simulation software10. Exercise on peck drilling

List of experiments

S. NoExperimentPage No.

1Generation of CNC program for CNC lathe using linear and circular interpolation5

2CNC programming of facing and step turning operations for the given diagram8

3CNC program generation for a cylindrical model whose diameter is continuously varying throughout its length.12

4Simulation of thread cutting operation in a CNC simulation software14

5Exercise on grooving cycle18

6Drilling and boring cycle operation in a CNC lathe20

7Generation of CNC program for CNC milling using linear and circular interpolation25

8CNC program generation of contour milling operation for the given diagram30

9Simulation of drilling operation of CNC milling in a simulation software33

10Exercise on peck drilling35

List of Mini projects (for the Academic year 2015- 2016)

S. NoTitle of the Project

1CNC program generation of multi operation which is performed in a single component

2Generate the CNC code for the rotor shaft in a motor

3NC code generation for a spur gear used in power transmission

4Generate the CNC program to manufacture the bearing used in a gear box

5CNC program generation for a lead screw used in a LATHE

6NC code generation for a collar used to stabilize lead screw

7Generate the CNC program to manufacture the drive sprocket used in power transmission

8CNC program generation for a 12.5 mm anti backlash nut

9NC code generation for a roller chain link used in chains

10Generate the CNC program to manufacture the screw of size 8*65

EX NO:1 DATE: GENERATION OF CNC PROGRAM FOR CNC LATHE USING LINEAR AND CIRCULAR INTERPOLATION

AIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define CNC programming.2. What is the use of linear interpolation ?3. Define circular interpolation.4. What is the difference between linear interpolation and circular interpolation?5. List some of the softwares used for CNC programming.

PROCEDURELINEAR INTERPOLATION AND CIRCULAR INTERPOLATIONMODEL

N5 G00 G54 G64 G90 G17 X-20 Y-20 Z50N10 S450 M03 F250 D01 (12.5 MM DIA)N15 C0N20 Z5N25 G01 Z0N30 Z-5N35 G42 X0 Y0 M08 (Linear motion)N40 X60 Y0 (Linear motion)N45 X85 Y30 (Linear motion) N50 X85 Y50 (Linear motion)N55 G03 X70 Y65 U15(Circular motion G03 for Counter Clockwise motion and U for arc radius)N60 G01 X45 Y65 (Linear motion)N65 G02 X30 Y50 U15(Circular motion G02 for Clockwise motion and U for arc radius)N70 G01 X10 Y50 (Linear motion)N75 X0 Y0 (Linear motion)N80 G40 X-20 Y-20N85 G00 Z50 M09N90 Y100N95 M30

VIVA QUESTIONS1. What is use of G21?2. What is mean by G28 U0 W0?3. What is the use of G40?4. What is the purpose of G98?5. What is mean by M30?

STIMULATING QUESTION1. BIT Logo have to be produced on the plate. How it can be produced ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:2 DATE: CNC PROGRAMMING OF FACING AND STEP TURNING OPERATIONS FOR THE GIVEN DIAGRAMAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. What is meant by facing ?2. How the step turning process is carried out in lathe ?3. What is the difference between facing and turning?4. What is the difference between step turning and plain turning?5. Define CNC programming.

PROCEDUREFACINGMODEL

NC PART PROGRAMN010 G21 G40 G98N020 G28 U0 W0N025 M06 T05N040 M03 S1200N050 G00 X21 Z2N060 G94 X0 Z-1 F60N070 Z-2N080 Z-3N090 Z-4N100 Z-5N110 G28 U0 W0N120 M05N130 M30

STEP TURNINGMODEL

NC PART PROGRAMN010 G21 G40 G98N020 G28 U0 W0N030 M06 T01N040 M03 S1200N050 G00 X21 Z2 N060 G90 X20 Z-10 F60N070 X19N080 X18N090 X17N100 X16N110 X15N120 X14N130 X13N140 X12N150 X11N160 X10N170 G00 X21 Z-10N180 G90 X20 Z-20N190 X19N200 X18N210 X17N220 X16N230 X14N240 G28 U0 W0 N250 M05 N260 M30VIVA QUESTIONS1. What is mean by Home position?2. What is mean by step?3. What is the use of G90?4. What is mean by M30?5. What is command used for chuck close?6. What is use of N block number?7. What is mean by G code?8. What is use of turning ?

STIMULATING QUESTION1. A steel pipe is longer in length than desired and the length should be reduced. How the length can be reduced ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:3 DATE: CNC PROGRAM GENERATION FOR A CYLINDRICAL MODEL WHOSE DIAMETER IS CONTINUOUSLY VARYING THROUGHOUT ITS LENGTH

AIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define taper turning.2. In a conventional lathe how the taper turning process is carried out ?3. What is the difference between step turning and taper turning ?4. What is the use of taper turning ?5. Mention some of the applications where taper turning process is used.

PROCEDUREMODEL

NC PART PROGRAMBILLET X20 Z50 N010 G21 G40 G98 N020 G28 U0 W0N030 M06 T01N040 M03 S1200N050 G00 X21 Z2//* Box turning cycle *//G90 X20 Z-40 R0 F60R = (Minor dia) / 2N070 X20 R-0.5 = (17 - 20) /2 N080 X20 R-1 = -3/2 = - 1.5N090 X20 R-1.5N100 G28 U0 W0N110 M05N120 M30

VIVA QUESTIONS1. What are the difference between G01 and C00?2. Mention the major components of the CNC machine?3. What is the expansion of FANUC?4. What is mean by major dia? 5. What is mean by R?

STIMULATING QUESTION1. A wooden support have to be produced for fixing with table. For this it should have the varying diameters at the ends. How is it possible ?RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.EX NO:4DATE: Simulation of thread cutting operation in a CNC simulation softwareAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define module.2. What do you meant by pitch diameter ?3. How the thread cutting process is carried out in a conventional lathe ?4. Define core.5. List some of the CNC codes used for thread cutting.

PROCEDUREMODEL

NC PART PROGRAMN010 G21 G40 G98N020 G28 U0 W0N030 M06 T01N040 M03 S1200N050 G00 X21 Z2N060 G71 U0.3 R1N070 G71 P80 Q150 U0.1 W0.1 F50//* Multiple turning cycle *//N080 G01 X10N090 Z0N100 G01 X12 Z-1N110 G01 Z-25N120 G01 X15N130 G01 Z-40N140 G01 X19N150 G01 Z -50N160 G70 P90 Q150 F70N170 G28 U0 W0N180 M06 T03//* Grooving cycle *//N190 M03 S800N200 G00 X14 Z-18N210 G75 R1N220 G75 X10 Z-20 P500 Q500 F10N230 G28 U0 W0 //*Threading cycle*//N240 M06 T0606 Threading calculationN250 M03 S500 Core = Nominal -height of threadN260 G00 X14 Z4 Cd = D - 2hN270 G92 X12 Z-15 F2 Calculation for height of threadN280 X11.9 h = 0.61343 x pitchN290 X11.8 h = 0.61343 x 2N300 X11.7 Core calculation N310 X11.6 cd = D - 2hN320 X11.5 cd = 12 - 2 )1.22686)N330 X11.4 cd = 9.54628mmN340 X11.3N360 X11.1N370 X11N380 X10.9N390 X10.8N400 X10.7N410 X10.6N420 X10.5N430 X10.4N440 X10.3N450 X10.2N460 X10.1N470 X10N480 X9.9N490 X9.8N510 X9.6N520 X9.5N530 X9.47N540 G28 U0 W0N550 M05N560 M30

VIVA QUESTIONS1. What are the uses of G codes?2. Write syntax for G75.3. Can G90 be used for facing?4. Name the command used for door open.5. What is the use of G75?

STIMULATING QUESTION1. An electrical switch have to be attached to the wall by using suitable method. Can you guess which method it is?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:5DATE: EXERCISE ON GROOVING CYCLEAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. What is the purpose of producing the groove in the component?2. Define grooving process.3. How the grooving process is carried out in a conventional lathe ?4. Define CNC programming.5. List some of the codes used for grooving in CNC.

PROCEDUREMODEL

NC PART PROGRAMN10 T0202N20 G92 S500 M42N30 G97 S400 M03N40 G00 X110 Z0 M08N50 G01 Z-22 F0.5N60 G75 R1N70 G75 X90 Z-60 P2000 Q3000 R0 F0.1N80 G00 X120 Z100N90 M30

VIVA QUESTIONS1. Write the applications of G codes2. Mention few important G codes3. What are the use of M codes?4. Write about some important M codes?5. What is the use of multiple turning cycle?

STIMULATING QUESTION1. Provision for holding the hand in a wooden stick is needed. For producing this which process can be used ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:6DATE: DRILLING AND BORING CYCLE OPERATION IN A CNC LATHE

AIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. What is the difference between drilling and boring ?2. Define some of the parameters in the drilling process.3. Why the boring process is carried out after drilling?4. How the drilling process is carried out in a lathe ?5. How the boring process is carried out in a lathe ?

PROCEDUREDRILLINGMODEL

NC PART PROGRAMN010 G21 G40 G98N020 G28 U0 W0N030 M06 T02//* Center drill *//N050 M03 S1500N060 G00 X0 Z3N070 G74 R1N080 G74 X0 Z-5 Q500 F30N085 G28 U0 W0N090 M06 T04//* 6mm drill *//N100 M03 S1500N110 G00 X0 Z3N120 G74 R1N130 G74 X0 Z-20 Q500 F30N140 G28 U0 W0N150 M06 T08//* 12mm drill *//N160 M03 S1000N170 G00 X0 Z3N180 G74 R1N190 G74 X0 Z-20 Q500 F30N200 G28 U0 W0N210 M05N220 M30

BORING

NC PART PROGRAMN010 G21 G40 G98N020 G28 U0 W0N030 M06 T02//* Center drill *//N050 M03 S1200N060 G00 X0 Z3N070 G74 R1N080 G74 X0 Z-5 Q500 F30N085 G28 U0 W0N090 M06 T04//* 6mm drill *//N100 M03 S1200N110 G00 X0 Z3N120 G74 R1N130 G74 X0 Z-20 Q500 F30N140 G28 U0 W0N150 N030 M06 T08//* 12mm drill *//N160 M03 S1200N170 G00 X0 Z3N180 G74 R1N190 G74 X0 Z-20 Q500 F30N200 G28 U0 W0N210 M06 T03//* 10mm boring bar *//N220 M03 S1200N230 G00 X12 Z2N240 G71 U0.5 R1N250 G71 P260 Q320 U0.2 W0.2 F50N260 G01 X24N270 G01 Z0N280 G01 Z-9.5N290 G03 X19 Z-12.5 R2.5N300 G01 W-3N310 G01 X15 W-3N320 G01 X12N330 G70 P260 Q320 F30N340 G28 U0 W0N350 M05N360 M30

VIVA QUESTIONS1. What are the difference between drilling and peck drilling?2. Mention the major components of the CNC machine?3. What is the expansion of FANUC?4. What are the important lathe operations?5. What are the important of drilling operation?

STIMULATING QUESTION1. An underground water is needed for agriculture in cultivating the sugarcane. How the water can be taken out ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:7DATE: GENERATION OF CNC PROGRAM FOR CNC MILLING USING LINEAR AND CIRCULAR INTERPOLATIONAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define CNC programming.2. What is the use of linear interpolation ?3. Define circular interpolation.4. What is the difference between linear interpolation and circular interpolation?5. List some of the softwares used for CNC programming.

PROCEDURELINEAR INTERPOLATION

NC PART PROGRAMN010 G21 G94N020 G91 G28 Z0N030 G28 X0 Y0N040 M06 T2N050 M03 S1200 N60 G90 G00 X-40 Y-40N070 Z5N080 G01 Z-1 F50N090 Y40 N100 X40N110 Y-40N120 X-40N130 X40 Y40N140 G00 Z5N150 G00 X-40 Y40N160 G01 Z-1 F50N170 X40 Y-40 N180 G00 Z5N190 M05N200 G91 G28 Z0N210 G28 X0 Y0N220 M30

CIRCULAR INTERPOLATION

NC PART PROGRAMN010 G21 G94 N020 G91 G28 Z0N030 G28 X0 Y0N040 M06 T2N050 M03 S1200N060 G90 G00 X-22.5 Y-37.5N070 G00 Z5N080 G01 Z-1 F50N090 G03 X-37.5 Y-22.5 R15N100 G01 Y22.5N110 G03 X-22.5 Y37.5 R15N120 G01 X22.5 N130 G02 X37.5 Y22.5 R15N140 G01 Y-22.5N150 G03 X22.5 Y-37.5 R15N160 G01 X-22.5N170 G00 Z5N180 G00 X-15 Y0N190 G01 Z-1 F50N200 G03 X15 Y0 R15N210 G03 X-15 Y0 R15N220 G00 Z5N230 M05N240 G91 G28 Z0N250 G28 X0 Y0N260 M30VIVA QUESTIONS1. How to change the tool speed in CNC milling?2. What is the difference between absolute and incremental system?3. What are the axes to be considered while writing program for CNC milling?4. What is the file extension of CNC program?5. What are the codes for coolants on or off?

STIMULATING QUESTIONS1. Symbol of om in hindu religion should be produced on the plate in the door. How is it possible ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:8DATE: CNC PROGRAM GENERATION OF CONTOUR MILLING OPERATION FOR THE GIVEN DIAGRAMAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. What is meant by contour milling ?2. What are the profiles available in contour milling ?3. How the contour milling process is carried out in a milling machine?4. List the CNC codes used for contour milling.5. What are the operations that can be performed in a milling machine ?

PROCEDUREMODEL

NC PART PROGRAMN5 G17 G71 G90 G94 G54; (Parameters Setting) N10 T2 L90; (Home position) N15 G00 D2 Z50 M3 S700 X10 Y-25; (Position of tool) N20 G01 Z-1.5; (Position of cut) N25 G01 X4 F100 M8; (Cutting slat) N30 G00 Z100 M9; (Final position of tool) N35 M30; (Main programme end)MODEL

NC PART PROGRAMN2 G17 G71 G90 G94 G54; (Parameters Setting) N4 T1 L90; (Home position) N6 G00 Z5 D5 M3 S500 X20 Y90; (Position of tool) N8 G01 Z-2 F50; (Position of cut) N10 G02 X60 Y50 I0 J-40; (Circular interpolation clockwise-CW) N12 G03 X80 Y50 I20 J0; (Circular interpolation clockwise-CCW) N14 G00 Z100; (Final position of tool) N16 M02; (End of programme)

VIVA QUESTIONS1. What is the g code for circular pocketing?2. How to change the depth of cut in milling operation?3. What is the use of mirroring?4. What are the functional keys uses in Fanuc programming?5. What is use of dry run option?

STIMULATING QUESTIONS1. INDIA map outline should be produced on the batch given to the social people. Can you think it is possible ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:9DATE: SIMULATION OF DRILLING OPERATION OF CNC MILLING IN A SIMULATION SOFTWAREAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define drilling.2. What is the use of drilling in manufacturing ?3. How the drilling process is carried out in a conventional milling machine ?4. List the CNC codes used for drilling process.5. Mention the applications of drilling process.

PROCEDUREMODEL

NC PART PROGRAMN5 G17 G71 G90 G94 G55; N10 T1 L90; N15 G00 D5 Z5 M3 S600 X27 Y27; N20 G81 R02=5, R03=-33, R11=3, F50 M7; N25 X97; N30Y97; N35 X27; N40 G00 G80 Z100 M9; N45 M02;

VIVA QUESTIONS1. What is mean by G02?2. What is the difference between absolute and incremental system?3. What are the axes to be considered while writing program for CNC Milling?4. What is the code for multiple cycles?5. What is mean by G91?

STIMULATING QUESTION1. A wallclock should be attached to the wall by using steel pin. Is it possible ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.

EX NO:10DATE: EXERCISE ON PECK DRILLINGAIM: To prepare the manual part program and to verify it using cncez simulation software.

REQUIREMENT: SOFTWARE: cncez simulation software HARDWARE: Pentium dual core processor 1GB RAM 80 GB HDD

PREREQUISITE QUESTIONS1. Define drilling process.2. What is meant by peck drilling process ?3. Enumerate the difference between the drilling and peck drilling process.4. How the peck drilling process is carried out in a milling machine ?5. List the specification of tool used for peck drilling process.

PROCEDUREMODEL

NC PART PROGRAMR00 Dwell time at the starting point for chip removal. R01 First drilling depth (incremental) without sign. R02 Reference plane absolute with sign. R03 Final depth of hole absolute with sign. R04 Dwell time at the bottom of drilled hole for chip breaking. R05 Amount of digression is without sign. R10 Retract plane without sign. R11 Drilling axis number 1 to 3. % 401; N5 G17 G71 G90 G94 G55; N10 T1 L90; N15 G00 D5 Z5 M3 S600 X62 Y62; N20 G83 R00=30, R01=15, R02=5, R03=-60, R04=1, R05=15, R10=80, R11=3, F50 M7; N25 G00 G80 Z100 M9; N30 M02;

VIVA QUESTIONS1. What is meant by cutter compensation?2. What is use of G98?3. Milling machine used to make Gear yes or no?4. How the subprogram is named?5. Why fixed/canned cycles are preferred?

STIMULATING QUESTION1. A pipeline should be attached to kitchen in the building. The pipelines are connected to all the places in the building except kitchen. Is the pipeline can be fixed to the kitchen ?

RESULTThus the manual part program for the given component is prepared and it is verified by using cncez simulation software.