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KARPAGAM INSTITUTE OF TECHNOLOGY

Seeraplayam, Coimbatore641105.

AE 2307

CAD/CAM LABORATORY RECORD BOOK

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KARPAGAM INSTITUTE OF TECHNOLOGY

Seeraplayam, Coimbatore641105.

Certified that this is the bonafide record of work done by

Mr/Ms__________________________________________Regd.No.______________________

in the AE 2307 CAD/CAM Laboratory of B.E Aeronautical Engineering of this institution

as prescribed by Anna University Chennai for III year V semester during academic year of

2013-2014

Staff in charge Head of the Department

Submitted for the University practical Examination of Anna University Chennai

conducted on __________________

Internal Examiner External Examiner

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INDEX

S.No Date ContentsPage

NoMarks Signature

1 Design and modeling of rectangular plate with hole

2 Design and analysis of Truss

3 Design and analysis of Beam distributed load

4 Design and modeling of Spar components

5 Design and modeling of Aerofoil structures

6 Design and modeling of Cut Section for wings

7 Design and modeling of Machine component

8 Design and modeling of Machine components

9 CNC program for step turning operation

10 CNC program for taper turning operation

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SUMMERY OF EXPERIMENTS

Expt

No.Name of the Experiment

Experiment

Date

Marks

Initial of

Faculty

Practical

Class

AssessmentRecord

Viva

VoiceTotal

1 Design and modeling of rectangular

plate with hole

2 Design and analysis of Truss

3 Design and analysis of Beam

distributed load

4 Design and modeling of Spar

components

5 Design and modeling of Aerofoil

structures

6 Design and modeling of Cut Section

for wings7 Design and modeling of Machine

component

8 Design and modeling of Machine

components

9 CNC program for step turning

operation

10 CNC program for taper turning

operation

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DESIGN AND MODELING OF RECTANGULAR PLATE WITH HOLE

Aim:

To draw the design and modeling of rectangular plate with hole using the Solid Works

package

Problem Description:

A simple rectangular steel plate with a circular hole at centre having dimension 200 X

100 X 20 mm is constrained as shown in Fig (1).

Fig.1 Rectangular plate with hole

Commands used:

Rectangle Circle Extrude Remove material

Procedure:

1) Open the software tool Solid Works package.2) Set the units and limits for the display screen3) Use the Rectangle command and draw as per the given dimensions4) Draw the circle by the given dimensions5) Extrude the dimensions for the rectangular job6) Save the diagram in specified directory

Result:

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND ANALYSIS OF TRUSS

Aim:

To design and analysis of truss using an ANSYS Software.

Problem Description:

Determine the nodal deflections, reaction forces, and stress for the truss system shown

below Fig 2 (E = 200GPa, A = 3250mm2)

Fig.2 Truss structure

Procedure:

The procedure involves three steps and they are Preprocessing, Solution and Post

processing.

Preprocessing

1. Specify the title

2. Set preferences

3. Define element types

4. Define real constants

5. Define material properties

6. Create a model using modeling command

7. Create an element between nodes.

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Solution

8. Apply displacement constraints and pressure loads

9. Solve using Current LS

Post Processing

10. Enter general post processor and read the results

11. Plot the Von misses equivalent stress

12. Plot the deformed shape

13. Exit the ANSYS program.

Result:

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND ANALYSIS OF BEAM DISTRIBUTED LOAD

Aim:

To design analysis of beam distributed load an ANSYS Software

Problem Description:

A simple, stress analysis is to be done on cantilever beam as shown in Fig 3.

The given material properties are,

1. Elastic modulus = 70000 MPa

2. Poissons ratio = 0.33

Fig .3 Cantilever Beam

Approach and Assumptions:

Assume plane stress for this analysis. Since the pipe having thickness, and one end isfixed and other end is loaded vertically downward with a load of 100 N. Our approach is to use

3D elastic straight pipe element type and mesh it manually with element length of 20 mm.

(Alternatively, we could enter the number of divisions we want in the line. For element length of

20 mm, we could enter 25 divisions.)

Procedure:

The procedure involves three steps and they are Preprocessing, Solution and Post

processing.

Preprocessing

1. Specify the title

2. Set preferences

3. Define element types

4. Define real constants

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5. Define material properties

6. Create a model using modeling command

7. Mesh using manual size command

Solution

8. Apply displacement constraints and vertically downward load

9. Solve using Current LS

Post Processing

10. Enter general post processor and read the results

11. Plot the deformed shape

12. Plot the Nodal solution per node

13. Plot the stress by Von-misses criteria

14. Exit the ANSYS program.

Result:

Thus the required drawing was designed and modeled and analyzed .

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DESIGN AND MODELLING OF SPAR COMPONENTS

Aim:

To draw the design and modeling of spar components using the Solid Works package

Problem Description:

A simple Spar component having dimension length of 500 mm is constrained as shown

in Fig (4).

Fig.4 spar component

Commands used:

Lines Circle Extrude Edge Fillet

Procedure:

1) Open the software tool Solid Works package.2) Create the new file and save it in the directory3) Set the units and limits for the display screen4) Use the line command and as per the given dimensions5) Draw the spar assembly by the given dimensions6) Mark the dimensions for the Spar7) Save the diagram in specified directory

Result:

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND MODELING OF AEROFOIL STRUCTURES

Aim:

To draw the Design and Modeling of Aerofoil structures using the Solid works package

Problem Description:

An Aerofoil Structure having coordinate points of 65412 is constrained and statically

loaded as shown in Fig (5).

Fig. 5 Aerofoil Structure

Commands used:

Dots Spline Coordinate points

Procedure:

1.Open the Solid works package.

2.Create the new file and save it in the directory

3.Set the units and limits for the display screen

4.Use the point command and draw as per the given dimensions

5.Draw the drawing by the given dimensions6.Save the diagram in specified directory

Result :

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND MODELING OF CUT SECTION OF WING

Aim:

To draw the Design and Modeling of cut section of wings using the Solid works package

Problem Description:

The Cut section of wing Structure having coordinate points of 65412 is constrained as

shown in Fig (6).

Fig. 6 Cut Section wing

Commands used:

Spline Coordinate points Plane Loft

Procedure

1. Open the Solid works package.2. Create the new file and save it in the directory3. Set the units and limits for the display screen4. Use the line command and draw the as per the given dimensions5. Draw the diagram by the given dimensions6. Mark the dimensions for the riveted job7. Save the diagram in specified directory

Result :

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND MODELING OF MACHINE COMPONENT

Aim:

To draw the Design and Modeling of machine components using the Solid works

package

Problem Description:

A simple mechanical component shell as shown in Fig (7).

Fig. 7 Flange

Approach and Assumptions:

Remove the material from selected face, Create a hallow block from solid block

Procedure

1. Open the solid works package.2. Create the new file and save it in the directory3. Select the plane and draw 2D sketch4. Extrude the 2D Sketch5. Sketch the cut profile6. Select solid feature and remove the material.

Result

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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DESIGN AND MODELING OF MACHINE COMPONENTS

Aim:

To draw the Design and Modeling of machine components using the Solid works

package

Problem Description:

An Flange coupling as shown in Fig (8).

Fig .8 Flange coupling

Procedure

1. Open the solid works package.2. Create the new file and save it in the directory3. Select the plane and draw 3D sketch4. Select the assembly5. Mating the sketches6. Save the assembly.

Result

Thus the required drawing was designed and modeled as per the given dimension and

verified.

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CAM PART

Computer-aided manufacturing

Computer-aided manufacturing (CAM) is the use of computer-based software tools

that assist engineers and machinists in manufacturing or prototyping product components. Its

primary purpose is to create a faster production process and components with more precise

dimensions and material consistency, which in some cases, uses only the required amount of raw

material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is a

programming tool that makes it possible to manufacture physical models using computer-aided

design (CAD) programs. CAM creates real life versions of components designed within a

software package

G-codes

G-Code, or preparatory code or function, are functions in the Numerical control

programming language. The G-codes are the codes that position the tool and do the actual work,

as opposed to M-codes, that manages the machine; T for tool-related codes. S and F are tool-

Speed and tool-Feed, and finally D-codes for tool compensation. The programming language of

Numerical Control (NC) is sometimes informally called G-code. But in actuality, G-codes are

only a part of the NC-programming language that controls NC and CNC machine tools.

A basic list of `G' operation codes is given below. These direct motion of the tool.

1. G00 - Rapid move (not cutting)2. G01 - Linear move3. G02 - Clockwise circular motion4. G03 - Counterclockwise circular motion5. G04 - Dwell6. G05 - Pause (for operator intervention)7. G08 - Acceleration8. G09 - Deceleration9. G17 - x-y plane for circular interpolation10. G18 - z-x plane for circular interpolation11. G19 - y-z plane for circular interpolation12. G20 - turning cycle or inch data specification13. G21 - thread cutting cycle or metric data specification14. G24 - face turning cycle15. G25 - wait for input #1 to go low (Prolight Mill)

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16. G26 - wait for input #1 to go high (Prolight Mill)17. G28 - return to reference point18. G29 - return from reference point19. G31 - Stop on input (INROB1 is high) (Prolight Mill)20. G33-35 - thread cutting functions (Emco Lathe)21.

G35 - wait for input #2 to go low (Prolight Mill)22. G36 - wait for input #2 to go high (Prolight Mill)

23. G40 - cutter compensation cancel24. G41 - cutter compensation to the left25. G42 - cutter compensation to the right26. G43 - tool length compensation, positive27. G44 - tool length compensation, negative28. G50 - Preset position29. G70 - set inch based units or finishing cycle30. G71 - set metric units or stock removal31. G72 - indicate finishing cycle (EMCO Lathe)32.

G72 - 3D circular interpolation clockwise (Prolight Mill)33. G73 - turning cycle contour (EMCO Lathe)

34. G73 - 3D circular interpolation counter clockwise (Prolight Mill)35. G74 - facing cycle contour (Emco Lathe)36. G74.1 - disable 360 deg arcs (Prolight Mill)37. G75 - pattern repeating (Emco Lathe)38. G75.1 - enable 360 degree arcs (Prolight Mill)39. G76 - deep hole drilling, cut cycle in z-axis40. G77 - cut-in cycle in x-axis41. G78 - multiple threading cycle42. G80 - fixed cycle cancel43. G81-89 - fixed cycles specified by machine tool manufacturers44. G81 - drilling cycle (Prolight Mill)45. G82 - straight drilling cycle with dwell (Prolight Mill)46. G83 - drilling cycle (EMCO Lathe)47. G83 - peck drilling cycle (Prolight Mill)48. G84 - taping cycle (EMCO Lathe)49. G85 - reaming cycle (EMCO Lathe)50. G85 - boring cycle (Prolight mill)51. G86 - boring with spindle off and dwell cycle (Prolight Mill)52. G89 - boring cycle with dwell (Prolight Mill)53. G90 - absolute dimension program54. G91 - incremental dimensions55. G92 - Spindle speed limit56. G93 - Coordinate system setting57. G94 - Feed rate in ipm (EMCO Lathe)58. G95 - Feed rate in ipr (EMCO Lathe)59. G96 - Surface cutting speed (EMCO Lathe)60. G97 - Rotational speed rpm (EMCO Lathe)61. G98 - withdraw the tool to the starting point or feed per minute

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62. G99 - withdraw the tool to a safe plane or feed per revolution63. G101 - Spline interpolation (Prolight Mill)

M-Codes

M-Codes control machine functions and these include,1. M00 - program stop2. M01 - optional stop using stop button3. M02 - end of program4. M03 - spindle on CW5. M04 - spindle on CCW6. M05 - spindle off7. M06 - tool change8. M07 - flood with coolant9. M08 - mist with coolant10.

M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill)11. M09 - coolant off

12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill)14. M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool

change

15. M17 - subroutine end16. M20 - tailstock back (EMCO Lathe)17. M20 - Chain to next program (Prolight Mill)18. M21 - tailstock forward (EMCO Lathe)19. M22 - Write current position to data file (Prolight Mill)20. M25 - open chuck (EMCO Lathe)21. M25 - set output #1 off (Prolight Mill)22. M26 - close chuck (EMCO Lathe)23. M26 - set output #1 on (Prolight Mill)24. M30 - end of tape (rewind)25. M35 - set output #2 off (Prolight Mill)26. M36 - set output #2 on (Prolight Mill)27. M38 - put stepper motors on low power standby (Prolight Mill)28. M47 - restart a program continuously, or a fixed number of times (Prolight

Mill)

29. M71 - puff blowing on (EMCO Lathe)30. M72 - puff blowing off (EMCO Lathe)31. M96 - compensate for rounded external curves32. M97 - compensate for sharp external curves33. M98 - subprogram call34. M99 - return from subprogram, jump instruction35. M101 - move x-axis home (Prolight Mill)36. M102 - move y-axis home (Prolight Mill)37. M103 - move z-axis home (Prolight Mill)

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CNC PROGRAM FOR STEP TURNING OPERATION

Aim:

To write the CNC program for the given operation using FANUC language

Requirement:

FANUC programming software

Program:

N10 G21 G90;

N20 G28;

N30 M06 T01;

N40 M03;

N50 G00 X33 z0;

N60 G01 Z0 F75;

N70 X-1;

N80 Z1;

N90 X33;

N100 G28 U0 W0;

N110 M06 T02;

N120 G71 U0.5 R1;

N130 G71 P140 Q190 U0.2 W0.2 F75

N140 G012 X25;

N150 Z-20N160 X30;

N170 Z-50;

N190 G01 X33;

N200 G28 U0 W0;

N210 G28 U0 W0;

N220 G78 P140 Q190;

N230 G28 U0 W0;

N240 M05;

N250 M30;

Result:

Thus the program was written and executed successfully using FANUC.

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CNC PROGRAM FOR TAPER TURING OPERATION

Aim:

To write the CNC program for the given operation using FANUC language

Requirement:

FANUC programming software

Program:

000001

N10 G21 G90;

N20 G28 U0 W0;

N30 M06 T01;

N40 M03 S2000;

N50 G00 X33 Z2;

N60 G01 Z0 F75;

N70 X-1;

N80 Z1;

N90 X33;

N100 G28 UO WO;

N110 M06 T02;

N120 G71 U0.5 R1;

N130 P140 G180 U0.2 F75;

N140 X25;N150 X30 Z-20;

N160 Z-50;

N170 X32;

N180 Z-60;

N190 G00 ZO;

N200 G28 UO WO;

N210 M06 T03;

N220 G70 P140 Q180;

N230 G28 UO WO;

N240 M05;

N250 M30;

Result:

Thus the program was written and executed successfully using FANUC.