Computer Integrated Manufacturing Laboratory

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COMPUTER INTEGRATEDMANUFACTURING LAB PUJI INSTITUTEOF ENGINEERINGANDTECHNOLOGYDAVANGERE-577 004

DEPARTMENT OFMECHANICAL ENGINEERINGCOMPUTER INTEGRATEDMANUFACTURING LAB MANUAL2018(17MEL77)As per VTU Syllabus CBCS scheme for VII SemesterName: USN: Semester: Batch No . .Ravikumar H.NMallikarjuna V.KFaculty InchargeInstructorBAPUJI INSTITUTE OF ENGINEERING AND TECHNOLOGYDAVANGERE- 577 004

VISION OF THE INSTITUTETo be center of excellence recognized nationally and internationally, indistinctive areas of engineering education and research, based on a culture ofinnovation and invention.MISSION OF THE INSTITUTEBIET contributes to the growth and development of its students by impartinga broad based engineering education and empowering them to be successful intheir chosen field by inculcating in them positive approach, leadership qualitiesand ethical values.VISION OF THE DEPARTMENTThe department endeavors to be a center of excellence, to provide qualityeducation leading the students to become professional mechanical engineers withethics, contributing to the society through research, innovation, entrepreneurialand leadership qualities.MISSION OF THE DEPARTMENT1. To impart quality technical education through effective teaching- learningprocess leading to development of professional skills and attitude to excelin Mechanical Engineering.2. To interact with institutes of repute, to enhance academic and researchactivities.3. To inculcatecreativethinking abilities among studentsdevelop entrepreneurial skills.and4. To imbibe ethical, environmental friendly and moral values amongststudents through broad based education

PROGRAM EDUCATIONAL OBJECTIVES (PEO’S)1. Enable to understand mechanical engineering systems those are technicallyviable, economically feasible and socially acceptable to enhance quality oflife.2. Apply modern tools and techniques to solve problems in mechanical andallied engineering streams.3. Communicate effectively using innovative tools, to demonstrate leadershipand entrepreneurial skills.4. Be a professional having ethical attitude with multidisciplinary approach toachieve self and organizational goals.5. Utilize the best academic environment to create opportunity to cultivatelifelong learning skills needed to succeed in profession.PROGRAM SPECIFIC OUTCOMES (PSO’S)PS01:-Apply the acquired knowledge in design, thermal, manufacturing andinterdisciplinary areas for solving industry and socially relevant problems.PS02:-To enhance the abilities of students by imparting knowledge inemerging technologies to make them confident mechanical engineers.

COMPUTER INTEGRATEDMANUFACTURING LABB.E, VII Semester, MechanicalEngineering[As per Choice Based Credit System(CBCS) scheme]Course CodeNumber of LectureHours/Week17MEL7703 (1 HourInstruction 2 HoursLaboratory)Total Hours40CIE Marks40SEE Marks60Exam Hours03Credits –02Course Objectives:CLO1To expose the students to the techniques of CNC programming and cutting tool pathgeneration through CNC simulation software by using G-Codes and M-codesCLO2To educate the students on the usage of CAM packages and cut part on virtual CNC machinesimulator.CLO3To make the students understand the importance of automation in industries throughexposure to FMS, Robotics, andHydraulics and Pneumatics.Part-AManual CNC part programming for 2 turning and 2 milling parts. Selection and assignment of tools,correction of syntax and logical errors, and verification of tool path.CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling operations. 3typical simulations to be carried out using simulation packages like: Cadem CAM Lab-Pro, Master- CAM.Program generation using software. Optimize spindle power, torque utilization, and cycle time. Generationand printing of shop documents like process and cycle time sheets, tool list, and tool layouts. Enterprogram, take tool offsets, cut part in single block and auto mode, measure the virtual part on screen in thevirtual CNC machine simulator, for standard CNC control systems FANUC, FAGOR, HAAS andSINUMERIK.Part B(Only for Demo/Viva voce)FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval system (ASRS)and linear shuttle conveyor Interfacing CNC lathe, milling with loading unloading arm and ASRS to becarried out on simple components.

(Only for Demo/Viva voce)Robot programming: Using Teach Pendent & Offline programming to perform pick and place, stacking ofobjects (2 programs).Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these topics to beconducted.After studying this course, students will be able to:Course Outcomes:CO1Understand & write CNC part program for Turning, Facing, Chamfering, Grooving, Step turning,Taper turning, Circular interpolation etc.CO2Analyse CNC Mill Part programming for Point to point motions, Line motions, Circularinterpolation, Contour motion, Pocket milling- circular, rectangular, Mirror commands etc.CO3choose high end CAM packages for machining complex parts and state of art cutting tools andrelated cutting parameters; optimize cycle time, set up and cut part on anduse Canned Cycles forDrilling, Peck drilling, Boring, Tapping, Turning, Facing,Taper turning Thread cutting etc.CO4Simulate Tool Path for different Machining operations of small components using CNC Lathe &CNC Milling Machine. Understand& write programs for Robot control; understand the operatingprinciples of hydraulics, pneumatics and electro pneumatic systems.Scheme for Examination:Two Questions from Part A - 60 Marks (30 30) Viva-Voce - 20 MarksTotal: 80 Marks

DO’s1. Students must always wear uniform and shoes before entering the lab.2. Proper code of conduct and ethics must be followed in the lab.3. Windows and doors to be kept open for proper ventilation and air circulation.4. Check for the electrical connections and inform if any discrepancy found to the attention oflecturer/lab instructor.5. alecturer/labinstructor only.6. In case of fire use fire extinguisher/throw the sand provided in the lab.7. Any unsafe conditions prevailing in the lab can be brought to the notice of the lab incharge.DONT’s1. Do not touch any system without their prior knowledge,2. Never overcrowd the laboratory Leave sufficient space for the person to operate theequipment’s.3. Never rest your hands on the system and the display board.

CONTENTSSL.TITLEPAGE NOPART-A1CNC PART PROGRAMMING1-1GENERALLY USED G-CODES IN TURNING2-2GENERALLY USED G-CODES IN TURNING3-3LIST OF G & M CODES USED IN SSCNC FOR TURNING CENTER24-4GENERATE ABSOLUTE PART PROGRAM TO CREATE THE FOLLOWING 5-15PROFILE WITH FACING AND OD TURNING AND WRITE COMMENTS.345678WRITE A PART PROGRAM TO CREATE THE FOLLOWING PROFILE WITH 16-17FACING AND OD TURNING. ABSOLUTE, INCREMENTAL ANDINCREMENTAL WITH USING CANNED CYCLE AND WRITE THECOMMENTS OF THE EACH LINE PROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING PROFILE WITH 18-19FACING, OD TURNING AND STEP TURNING WRITE THE COMMENTS OFTHE EACH LINE PROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING PROFILE WITH 20-20STEP TURNING (UNDER CUT) WRITE THE COMMENTS OF THE EACH LINEPROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING FACING OD 21-22TURNING AND TAPER PROFILE USING G90 AND G94 FIXED CYCLE WITHFACING, TAPER TURNING WRITE THE COMMENTS OF THE EACH LINEPROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING UNDER STEP 23-24CUTTING AND THREAD CUTTING PROFILE USING G90 AND G92 FIXEDCYCLE WRITE THE COMMENTS OF THE EACH LINE PROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING UNDER STEP 25-26CUTTING AND CONCAVE, CONVEX CUTTING PROFILE USING G90 ANDG02 CIRCULAR CYCLE WRITE THE COMMENTS OF THE EACH LINEPROGRAM.

91011WRITE A PART PROGRAM TO CREATE THE FOLLOWING UNDER STEP 27-29CUTTING AND CONCAVE, CONVEX CUTTING, USING G90 AND G02 ANDG03 CIRCULAR CYCLE WRITE THE COMMENTS OF THE EACH LINEPROGRAM.WRITE A PART PROGRAM TO CREATE THE FOLLOWING PECK DRILLING 30-31OPERATION USING G74 AND Q PECK DISTANCE IN MICRONS.USING SWANSOFT WRITE A PART PROGRAM TO CREATE THE 32-32FOLLOWING PROFILE WITH FACING, TURNING, STEP TURNING,DRILLING, CONCAVE/CONVEX AND THREAD CUTTING M50 X 3MMPITCH, CHOOSE A WORK PIECE OF SIZE 55 DIAMETER 250 LENGTHS.PART-BOPERATING PROCEDURE OF MASTER CAM121314TO PREPARE THE EXERCISE 1 MODEL AS PER THESKETCH USING 33-48MASTER CAM TOOL.TO PREPARE THE EXERCISE 1 MODEL AS PER THESKETCH USING 49-57MASTER CAM TOOL.TO PREPARE THE EXERCISE 1 MODEL AS PER THESKETCH USING 58-75MASTER CAM TOOL.

CIM LAB LAY OUT

Computer Integrated Manufacturing LaboratoryCNC PART PROGRAMMINGSoftware: SwanSoft FANUC 0iT CNC TurningList of G & M Codes used in SSCNC for Turning CenterGENERALLY USED G-CODES IN TURNINGSTANDARD G CODE FUNCTIONG00Positioning in RapidG01Straight InterpolationG02Circular Interpolation ( CW )G03Circular Interpolation (CCW)G04DwellG10Change in Setting ValueG20Data Input in InchG21Data Input in metricG22Stored Stroke Limit onG23Stored Stroke Limit offG25Spindle Speed Fluctuation detection OFFG26Spindle Speed Fluctuation detection ONG27Machine Reference CheckG28Automatic Machine ReferenceG29Return From ReferenceG30The 2nd Reference returnG31Skip FunctionG32Threading Process CycleG40Cancel of CompensationG41Compensation of the leftG42Compensation of the rightG65Call custom MacroG70Repeat Cycle - FinishingG71Stock Removal in TurningG72Stock Removal in FacingG73Pattern Repeating CycleG74Peck Drilling in Z DirectionG75Grooving in X - DirectionG76Thread Process CycleG90Fixed Process Cycle in TurningG92Fixed Process Cycle in ThreadingG94Fixed Process Cycle in FacingG96Constant Surface speedG97Constant Surface speed cancelG98Per min feedG99Per revolution feedDepartment of Mechanical Engineering, BIET, Davanagere2

Computer Integrated Manufacturing LaboratoryGENERALLY USED M-CODES IN TURNINGSTANDARD M CODESFUNCTIONM00Unconditional program stopM01Conditional program stopM02End of Program with return to program startM03Spindle Rotation, Clock WiseM04Spindle Rotation, Counter Clock WiseM05Spindle StopM06Tool ChangeM08Coolant ONM09Coolant OFFM30End of Program, Reset and return to program beginningM94Cancel Mirror ImageM95X Coordinate Mirror ImageM96Y Coordinate Mirror ImageM98Subprogram callM99End of Sub ProgramDepartment of Mechanical Engineering, BIET, Davanagere3

Computer Integrated Manufacturing LaboratoryList of G & M Codes used in SSCNC for Turning CenterDepartment of Mechanical Engineering, BIET, Davanagere4

Computer Integrated Manufacturing Laboratory1. Write a Absolute part program to create the following profile with facing andOD Turning and write comments.Work piece InformationBarDiameter: 70.000Length: 250.000Material:08F low-carbon steelTool Information Work offset at the centerTools Management – Select the External turning 350 / 900 tool.ProcedureChoose the stand alone buttonClick on drop down buttonSelect Fanuc OiT CNC SystemSelect MAC EncryptionGo to RunRelease the Emergency buttonDepartment of Mechanical Engineering, BIET, Davanagere5

Computer Integrated Manufacturing LaboratoryPress write protect offPress Reference and X and ZGo to Parameter settingDepartment of Mechanical Engineering, BIET, Davanagere6

Computer Integrated Manufacturing LaboratorySelect– 4 Position turret and press okWorkpiece Setting, Go to – Stock sizeDepartment of Mechanical Engineering, BIET, Davanagere7

Computer Integrated Manufacturing LaboratoryChoose Length of Work Piece 250mm Choose Diameter of the Work Piece 80mm Check Replace work piece button to replace existing work piece . Press OK button.Tool Management: Add New Tool Edit ToolDepartment of Mechanical Engineering, BIET, Davanagere8

Computer Integrated Manufacturing Laboratory Tool SelectionEnter Diameter and Length of the tool in respected places Enter Rpm and Feed . Enter thickness of the insert. Enter Shank and its width. Then click OK button to add the toll to Library.– select the External turning 35/55/900 tool – drag and drop to tool magazine– mount the toolWorkpiece setting – rapid position at centerDepartment of Mechanical Engineering, BIET, Davanagere9

Computer Integrated Manufacturing LaboratoryPress Work set setting Button to view above Menu. To open Locate instantly window select RapidPosition button.Select the position and press OK button.Close the machine doorDepartment of Mechanical Engineering, BIET, Davanagere10

Computer Integrated Manufacturing LaboratoryOffset setting – work – X00 – measure --- Z00 – measure(Do not use this step if X and Z axis home position is zero)Getting Ready to enter your first programBefore writing program you have to register for memory space.Department of Mechanical Engineering, BIET, Davanagere11

Computer Integrated Manufacturing Laboratoryprog – edit – DIR – O0013 (Register your program No. start with alphabet ‘O’)Press DIR Button in the Numerical panel to register the program. Type registry number in Program panel.The registry number start with letter ‘O’Followed by number (ex: O0009).Type the program by using Program panel or by using the computer key board .Department of Mechanical Engineering, BIET, Davanagere12

Computer Integrated Manufacturing LaboratoryIn program panel press letter in smaller font press Shift then press button for example to type letter p pressShift then press O and P Button. After entering one line of code press EOF button press Insert button addthis code to numerical control panel.Department of Mechanical Engineering, BIET, Davanagere13

Computer Integrated Manufacturing LaboratoryAbsolute MethodComments / RemarksO0012Program NumberG54Work co-ordinate systemT0100Tool T01 selectionS400M03Spindle to rotate at 400 RPM in Clockwise 00X71G01Z-5Coolant onTool T01 Positions in Rapid traverse1 mm away from the set coordinateLanier Interpolation ( G01 ) Movements in X & Z Directions tocreate the paths. The feed is at 0.25mm/rev. Table feed 0.25 x400 rpm 0G01Z-205G00X61G28U0W0M09M05M30Go Back to tool change position in rapid ( m/c 00 )Coolant offSpindle offProgram EndAfter entering the programGo to Auto modeSelect block by blockCycle StartDepartment of Mechanical Engineering, BIET, Davanagere14

Computer Integrated Manufacturing LaboratoryDepartment of Mechanical Engineering, BIET, Davanagere15

Computer Integrated Manufacturing Laboratory2. Write a part program to create the following profile with facing and OD Turning. Absolute,Incremental and Incremental with using canned cycle and write the comments of the each lineprogram .Work piece InformationBarDiameter: 80.000Length: 250.000Material:08F low-carbon steelTool Information Work offset at the center Tools Management – Select the External turning 350 / 900 tool.Procedure1. Relese the Emergency button2. Press Reference and X and Z3. Press write protect off4. Go to Parameter setting – 4 Position turret5. Tools Management – select the External turning 35/55/900 tool – drag and drop to tool magzine–mount the tool6. Workpiece setting – stock size – Ø80, 250 length7. Workpiece setting – rapid position at center8. Close the machine door9. Offset setting – work – X00 – measure --- Z00 – measure(Do not use this step if X and Z axis home position is zero)10. prog – edit – DIR – O0013 (Register your program No. start with alphabet ‘O’)CNC CodesDepartment of Mechanical Engineering, BIET, Davanagere16

Computer Integrated Manufacturing LaboratoryAbsolute 00U1G28U0W0M09M05M30Department of Mechanical Engineering, BIET, DavanagereIncremental with using 5G28U0W0M09M05M3017

Computer Integrated Manufacturing Laboratory3. Write a part program to create the following profile with facing, OD Turning andStep Turning write the comments of the each line program .Workpiece InformationBarDiameter: 80.000Length: 250.000Material:08F low-carbon steelTool Information Work offset at the center Tools Management – Select the External turning 350 tool.CNC CodesAbsolute W-50U10G28U0W0M09M05M30Department of Mechanical Engineering, BIET, DavanagereIncremental with usingcanned U0W0M09M05M3018

Computer Integrated Manufacturing LaboratoryDepartment of Mechanical Engineering, BIET, Davanagere19

Computer Integrated Manufacturing Laboratory4. Write a part program to create the following profile with Step Turning ( under cut)write the comments of the each line program .Workpiece InformationBarDiameter: 80.000Length: 200.000Material:08F low-carbon steelTool Information Work offset at the center Tools Management – Select the Groveeing tool with thickness of 1mm and that edge alsotaken into consideration. ( move 1mm and give 19mm cutting)CNC 0M09M05M30%Department of Mechanical Engineering, BIET, Davanagere20

Computer Integrated Manufacturing Laboratory5. Write a part program to create the following Facing OD Turning and Taper profileusing G90 and G94 fixed cycle with facing, Taper Turning write the comments of theeach line program .Work piece Information:BarDiameter: 80.000Length: 250.000Material:08F low-carbon steelTool Information Work offset at the center Tools Management – select the External turning 350 tool – drag and drop tool.CNC CodesAbsolute 2.5G28U0W0M09M05M30Department of Mechanical Engineering, BIET, Davanagere21

Computer Integrated Manufacturing LaboratoryDepartment of Mechanical Engineering, BIET, Davanagere22

Computer Integrated Manufacturing Laboratory5. Write a part program to create the following Under Step Cutting and Thread Cuttingprofile using G90 and G92 fixed cycle write the comments of the each line program .Work piece Information:BarDiameter: 80.000Length: 200.000Material:08F low-carbon steelTool Information Work offset at the center Tools Management –First Select the Grooving tool with thickness of 1mm and that edgeconsideration. ( move 1mm and give 19mm cutting)also taken intoSecond select the Thread cutting tool Insert parameter Length 2.5 insert thickness and insertdiameter 12 tool – drag and drop tool.Pitch 0.061 x diameterCNC 0G00U2Department of Mechanical Engineering, BIET, Davanagere23

Computer Integrated Manufacturing ment of Mechanical Engineering, BIET, Davanagere24

Computer Integrated Manufacturing Laboratory6. Write a part program to create the following Under Step Cutting and Concave,Convex Cutting profile using G90 and G02 circular cycle write the comments of theeach line program .Work piece InformationBarDiameter: 80.000Length: 200.0

virtual CNC machine simulator, for standard CNC control systems FANUC, FAGOR, HAAS and SINUMERIK. Part B (Only for Demo/Viva voce) FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval system (ASRS) and linear shuttle conveyor Interfacing CNC lathe, milling with loading unloading arm and ASRS to be

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