DEPARTMENT OF MECHANICAL ENGINEERING

COMPUTER INTEGRATED MANUFACUTRING LAB

(PG)

LAB MANUAL

Prepared by

Praveen. R, B.E., M.E., MISTE., (PhD)

ASSISTANT PROFESSOR – II / MECH
 INDEX

[Link] [Link]. NAME OF THE EXPERIMENT PAGE NO. DATE

CAD LABORATORY
1. Introduction to 3D Design Software - CATIA 1
1. D01 Assembly of Foot Step Bearing 9
2. D02 Assembly of Universal Coupling 11
3. D03 Modelling of Helical Gear 13
4. D04 Modelling of Jig, Fixture & Die Assembly 15
5. D05 Modelling of Sheet Metal Components 17
CAM LABORATORY
2. Introduction to Edge CAM / Master CAM 20
3. Exercise on CNC Lathe 25
6. L01 Plain Turning 31
7. L02 Step turning 33
8. L03 Taper turning 35
9. L04 Threading 37
10. L05 Grooving 39
11. L06 Canned cycle 41
4. Exercise on CNC Milling Machine 43
12. M01 Profile Milling 51
13. M02 Mirroring 53
14. M03 Scaling 55
15. M04 Canned cycle 57
5. Study of Sensors, Transducers & PLC
16. S01 Hall-effect sensor, Pressure sensors 59
17. S02 Strain Gauge, PLC 62
18. S03 LVDT, Load Cell 64
19. S04 Angular potentiometer, Torque 68
20. S05 Temperature & Optical Transducers. 70
6. Mini project on any one of the CIM elements
 1. INTRODUCTION
CATIA (Computer Aided Three-dimensional Interactive Application) is a multi-
platform CAD/CAM/CAE commercial software suite developed by the French
company Dassault Systèmes. Written in the C++ programming language, CATIA
is the cornerstone of the Dassault Systèmes product lifecycle management software
suite.

THE SKETCHER WORKBENCH

The Sketcher workbench is a set of tools that helps you create and constrain 2D
geometries. Features (pads, pockets, shafts, etc...) may then be created solids or
modifications to solids using these 2D profiles. You can access the Sketcher
workbench in various ways. Two simple ways are by using the top pull down menu

(Start – Mechanical Design – Sketcher), or by selecting the Sketcher icon.

When you enter the sketcher, CATIA requires that you choose a plane to sketch
on. You can choose this plane either before or after you select the Sketcher icon.

To exit the sketcher, select the Exit Workbench icon.

The Sketcher workbench contains the following standard workbench specific
toolbars.
• Profile Toolbar: The commands located in
this toolbar allow you to create simple
geometries (rectangle, circle, line, etc...) and
more complex geometries (profile, spline, etc...).
• Operation Toolbar: Once a profile has been created, it can
be modified using commands such as trim, mirror, chamfer,
and other commands located in the Operation toolbar.

1
•Constraint Toolbar: Profiles may be constrained with
dimensional (distances, angles, etc...) or geometrical
(tangent, parallel, etc...) constraints using the commands
located in the Constraint toolbar.
• Sketch Tools Toolbar: The commands in this toolbar allow
you to work in different modes which make sketching easier.
• User Selection Filter Toolbar: Allows you to activate

different selection filters.

• Visualization Toolbar: Allows you to, among other things to
cut the part by the sketch plane and choose lighting effects and other factors that
influence how the part is visualized.
• Tools Toolbar: Allows you to, among others other things, to analyze a sketch for
problems, and create a datum.

THE SKETCH TOOLS TOOLBAR

The Sketch tools toolbar contains icons that activate
and deactivate different work modes. These work
modes assist you in drawing 2D profiles. Reading from left to right, the toolbar
contains the following work modes; (Each work mode is active if the icon is
orange and inactive if it is blue.)
• Grid: This command turns the sketcher grid on and off.
• Snap to Point: If active, your cursor will snap to the intersections of the grid
lines.
• Construction / Standard Elements: You can draw two different types of
elements in CATIA a standard element and a construction element. A standard
element (solid line type) will be created when the icon is inactive (blue). It will be
2
used to create a feature in the Part Design workbench. A construction element
(dashed line type) will be created when the icon is active (orange). They are used
to help construct your sketch, but will not be used to create features.
• Geometric Constraints: When active, geometric
constraints will automatically be applied such as
tangencies, coincidences, parallelisms, etc...
• Dimensional Constraints: When active, dimensional constraints will
automatically be applied when corners (fillets) or chamfers are created, or when
quantities are entered in the value field. The value field is a place where
dimensions such as line length and angle are manually entered.

PROFILE TOOLBAR
The Profile toolbar contains 2D geometry commands. These geometries range
from the very simple (point, rectangle, etc...) to the very complex (splines, conics,
etc...). The Profile toolbar contains many sub-toolbars. Most of these sub toolbars
contain different options for creating the same geometry. For example, you can
create a simple line, a line defined by two tangent points, or a line that is
perpendicular to a surface. Reading from left to right, the Profile toolbar contain
the following commands.

3
• Profile: This command allows you to create a continuous set of lines and arcs
connected together.
• Rectangle / Predefined Profile Toolbar: The default top command is rectangle.
Stacked underneath are several different commands used to create predefined
geometries.
• Circle / Circle Toolbar: The default top command is circle. Stacked underneath
are several different options for creating circles and arcs.
• Spline / Spline Toolbar: The default top command is spline which is a curved
line created by connecting a series of points.
• Ellipse / Conic Toolbar: The default top command is ellipse. Stacked underneath
are commands to create different conic shapes such as a hyperbola.
• Line / Line Toolbar: The default top command is line. Stacked underneath are
several different options for creating lines.
• Axis: An axis is used in conjunction with commands like mirror and shaft
(revolve). It defines symmetry. It is a construction element so it does not become a
physical part of your feature.
• Point / Point Toolbar: The default top command is point. Stacked underneath are
several different options for creating points.

PREDEFINED PROFILE TOOLBAR: Predefined profiles are frequently used

geometries. CATIA makes these profiles available for easy creation which speeds
up drawing time. Reading from left to right,
the Predefined Profile toolbar contains the
following commands.
• Rectangle: The rectangle is defined by two corner points. The sides of the
rectangle are always horizontal and vertical.
4
• Oriented Rectangle: The oriented rectangle is defined by three corner points.
This allows you to create a rectangle whose sides are at an angle to the horizontal.
• Parallelogram: The parallelogram is defined by three corner points.
• Elongated Hole: The elongated hole or slot is defined by two points and a radius.
• Cylindrical Elongated Hole: The cylindrical elongated hole is defined by a
cylindrical radius, two point and a hole radius.
• Keyhole Profile: The keyhole profile is defined by two center points and two
radii.
• Hexagon: The hexagon is defined by a center point and the radius of an inscribed
circle.
• Centered Rectangle: The centered rectangle is defined by a center point and a
corner point.
• Centered Parallelogram: The centered parallelogram is defined by a center point
(defined by two intersecting lines) and a corner point.

CIRCLE TOOLBAR: The Circle toolbar contains several different ways of

creating circles and arcs. Reading from left to right,
the Circle toolbar contains the following
commands.

• Circle: A circle is defined by a center point and a radius.

• Three Point Circle: The three point circle command allows you to create a circle
using three circumferential points.
• Circle Using Coordinates: The circle using coordinates command allows you to
create a circle by entering the coordinates for the center point and radius in a Circle
Definition window.
5
• Tri-Tangent Circle: The tri-tangent circle command allows you to create a circle
whose circumference is tangent to three chosen lines.
Three Point Arc: The three point arc command allows you to create an arc defined
by three circumferential points.
• Three Point Arc Starting With Limits: The three point arc starting with limits
allows you to create an arc using a start, end, and midpoint.
• Arc: The arc command allows you to create an arc defined by a center point, and
a circumferential start and end point.

SPLINE TOOLBAR
Reading from left to right, the Spline toolbar contains the following
commands.
• Spline: A spline is a curved profile defined by three or more points. The tangency
and curvature radius at each point may be specified.
• Connect: The connect command connects two points or profiles with a spline.

CONIC TOOLBAR

Reading from left to right, the Conic toolbar contains the

following commands.
• Ellipse: The ellipse is defined by center point and a major and minor axis points.
• Parabola by Focus: The parabola is defined by a focus, apex and a start and end
point.
• Hyperbola by Focus: The hyperbola is defined by a focus, center point, apex and
a start and end point.

6
• Conic: There are several different methods that can be used to create conic
curves. These methods give you a lot of flexibility when creating above three types
of curves.
LINE TOOLBAR
The Line toolbar contains several different ways of creating
lines. Reading from left to right, the Line toolbar contains the
following commands.
• Line: A line is defined by two points.
• Infinite Line: Creates infinite lines that are horizontal, vertical or defined by two
points.
• Bi-Tangent Line: Creates a line whose endpoints are tangent to two other
elements.
• Bisecting Line: Creates an infinite line that bisects the angle created by two
other lines.
• Line Normal to Curve: This command allows you to create a line that starts
anywhere and ends normal or perpendicular to another element.

POINT TOOLBAR
The Point toolbar contains several different ways of
creating points. Reading from left to right, the Point toolbar
contains the following commands.
• Point by Clicking: Creates a point by clicking the left mouse button.
• Point by using Coordinates: Creates a point at a specified coordinate point.
• Equidistant Points: Creates equidistant points along a predefined path curve.
• Intersection Point: Creates a point at the intersection of two different elements.
• Projection Point: Projects a point of one element onto another.
7
CONSTRAINT TOOLBAR
Constraints can either be dimensional or geometrical. Dimensional constraints are
used to constrain the length of an element, the radius or diameter of an arc or
circle, and the distance or angle between elements. Geometrical constraints are
used to constrain the orientation of one element relative to another. For example,
two elements may be constrained to be perpendicular to each other. Other
common geometrical constraints include parallel, tangent, coincident, concentric,
etc... Reading from left to right:
•Constraints Defined in Dialoged Box: Creates geometrical and dimensional
constraints between two elements.
• Constraint: Creates dimensional constraints.
• Contact Constraint: Creates a contact constraint
between two elements.
• Fix Together: The fix together command groups
individual entities together.
• Auto Constraint: Automatically creates dimensional
constraints.
• Animate Constraint: Animates a dimensional constraint between to limits.

8
9
[Link]: 01 ASSEMBLY OF FOOT STEP BEARING

DATE:

AIM:
Preparation of 3D Assembly model using CATIA V5.18 software

TOOLS USED:
Existing Component icon, Manipulate, Constraining etc.,

PROCEDURE:
1. Assembly Design command is activated to launch the required workbench.
2. The commands for assembling parts are available in the toolbar on the right side
of the application window.
3. Click the Existing Component icon in the Product Structure toolbar, then the File
Selection dialog box is displayed were the required part model is selected.
4. To constrain a model for positioning parts correctly is carried using the various
constraints tools like Constraining and Manipulating and Select the fix component
icon, to Fix a part in the space.
5. Then the parts are assembled in the following order Block, Bush, Shaft by
adopting above methods
6. Select the update icon for assembly to be updated, all assembly design models
are ensured that it is in constraints condition before the models are finished.

RESULT:
Thus the given 3D assembly model as per the drawing is modelled using CATIA
V5.18 software.
10
11
[Link]: 02 ASSEMBLY UNIVERSAL COUPLING
DATE:

AIM:
Preparation of 3D Assembly model using CATIA V5.18 software

TOOLS USED:
Existing Component icon, Manipulate, Constraining etc.,

PROCEDURE:
1. Assembly Design command is activated to launch the required workbench.
2. The commands for assembling parts are available in the toolbar on the right side
of the application window.
3. Click the Existing Component icon in the Product Structure toolbar, then the File
Selection dialog box is displayed were the required part model is selected.
4. To constrain a model for positioning parts correctly is carried using the various
constraints tools like Constraining and Manipulating and Select the fix component
icon, to Fix a part in the space.
5. Then the parts are assembled in the following order Fork, Centre, Shaft,
Parallel Key, Pin, Collar, Taper Pin by adopting above methods
6. Select the update icon for assembly to be updated, all assembly design models
are ensured that it is in constraints condition before the models are finished.

RESULT:
Thus the given 3D assembly model as per the drawing is modelled using CATIA
V5.18 software.

12
13
[Link]: 03 MODELLING OF HELICAL GEAR
DATE:

AIM:
Preparation of 3D Assembly model using CATIA V5.18 software

TOOLS USED:
Existing Component icon, Manipulate, Constraining etc.,

PROCEDURE:
1. Assembly Design command is activated to launch the required workbench.
2. The commands for assembling parts are available in the toolbar on the right
side of the application window.
3. Click the Existing Component icon in the Product Structure toolbar, then the
File Selection dialog box is displayed were the required part model is selected.
4. To constrain a model for positioning parts correctly is carried using the various
constraints tools like Constraining and Manipulating and Select the fix
component icon, to Fix a part in the space.
5. Then the parts are assembled in the following order by adopting above
methods
6. Select the update icon for assembly to be updated, all assembly design models
are ensured that it is in constraints condition before the models are finished.

RESULT:
Thus the given 3D assembly model as per the drawing is modelled
using CATIA V5.18 software.

14
15
[Link]: 04 MODELLING OF JIG, FIXTURE & DIE ASSEMBLY
DATE:

AIM:
Preparation of 3D Assembly model using CATIA V5.18 software

TOOLS USED:
Existing Component icon, Manipulate, Constraining etc.,

PROCEDURE:
1. Assembly Design command is activated to launch the required workbench.
2. The commands for assembling parts are available in the toolbar on
the right side of the application window.
3. Click the Existing Component icon in the Product Structure
toolbar, then the File Selection dialog box is displayed were the
required part model is selected.
4. To constrain a model for positioning parts correctly is carried using
the various constraints tools like Constraining and Manipulating and
Select the fix component icon, to Fix a part in the space.

5. Then the parts are assembled in the following order by adopting above methods
6. Select the update icon for assembly to be updated, all assembly
design models are ensured that it is in constraints condition before the
models are finished.

RESULT:
Thus the given 3D assembly model as per the drawing is modelled
using CATIA V5.18 software.
16
17
EX. NO.: 05 MODELLING OF SHEET METAL COMPONENT

DATE:

AIM:

Preparation of 3D model using CATIA V5.18 software

TOOLS USED:

Pad, Pocketing etc.,

PROCEDURE:

1. Click the Sketcher icon to start the Sketcher workbench.

2. Select XY, YZ, ZX plane to define the sketch plane, now the
Sketcher workbench isdisplayed, it contains the tools needed for
sketching any profile.
3. Select the profile and draw the part which is given in the model.

4. Using Constraint command the dimensions are modified as per the given
model.

5. Exit the Sketcher workbench, click Pad and give the thickness for the part.

6. Select the face to define the work plane and draw the second element.

7. Using Pocket command material is removed and the final model is created.

RESULT:
Thus the given 3D assembly model as per the drawing is modelled
using CATIA V5.18 software.
18
CAM LABORATORY

19
 INTRODUCTION TO CNC

DEFINITION OF CNC

“A system in which the actions are controlled by direct insertion of numerical data at
some point .The system must automatically interpret at least some portion of this data”

WHY IT IS CALLED AS CNC?

Since the information required to actuate and control slides of the machine are coded
numerically, this technology came to be known as Numerical Control.

WHAT IS CNC?
CNC is acronym for Computer Numerical Control.
A dedicated computer is used to perform all the basic NC functions. The complete part
programme to produce a component is input and stored in the computer memory and the
information for each operation is fed to the machine tools. The program can be stored and
used in future

AXIS IN CNC MACHINES

THE BASIS OF AXIS IDENTIFICATION IS THE 3-DIMENSIONAL

CARTESIAN CO-ORDINATE SYSTEM AND THREE AXIS OF MOVEMENT
ARE IDENTIFIED AS X,Y AND Z AXIS

Z AXIS.
Z- Axis The Z Axis of motion is always the axis of the main spindle of the [Link]
doses not matters whether the spindle carries the work piece or the cutting tool . On
vertical machining centers Z axis is vertical and on horizontal machining center and
turning centers Z axis is horizontal

Positive Z Movement is away from the spindle

20
X-Axis The axis is always horizontal and is always parallel to the work holding surface.
Positive X Axis movement is identified as being to the right, when looking from the
spindle towards its supporting column.

Y- Axis The axis is always at right angle to both X-Axis and Z-Axis

Rotary axis .The rotary motion about the X,Y and Z-Axis are identified by A,B,C
respectively .Clockwise is designated as +VE. .Positive rotation is identified looking in x
,y and z direction respectively

AXIS IN CNCLATHE

21
AXIS IN MILLING MACHINE

A milling machine has 3 axes of movement identified by X, Y & Z axes

The maximum work piece dimensions correspond to the possible traversing path of the
tool in the particular axis.

AXIS IN MILLING MACHINE

+Z
Z
-
+Y

+
Y
X +X
- - -X
+

-Y
-Z

22
ZERO POINTS REFERENCE POINT

The reference point R serves for calibrating and for controlling of measuring systems of
the slides and tool traverses. The position of the reference point is accurately
predetermined in every traverse axis by the trip dogs and limit switches. Therefore, the
reference point coordinates always have the same, precisely known numerical value in
relation to the machine zero point.

After initiating the control system, the reference point must always be approached from
all axes to calibrate the traverse measuring system.

23
DIMENSION SYSTEM

Dimensional information in a work piece drawing can be stated in two ways Absolute
Dimension System and Incremental Dimension System.

Absolute Dimension System

Data in absolute dimension system always refer to a fixed reference point. This point has
the function of a coordinate zero point. The dimension lines run parallel to the coordinate
axes and always start at the reference point. Absolute dimensions are also called as
'Reference dimensions'
Incremental Dimension System

When using Incremental Dimension system, every measurement refers to a previously

dimensioned position Incremental dimensions are distance between adjacent points.
These distances are converted into incremental coordinates by accepting the last
dimension point as the coordinate origin for the new point. This may be compared to a
small coordinate system, i.e., shifted consequently form point to point (P1..P2..through
P9). Incremental dimensions are also frequently called 'Relative dimensions' or 'Chain
dimensions'.

DIMENSION SYSTEM

φ30

P5
P6
φ20 ABSOLUTE INCREMENIAL
DIMENSIONING DIMENSIONING
P4
P3
φ10
POINTS X Z POINTS U W

P2
P1 P1 10 0 P1 10 0
P2 10 -10 P2 0 -10
(0,0)
P3 20 -10 P3 10 0
P4 20 -25 P4 0 -15
P5 30 -25 P5 10 0
P6 30 -35 P6 0 -10

30 20 10

24
 STUDY OF ISO CODES

CNC TURNING

AIM: To study various CNC Turning codes and addresses

G Codes
G00: Point to point positioning (Rapid traverse)
G01: Linear interpolation
G02: Circular interpolation clockwise
G03: Circular interpolation counter clockwise
G04: Dwell, Exact stop
G17: X Y Plane selection
G18: Z X plane selection
G19: Y Z Plane selection
G20: Input in inch
G21: Input in metric (mm)
G28: Return to reference point
G32: Thread Cutting
G40: Cutter compensation cancel
G41: Cutter Compensation left
G42: Cutter Compensation right
G49: Tool length compensation cancel
G50: Work co-ordinate Change / Max Spindle speed setting
G70: Finishing cycle
G71: Stock removal in turning
G72: Stock removal in facing
25
G73: Pattern repeating
G74: Peck drilling in z axis
G75: Grooving in x axis
G76: Thread Cutting Cycle

G80: Canned cycle cancel

G90: Cutting cycle A
G92: Thread cutting cycle
G94: Cutting cycle B
G96: Constant surface speed control
G97: Constant surface speed control cancel
G98: Feed per minute
G99: Feed per revolution

M Codes
M00: Program stop
M01: Optional (planned) stop
M02: End of program
M03: Spindle forward clockwise
M04: Spindle forward counter clockwise
M05: Spindle stop
M06: Tool change
M08: Coolant ON
M09: Coolant OFF
M10: Chuck open
M11: Chuck close
M62: Output 1 ON
M63: Output 2 ON

26
M64: Output 1 OFF
M65: Output 2 OFF
M66: Wait input 1 ON
M67: Wait input 2 ON
M76: Wait input 1 OFF
M77: Wait input 2 OFF
M98: Sub program Call
M99: Sub program Exit

Common Lathe G-Codes

*G00 Rapid linear move. [X, Z, U, W] Moves the machine at the fastest rate possible
to the X, Z location specified or incrementally U (X) W(Z) distance.
G01 Linear feed move [X, Z, U, W, F] Moves the machine at the specified feed rate
(F) to the X, Z location specified or incrementally U (X) W(Z) distance.
G02 Circular interpolation; CW. [X, Z, U, W, F, R (or I, K)] Moves the machine, in
a clockwise circular path to the X, Z, location (or incrementally by U,W) with
radius R, or with a center point defined relative to the start point in the X,& Z axis
by I, & K respectively.
G03 Circular interpolation; CCW. [X, Z, U, W, F, R (or I, K)] Same as G02, but
opposite direction of movement.
G28 Machine home. Causes the machine to return to it’s X0, Z0 position at a rapid
rate.
*G40 Tool nose compensation, CANCEL. [X, Z, U, W, I, K, F] Cancels the G41 or
G42 Cutter compensation listed below. Causes a feed move to X and/or Z at feed
rate F (or at modal feed F, if not specified). The distance of the move must be
greater than the radius of the tool.

27
G41 Tool nose compensation, LEFT. [X, Z, U, W, D, F] Looking from the spindle
toward the part, G41 offsets the position of the tool left of the programmed tool
path by the value stored in the offsets register position called by the D word.
Causes a feed move from the current position to the compensated position
specified by X, Y, at feed F (or at modal feed F if not specified). The distance of
this move must be greater than the radius of the tool.
G42 Tool nose compensation, RIGHT. Same as G41 above except that the tool is
compensated to the right of the programmed tool path.
NOTE: Cutter compensation may be accomplished at the machine, through the
tool path generated by the CAM program, or both.

G50 Spindle speed clamp. Specifies the maximum RPM the spindle can run during
constant surface speed operation.
G70 Finishing Cycle

G71 Multiple Turning Cycle. It is used when the major direction of cut is along the Z
axis. It causes the profile to be roughed out by turning.
G72 Multiple Facing Cycle, used when the major direction of cut is along the X axis.
This cycle causes the profile to be roughed out by facing.
G73 Pattern Repeating Cycle, provides for roughing out of a form by repeating the
desired tool path a set number of times, the tool path being incremented into the
work piece until the full form is completed.
G75 Grooving Cycle
G92 Single Thread cycle. This is a Box type cycle producing a single pass of the
threading tool.

28
G76 Multiple Threading Cycle. This is a box type cycle that is repeated a given
number of times. After the first pass subsequent passes cut with one edge of the
threading tool only to reduce the load at the tool tip.
G74 End Face Peck Drilling. This cycle is designed for deep hole drilling, the drill
entering the work piece by a predetermined amount then by backing off by
another set amount to provide breaking and allowing swarf to clear the drill flutes.
G90 Single Turning Cycle, used to produce either a parallel or tapered tool path. It
performs four distinct moves with one line of information and it is equivalent to
rapid to X position, feed to Z position, feed to start X position, rapid to start Z
position
G94 Facing Cycle .This cycle is used for stock removal either parallel or at an angle to
work piece face. It is equivalent of rapid to Z position, feed to X Position, and
feed to start Z position and rapid to start X position. If R value is specified
tapering will be performed.
Common Lathe M-Codes
M00 Program stop. Stops the machine, requiring the operator to restart the program
to continue.
M01 Optional stop. Stops the machine as above only when the optional stop button has
been pressed prior to this command in the program.
M03 Spindle start, CW. [S] Starts the spindle in a clockwise direction, at the RPM
specified by the S word accompanying the code.
M04 Spindle start, CCW. [S] Similar to above, but rotation is reversed.
M05 Spindle stop.
M06 Tool Change. The M06 in conjunction with “T” word, is used to call up the
required tool on an automatic indexing turret machine, and to activate its tool
offsets.
M08 Coolant on.
M09 Coolant off.
M10 Chuck Open
M11 Chuck Close
M13 Spindle Forward, Coolant ON
M14 Spindle Reverse, Coolant ON
M19 Spindle orientation.

29
M25 Quill (Tailstock) Extend
M26 Quill (Tailstock) Retract
M30 Program stops and rewind. To program start
M38 Door Open
M97 Local subroutine call. [N] Causes the program to skip to a subprogram contained
inside the current program at line number N.
M98 Subprogram call [P, L] the program will call another program number, specified
by the P word, and execute it L times.
M99 Subprogram return. Contained at the end of the subprogram (or subroutine) will
return the control to the main program.
Note: only one M Code can be used per line and will be executed after all other
operations specified in the line.

RESULT:
Thus various CNC Turning codes and addresses were studied.

30
Write a manual part program for simple Turning and Facing operation for component
shown in [Link].T01

[Link].T01

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1001 [Link]
Tool Spindle
Tool Feed,
[Link] Operation Tool type Tool dia., mm Station offset No. speed, mm/min
No. rpm
Simple
1 SDJCR121H11 DCMT11T304 1 1 1200 45
Facing

31
 PLAIN TURNING AND FACING

[Link]: L01

DATE:

AIM:
To write a manual part program for simple turning and facing operation for
component shown in [Link].T01

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 70mm, Diameter 22mm

PROGRAM:

O0001 G00 Z3
G21 G98 G00 X21.5
G28 U0 W0 G01 Z-30 F45
M06 T0101 G00 X23
M03 S1200 G00 Z3
G00 X23 Z3 G00 X21
G00 Z-0.5 G01 Z-30 F45
G01 X-1 F45 G00 X23
G00 Z3 G00 Z3
G00 X23 G00 X20.5
G00 Z-1 G01 Z-30 F45
G01 X-1 F45 G00 X23
G00 Z3 G00 Z3
G00 X23 G00 X20
G00 Z-1.5 G01 Z-30 F45
G01 X-1 F45 G00 X23
G00 Z3 G28 U0 W0
G00 X23 M05
G00 Z-2 M30
G01 X-1 F45

RESULT:

Thus the manual part program was written to the given dimensions and
executed in CNC Lathe.

32
 Write a manual part program for Step Turning operation with G90 cycle for
component shown in [Link].T02

[Link].T02

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1002 [Link]
Tool Spindle
Tool Feed,
[Link] Operation Tool type Tool dia., mm Station offset No. speed, mm/min
No. rpm
Step
1 SDJCR121H11 DCMT11T304 1 1 1200 30
Turning

Cutting Cycle
G90 X(U) Z(W) F(*f)
X Diameter to which the movement is being made.
U The incremental distance from the current tool position to the required final
Diameter Z The Z Axis Co-ordinate to which the movement is being made.
W The incremental distance from the current tool position to the required Z axis Position
fFeed rate

33
 STEP TURNING

[Link]: L02

DATE:

AIM:
To write a manual part program for step turning operation with G90 cycle for
component shown in [Link].T02

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 70mm, Diameter 22mm

PROGRAM:

O0001
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G90 X22 Z-30 F30
X21
X20
X19
X18
X17
X16
X15
X14
G00 X14 Z1
G90 X14 Z-15 F30
X13
X12
X11
X10
G28 U0 W0
M05
M30

RESULT:

Thus the manual part program was written to the given dimensions and
executed in CNC Lathe.

34
 Write a manual part program for Taper Turning operation for component shown
in [Link].T03

[Link].T03

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1003 [Link]
Tool Spindle
Tool Feed,
[Link] Operation Tool type Tool dia., mm Station offset No. speed, mm/min
No. rpm
Taper
1 SDJCR121H11 DCMT11T302 3 3 1000 30
Turning

Cutting Cycle
G90 X(U) Z(W) R F
X Diameter to which the movement is being made.
U The incremental distance from the current tool position to the required final
Diameter Z The Z Axis Co-ordinate to which the movement is being made.
W The incremental distance from the current tool position to the required Z axis Position R The
difference in incremental of the cut start radius value and the cut finish radius value.
fFeed rate

35
 TAPER TURNING

[Link]:L03

DATE:

AIM:
To write a manual part program for taper turning operation for component shown
in [Link].T03

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 70mm, Diameter 22mm

PROGRAM:

O0002
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G90 X22 Z-30 R0 F30
X22 R-0.5
X22 R-1
X22 R-1.5
X22 R-2
X22 R-2.5
X22 R-3
X22 R-3.5
X22 R-4
X22 R-4.5
X22 R-5
X22 R-5.5
G28 U0 W0
M05
M30

RESULT:

Thus the manual part program was written to the given dimensions and
executed in CNC lathe.

36
 Write a manual part program for Multiple Threading operations for component
shown in [Link].T06

[Link].T06

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1006 [Link]
Tool Spindle
Tool offset Feed,
[Link] Operation Tool type Tool dia., mm Station speed,
No. mm/min
No. rpm
Multiple
1 Rough SDJCR121H11 DCMT11T304 1 1 1200 35
turning
2 Finishing SDJCR121H11 DCMT11T302 2 2 1450 25
3 Grooving HSS 3mm width 5 5 750 15

MULTIPLE THREADING CYCLE

G76 P(m) (r)(a) U(*u2) W(*w2) F(*f) S(*s) T(*t) Q(*q1) R(*r1)
G76 X(*x) Z(*z) P(*p2) Q(*q2) F(*f)
Where
m- Repetitive depth of cut in z axis count in finishing (1 to 99)
r = Pull out angle Relief Amount Starting
a= Angle of tool Line Number Ending tip
*X = Minor Line Number diameter (core diameter)
*z = End
*p2 = Height of
the amount and direction of the finishing allowance left in the X Axisposition of thread
thread as a radius value
x 1000, value in
the amount and direction of the finishing allowance left in the Z Axismicrons e.g. 1.02mm
becomes p1020 Feed Rate
*q2 = depth of spindle speed the first cut as a radius value x 1000 , value is microns. E.g. 0.25
mm becomes tool number Q250 *f = Lead or pitch of thread. E.g. lead 1.5 = F1.5
*q1 = Min. cutting depth
*r1 = Finishing allowance

37
 THREADING

[Link]:L04

DATE:

AIM:
To write a manual part program for multiple threading operation for component
shown in [Link].T06

MATERIAL REQUIRED:

Material : Aluminium
Size: : Length 70mm, Diameter 22mm

PROGRAM:

O0006
G21 G98
G28 U0 W0
M06 T0404
M03 S600
G00 X22.5 Z2
G76 P031560 Q050 R0.02
G76 X20.162 Z-20 P920 Q100 F1.5
G28 U0 W0
M05
M30

RESULT

Thus the manual part program was written to the given dimensions and
executed in CNC lathe.

38
 Write a manual part program for External Grooving operation for component
shown in [Link].T05

[Link].T05

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1005 [Link]
Tool Spindle
Tool Feed,
[Link] Operation Tool type Tool dia., mm Station offset No. speed, mm/min
No. rpm
Multiple
1 Rough SDJCR121H11 DCMT11T304 1 1 1200 35
turning
2 Finishing SDJCR121H11 DCMT11T302 2 2 1450 25
3 Grooving HSS 3mm width 5 5 750 15

GROOVING CYCLE

G75 R (*r1)
G75 X(u) Z(w) P(*p) Q(*q) F (*f)
Where, r1-Return Amount w-Total Depth along Z Axis ( Incremental)
X-Total Depth along X Axis ( Absolute) p-Peck Increment in X Axis in microns
u-Total Depth along X Axis ( Incremental) q -Stepping distance in Z Axis in microns
z-Total Depth along Z Axis ( Absolute) f -Feed Rate in mm

39
 GROOVING

[Link]:L05

DATE:

AIM:
To write a manual part program for external grooving operation for component
shown in [Link].T05

MATERIAL REQUIRED:
Material : Aluminium
Size : Length 70mm, Diameter 22mm

PROGRAM:
O0005
G21 G98
G28 U0 W0
M06 T03
M03 S1200
G00 X22 Z2
G71 U0.5 R1
G71 P10 Q20 U0.1 W0.1 F45
N10 G01 X8 Z0
G01 X10 Z-3
G01 Z-16
G01 X13
G01 X15 Z-19
G01 Z-24
G03 X20 Z-29 R5
G01 Z-36
N20 G01 X22 Z-39
M03 S1600
G70 P10 Q20 F30
G28 U0 W0
M06 T0707
M03 S600
G00 X10.5 Z-8
G75 R1
G75 X7 Z-10 P100 Q1000 F40
G28 U0 W0
M05
M30

RESULT
Thus the manual part program was written to the given dimensions and
executed in CNC lathe.

40
 Write a manual part program for Multiple Turning operation for component
shown in [Link].T04

[Link].T04

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 22x60 MATERIAL: Aluminium
PROGRAM NO:1004 [Link]
Tool Spindle
Tool Feed,
[Link] Operation Tool type Tool dia., mm Station offset No. speed, mm/min
No. rpm
Multiple
1 Rough SDJCR121H11 DCMT11T304 1 1 1200 35
turning
2 Finishing SDJCR121H11 DCMT11T302 2 2 1450 25

Multiple Turning Cycle

G72 W (*w1) R (*r)
G72 P(*p) Q(*q)
where
*w1
*r
*P
*q
*u2
*w2
*f
*s
*t
41
 CANNED CYCLE – MULTIPLE TURNING

[Link]: L06

DATE:

AIM:
To write a manual part program for multiple turning operation for component
shown in [Link].T04

MATERIAL REQUIRED:
Material : Aluminium
Size : Length 70mm, Diameter 22mm

PROGRAM:

O000
G21 G98
G28 U0 W0
M06 T0303
M03 S1200
G00 X22 Z2
G71 U0.5 R1
G71 P10 Q20 U0.1 W0.1 F45
N10 G00 X7 Z0
G01 X9 Z-2
G01 Z-10
G02 X14 Z-15 R5
G01 Z-23
G03 X19 Z-28 R5
G01 Z-36
N20 G01 X22 Z-39
M03 S1600 F30
G70 P10 Q20
G28 U0 W0
M05
M30

RESULT
Thus the manual part program was written to the given dimensions and executed
in CNC lathe.

42
 STUDY OF ISO CODES

CNC MILLING

AIM: To study various CNC Milling codes and addresses

PREPARATORY FUNCTIONS (G CODES)

A number following address G determines the meaning of the command for the
concerned block. G codes are divided into the following two types

Type Meaning
One-shot G code The G code is effective only in the block in
which it is specified
Modal G code The G code is effective until another G
code of the same group is specified

LIST OF G CODES
G00: Point to point positioning (Rapid traverse)
G01: Linear interpolation
G02: Circular interpolation clockwise
G03: Circular interpolation counter clockwise
G04: Dwell, Exact stop
G17: X Y Plane selection
G18: Z X plane selection
G19: Y Z Plane selection
G20: Input in inch
G21: Input in metric (mm)
G28: Return to reference point
G40: Cutter compensation cancel
G41: Cutter Compensation left
G42: Cutter Compensation right

43
G43: Tool length compensation positive direction
G44: Tool length compensation negative direction
G49: Tool length compensation cancel
G50: Scaling OFF
G51: Scaling ON
G54: Datum shift
G68: Rotation ON
G69: Rotation cancel
G73: High speed Peck drilling cycle
G74: L.H Tapping cycle
G76: Fine Boring
G80: Canned cycle cancel
G81: Continuous drilling cycle, Stop boring
G82: Continuous drilling cycle, Stop boring with dwell
G83: Peck drilling cycle
G84: R.H. Tapping cycle
G85: Boring cycle with feed retraction
G86: Boring cycle with rapid retraction
G87: Back boring cycle
G88: Boring cycle
G89: Boring cycle with dwell & feed retraction
G90: Absolute coordinates
G91: Incremental coordinates
G92: Set Datum
G94: Feed per minute
G95: Feed per revolution
G98: Return to initial point in a canned cycle
G99: Return to R point in a canned cycle
G170, G171: Circular pocketing
G172, G173: Rectangular pocketing

44
MISCELLANEOUS FUNCTIONS (M CODES)
When a three digit figure is specified following address M, a 3-digit BCD code signal and
a strobe signal are transmitted. These signals are used for ON/OFF control of a machine
function such as tool change, spindle rotation change, coolant ON/OFF. One M code can
be specified in one block. Selection of M codes for functions varies with the machine tool
builder.

LIST OF M CODES
M00: Program stop
M01: Optional (planned) stop
M02: End of program
M03: Spindle ON clockwise
M04: Spindle ON counter clockwise
M05: Spindle stop
M06: Tool change
M07: Coolant 2 ON
M08: Coolant 1 ON
M09: Coolant OFF
M10: Vice open
M11: Vice close
M12: Synchronization code
M13: Spindle clockwise and coolant ON
M14: Spindle counterclockwise and coolant ON
M19: Orientates Spindle
M20: ATC arm IN (Towards spindle)
M21: ATC arm out (Retracts from spindle)
M22: ATC arm down
M23: ATC arm up
M24: Activates ATC draw bar
M25: Releases draw bar
M30: Program stop & rewind

45
M32: Rotates ATC clockwise
M33: Rotates ATC counter clockwise
M38: Opens the door
M39: Closes the door
M62: Output 1 ON
M63: Output 2 ON
M64: Output 1 OFF
M65: Output 2 OFF
M66: Wait input 1 ON
M67: Wait input 2 ON
M70: X mirror ON
M71: Y mirror ON
M76: Wait input 1 OFF
M77: Wait input 2 OFF
M80: X mirror OFF
M81: Y mirror OFF
M98: Sub program Call
M99: Sub program Exit

COMMON MILLING G-CODES

(* Indicates default start-up codes)

*G00 Rapid linear move. [X, Y, Z] Moves the machine at the fastest rate possible to the
X, Y, Z location specified
G01 Linear feed move [X, Y, Z, F] moves the machine at the specified feed rate (F) to
the X, Y, Z location specified
G02 Circular interpolation; CW. [X, Y, Z, F, R (or I, J, K)] Moves the machine, in a
clockwise circular path to the X, Y, Z, location specified with radius R, or with a
center point defined relative to the start point in the X, Y, & Z axis by I, J, & K
respectively.
G03 Circular interpolation; CCW. [X, Y, Z, F, R (or I, J, K)] Same as G02, but
opposite direction of movement.

46
G28 Machine home. Causes the machine to return to its X0, Y0, and Z0 position at a
rapid rate.
*G40 Cutter compensation, CANCEL. [X, Y, F] Cancels the G41 or G42 Cutter
compensation listed below. Causes a feed move to X and/or Y at feed rate F (or at
modal feed F, if not specified). The distance of the move must be greater than the
radius of the tool.
G41 Cutter compensation, LEFT. [X, Y, D, F] Looking from the spindle toward the
part, G41 offsets the position of the tool left of the programmed tool path by the
value stored in the offsets register position called by the D word. Causes a feed
move from the current position to the compensated position specified by X, Y, at
feed F (or at modal feed F if not specified). The distance of this move must be
greater than the radius of the tool.
G42 Cutter compensation, RIGHT. Same as G41 above except that the tool is
compensated to the right of the programmed tool path.
NOTE: Cutter compensation may be accomplished at the machine, through the
tool path generated by the CAM program, or both.
G43 Tool Length compensation. [Z,H] Compensates for the length of the tool during
subsequent machine motion. Causes the spindle (Z axis) to move to designated Z
location offset by the value stored in the offsets register position called by the H
word. This compensation will remain in effect until cancelled during a tool
change by the G28 command.
*G53 Machine coordinate system (MCS). Cancels G-54 thru G59
G54-G59 Work coordinate offsets. Allows the user to establish one or more alternative
coordinate systems to correspond to individual work coordinate systems (WCS)
G80 Canned cycle cancel. This command cancels any active “canned cycle” commands
below.

47
CANNED CYCLE
A Canned cycle is a combination of machine movements that perform machining
operations like drilling, milling, boring and tapping. For example, the drilling cycle
consists of the following movements of the tool.
Fast approach to work
piece. Drill at feed rate
Rapid return to initial position.

These movements can be combined to form a cycle and give a code. When this code is
invoked, the machine performs all these operations. The use of canned cycle reduces
programming effort. This also saves the length of the program, thus saving the space
required to store the program.

G81 Drill cycle. [X, Y, Z, R, F] Will drill a hole to Z depth at a location defined by X,
Y, at feed rate F. R is the rapid plane, a Z-axis dimension “above the part” that
denotes the point where the machine switches from rapid rate to feed rate. Will
continue to drill the same hole profile at subsequent X, Y locations until cancelled
by G80.
G82 Spot drill / Counter bore cycle. [X, Y, Z, R, F, P] Similar to above, but adds the P
word to establish a dwell, or pause at the end of the Z-axis stroke.
G83 Deep Hole Peck drill cycle. [X, Y, Z, R, Q, (or I, J, K), R, F, P] Drills the hole in a
series of steps, or pecks, at either a constant peck depth Q, or at a decreasing peck
depth where I is the initial peck depth, J is the amount of decrease per peck and K
is the minimum peck depth. Other parameters are as for other drill cycles.
G84 Rigid tap cycle (right hand threads). [X, Y, Z, J, R, F] Precisely coordinates the
rotation of the spindle with the feed rate of the Z-axis for use with right hand taps.
The J word is a multiplying factor for the retract speed. Feed rate is computed by
multiplying rpm by thread pitch and is carried to 3 decimal places.
G85 Basic boring cycle. [X, Y, Z, R, F] Similar to the G81 drill cycle, except that the
tool is advanced into and out of the work at the feed rate speed, instead of a feed
in and rapid out of the G81.

48
*G90 Absolute Programming Mode. All X, Y, Z coordinates determined from a single
origin.
G91 Incremental Programming Mode Next X, Y, Z, coordinates are determined from
current location
G98 Canned cycle initial point return. Traverses from hole to hole at the initial point Z
height, typically 1.0 inch.
G99 Canned cycle rapid (R) plane return. Traverses from hole to at the rapid plane Z
height, typically 0.1 inch.

COMMON MILL M-CODES

M00 Program stops. Stops the machine, requiring the operator to restart the program to
continue.
M01 Optional stop. Stops the machine as above only when the optional stop button has
been pressed prior to this command in the program.
M03 Spindle start, CW. [S] Starts the spindle in a clockwise direction, at the RPM
specified by the S word accompanying the code.
M04 Spindle start, CCW. [S] Similar to above, but rotation is reversed.
M05 Spindle stops.
M06 Tool change. [T] Executes a tool change to the tool specified with the T word.
Automatically stops the spindle, returns the Z-axis to machine zero, and turns off
the coolant. On machines with automatic tool changers, the tools will be swapped.
On the Tool room machines, an alarm light signals the operator to switch tools
manually.
M08 Coolant on.
M09 Coolant off.
M19 Spindle orientation.
M30 Program stop and rewind. to program start
M97 Local subroutine call. [N] Causes the program to skip to a subprogram contained
inside the current program at line number N.

49
M98 Subprogram call [P, L] The program will call another program number, specified
by the P word, and execute it L times.
Sub Program
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 tell another subprogram. When the
main program call a subprogram, it is regarded as a one-loop subprogram call.
M99 Subprogram returns. Contained at the end of the subprogram (or subroutine) will
return the control to the main program.
Note: only one M Code can be used per line and will be executed after all other
operations specified in the line.

RESULT:
Thus various CNC Milling codes and addresses were studied.

50
 Write a manual part program for Profile Milling operation for the component
shown in [Link].4. Profile depth=1mm

[Link].4

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 100x100x10 MATERIAL: Aluminium
PROGRAM NO:1004 [Link]
Tool Tool
Spindle Feed,
[Link] Operation Tool type Tool dia., mm Station length
No. offset No. speed, rpm mm/min
1 Contouring Slot cutter 5 1 1 1500 30-50

51
 PROFILE MILLING

[Link]: M01

DATE:

AIM:
To write a manual part program for contouring operation for the component
shown in the DWG. NO.4

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 100mm, Width 100mm, Thickness 10mm

PROGRAM:

O0004
G21 G94
G91 G28 X0 Y0 Z0
M06 T01
M03 S1500
G90 G00 X50 Y70 Z5
G01 Z-1 F30
G01 X70
G01 Y50
G01 X50
G01 Y70
G03 X30 Y50 R20
G01 X30 Y10
G02 X20 Y20 R10
G02 X10 Y30 R10
G01 X50
G03 X70 Y50 R20
G00 Z5
G91 G28 X0 Y0 Z0
M05
M30

RESULT:

Thus the manual part program was written to the given dimensions and executed in
CNC milling.

52
 Write a manual part program for Mirroring operation for the component shown
in [Link].7. Profile depth=1mm

[Link].7

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 100x100x10 MATERIAL: Aluminium
PROGRAM NO:1007 [Link]
Tool Tool
Spindle Feed,
[Link] Operation Tool type Tool dia., mm Station length
No. offset No. speed, rpm mm/min
1 Contouring Slot cutter 5 1 1 1500 30-50

53
 MIRRORING

[Link]: M04

DATE:

AIM:
To write the manual part program for Mirroring Operation for the component
shown in [Link].7

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 100mm, Width 100mm, Thickness 10mm

PROGRAM:
O0007
G21 G94
G91 G28 X0 Y0 Z0
M06 T01
M03 S1200
G90 G00 X0 Y0 Z5
M98 P001 3535
M70
M98 P001 3535
M71
M98 P001 3535
M80
M98 P001 3535
M81
G91 G28 X0 Y0 Z0
M05
M30
:3535
G00 X5 Y15
G01 Z-1 F30
G01 X15
G01 Y5
G01 X5
G01 Y15
G02 X15 Y25 R10
G01 X35
G03 X30 Y30 R5
G03 X25 Y35 R5
G01 Y15
G02 X15 Y5 R10
G00 Z5
M99

RESULT:
Thus the manual part program was written to the given dimensions and executed
in CNC milling

54
 Write the manual part program for Scaling for the component shown in
[Link].6. Profile depth: 3mm. Depth of cut for each pass=1mm.

[Link].6

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 100x100x10 MATERIAL: Aluminium
PROGRAM NO:1006 [Link]
Tool Tool
Spindle Feed,
[Link] Operation Tool type Tool dia., mm Station length
No. offset No. speed, rpm mm/min
1 Contouring Slot cutter 5 1 1 1500 30-50

55
 SCALING

[Link]: M03

DATE:

AIM:
To write the manual part program for contouring operation through subroutine for
the component shown in [Link].6

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 100mm, Width 100mm, Thickness 10mm

PROGRAM:
O0006
G21 G94
G91 G28 X0 Y0 Z0
M06 T01
M03 S1500
G90 G00 X25 Y15 Z5
G01 Z0 F50
M98 P003 3242
G90 G00 Z5
G91 G28 X0 Y0 Z0
M05
M30
:3242
G91 G01 Z-1
G90 G01 X40 Y15
G02 X60 Y15 R10 F30
G01 X75 Y15
G02 X85 Y25 R10 F30
G01 X 85 Y40
G02 X85 Y60 R10
G01 X85 Y75
G02 X75 Y85 R10
G01 X60 Y85
G02 X40 Y85 R10
G01 X25 Y85
G02 X15 Y75 R10
G01 X15 Y60
G02 X15 Y40 R10
G01 X15 Y25
G02 X25 Y15 R10
M99

RESULT:
Thus the manual part program was written to the given dimensions and
executed in CNC milling.

56
 Write a manual part program for machining the component through Canned
Cycle for the component shown in the DWG. NO.9

[Link].9

PLANNING AND OPERATIONS SHEET

BILLET SIZE: 100x100x10 MATERIAL: Aluminium
PROGRAM NO:1009 [Link]
Tool Tool
Spindle Feed,
[Link] Operation Tool type Tool dia., mm Station length
No. offset No. speed, rpm mm/min
1 Drilling Slot drill 6 1 1 1500 35
2 Drilling Slot drill 10 2 2 1500 35

57
 DRILLING IN P.C.D (CANNED CYCLE)

[Link]:M04

DATE:

AIM:
To write a manual part program for machining the component through canned
cycle for the component shown in the DWG. NO.9

MATERIAL REQUIRED:

Material : Aluminium
Size : Length 100mm, Width 100mm, Thickness 10mm

PROGRAM:
O0009
G21 G94
G91 G28 X0 Y0 Z0
M06 T11
M03 S1500
G90 G00 X0 Y35 Z5
G98 G81 X0 Y35 Z-6 R2 F35
M98 P001 2525
G91 G28 X0 Y0 Z0
M05
M06 T01
M03 S1500
G90 G00 X0 Y35 Z5
G98 G81 X0 Y35 Z-3 R2 F35
M98 P001 2525
G91 G28 X0 Y0 Z0
M05
M30
:2525
X24.74 Y24.74
X35 Y0
X24.74 Y-24.74
X0 Y-35
X-24.74 Y-24.74
X-35 Y0
X-24.74 Y24.74
G00 Z10
G80
M99

RESULT:
Thus the manual part program was written to the given dimensions and
executed in CNC milling

58
 5. STUDY OF SENSORS AND TRANSDUCERS

1. Sensor

It is defined as an element which produces signal relating to the quantity being measured. According
to the Instrument Society of America, sensor can be defined as “ A device which provides a usable
output in response to a specified measurand. ” Here, the output is usually an ‘electrical quantity' and
measurand is a ‘physical quantity, property or condition which is to be measured'. Thus in the case of,
say, a variable inductance displacement element, the quantity being measured is displacement and the
sensor transforms an input of displacement into a change in inductance.

2. Transducer

It is defined as an element when subjected to some physical change experiences a related change or an
element which converts a specified measurand into a usable outputby using a transduction principle.

It can also be defined as a device that converts a signal from one form of energy to another form.

A wire of Constantan alloy (copper-nickel 55-45% alloy) can be called as a sensor because variation
in mechanical displacement (tension or compression) can be sensed as change in electric resistance.
This wire becomes a transducer with appropriate electrodes and input-output mechanism attached to
it. Thus we can say that ‘sensors are transducers

3. Sensor/transducers specifications

Transducers or measurement systemsare not perfect systems. Mechatronics design engineer must
know the capability and shortcoming of a transducer or measurement system to properly assess its
performance. These are a number of performance related parameters of a transducer or measurement
system. These parameters are called as sensor specifications.

Sensor specifications inform the user about deviations from the ideal behavior of the sensors.
Following are the various specifications of a sensor/transducer system.

3.1 Range

The range of a sensor indicates the limits between which the input can vary. Thus, for example, a
thermocouple for the measurement of temperature might have a range of 25-225°C.

3.2 Span

The span is difference between the maximum and minimum values of the input. Thus, the above-
mentioned thermocouple will have a span of 200°C.

3.3 Error

Error is the difference between the result of the measurement and the true value of the quantity being
measured. A sensor might give a displacement reading of 29.8 mm, when the actual displacement had
been 30 mm, then the error is - 0.2 mm.

59
3.4 Accuracy

The accuracy defines the closeness of the agreement between the actual measurement result and a true
value of the measurand. It is often expressed as a percentage of the full range output or full–scale
deflection. A piezoelectric transducer used to evaluate dynamic pressure phenomena associated with
explosions, pulsations, or dynamic pressure conditions in motors, rocket engines, compressors, and
other pressurized devices is capable to detect pressures between 0.1 and 10,000 psig (0.7 KPa to 70
MPa). If it is specified with the accuracy of about±1% full scale, then the reading given can be
expected to be within ± 0.7 MPa.

3.5 Sensitivity

Sensitivity of a sensor is defined as the ratio of change in output value of a sensor to the per unit
change in input value that causes the output [Link] example, a general purpose thermocouple
may have a sensitivity of 41 µV/°C.

3.6 Nonlinearity

Figure 2.1.1 Non-linearity error

The nonlinearity indicates the maximum deviation of the actual measured curve of a sensor from the
ideal curve. Figure 2.1.1 shows a somewhat exaggerated relationship between the ideal, or least
squares fit, line and the actual measured or calibration line. Linearity is often specified in terms of
percentage of nonlinearity, which is defined as:

Nonlinearity (%) = Maximum deviation in input ⁄ Maximum full scale input

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The static nonlinearity defined by Equation 2.1.1 is dependent upon environmental factors, including
temperature, vibration, acoustic noise level, and humidity. Therefore it is important to know under
what conditions the specification is valid.

3.7 Hysteresis

Figure 2.1.2 Hysteresis error curve

The hysteresis is an error of a sensor, which is defined as the maximum difference in output at any
measurement value within the sensor's specified range when approaching the point first with
increasing and then with decreasing the input parameter. Figure 2.1.2 shows the hysteresis error might
have occurred during measurement of temperature using a thermocouple. The hysteresis error value is
normally specified as a positive or negative percentage of the specified input range.

3.8 Resolution

Resolution is the smallest detectable incremental change of input parameter that can be detected in the
output signal. Resolution can be expressed either as a proportion of the full-scale reading or in
absolute [Link] example, if a LVDT sensor measures a displacement up to 20 mm and it provides
an output as a number between 1 and 100 then the resolution of the sensor device is 0.2 mm.

3.9 Stability

Stability is the ability of a sensor device to give same output when used to measure a constant input
over a period of time. The term ‘drift’ is used to indicate the change in output that occurs over a
period of time. It is expressed as the percentage of full range output.

3.10 Dead band/time

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The dead band or dead space of a transducer is the range of input values for which there is no output.
The dead time of a sensor device is the time duration from the application of an input until the output
begins to respond or change.

3.11 Repeatability

It specifies the ability of a sensor to give same output for repeated applications of same input value. It
is usually expressed as a percentage of the full range output:

Repeatability = (maximum – minimum values given) X 100/full range

3.12 Response time

Response time describes the speed of change in the output on a step-wise change of the measurand. It
is always specified with an indication of input step and the output range for which the response time is
defined. 4. Classification of sensors

Sensors can be classified into various groups according to the factors such as measurand, application
fields, conversion principle, energy domain of the measurand and thermodynamic considerations.
These general classifications of sensors are well described in the references [2, 3].

Detail classification of sensors in view of their applications in manufacturing is as follows.

A. Displacement, position and proximity sensors

o Potentiometer
o Strain-gauged element
o Capacitive element
o Differential transformers
o Eddy current proximity sensors
o Inductive proximity switch
o Optical encoders
o Pneumatic sensors
o Proximity switches (magnetic)
o Hall effect sensors
B. Velocity and motion
o Incremental encoder
o Tachogenerator
o Pyroelectric sensors
C. Force
o Strain gauge load cell
D. Fluid pressure
o Diaphragm pressure gauge
o Capsules, bellows, pressure tubes
o Piezoelectric sensors
o Tactile sensor
E. Liquid flow
o Orifice plate
o Turbine meter
F. Liquid level
o Floats

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 oDifferential pressure
G. Temperature
o Bimetallic strips
o Resistance temperature detectors
o Thermistors
o Thermo-diodes and transistors
o Thermocouples
o Light sensors
o Photo diodes
o Photo resistors
o Photo transistor

Principle of operation of these transducers and their applications in manufacturing are presented in the
next lectures.

Displacement sensors

1. Potentiometer Sensors

Figure 2.2.1 Schematic of a potentiometer sensor for measurement of linear displacement

Figure 2.2.1 shows the construction of a rotary type potentiometer sensor employed to measure the
linear displacement. The potentiometer can be of linear or angular type. It works on the principle of
conversion of mechanical displacement into an electrical signal. The sensor has a resistive element
and a sliding contact (wiper). The slider moves along this conductive body, acting as a movable
electric contact.

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The object of whose displacement is to be measured is connected to the slider by using

 a rotating shaft (for angular displacement)

 a moving rod (for linear displacement)
 a cable that is kept stretched during operation

The resistive element is a wire wound track or conductive plastic. The track comprises of large
number of closely packed turns of a resistive wire. Conductive plastic is made up of plastic resin
embedded with the carbon powder. Wire wound track has a resolution of the order of ± 0.01 % while
the conductive plastic may have the resolution of about 0.1 µm.

During the sensing operation, a voltage VS is applied across the resistive element. A voltage divider
circuit is formed when slider comes into contact with the wire. The output voltage (VA) is measured as
shown in the figure 2.2.2. The output voltage is proportional to the displacement of the slider over the
wire. Then the output parameter displacement is calibrated against the output voltage VA.

2. Strain Gauges

The strain in an element is a ratio of change in length in the direction of applied load to the original
length of an element. The strain changes the resistance R of the element. Therefore, we can say,

(2.2.5)

where G is the constant of proportionality and is called as gauge factor. In general, the value of G is
consideredin between 2 to 4 and the resistances are taken of the order of 100 Ω.

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Figure 2.2.3 A pattern of resistive foils

Figure 2.2.4 Wheatstone's bridge

Resistance strain gauge follows the principle of change in resistance as per the equation 2.2.5. It
comprises of a pattern of resistive foil arranged as shown in Figure 2.2.3. These foils are made of
Constantan alloy (copper-nickel 55-45% alloy) and are bonded to a backing material plastic
(ployimide), epoxy or glass fiber reinforced epoxy. The strain gauges are secured to the workpiece by
using epoxy or Cyanoacrylate cement Eastman 910 SL. As the workpiece undergoes change in its
shape due to external loading, the resistance of strain gauge element changes. This change in
resistance can be detected by a using a Wheatstone’s resistance bridge as shown in Figure [Link] the
balanced bridge we can have a relation,

(2.2.6)

where Rx is resistance of strain gauge element, R2 is balancing/adjustable resistor, R1 and R3 are

known constant value resistors. The measured deformation or displacement by the stain gauge is
calibrated against change in resistance of adjustable resistor R2 which makes the voltage across nodes
A and B equal to zero.

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Applications of strain gauges

Strain gauges are widely used in experimental stress analysis and diagnosis on machines and failure
analysis. They are basically used for multi-axial stress fatigue testing, proof testing, residual stress and
vibration measurement, torque measurement, bending and deflection measurement, compression and
tension measurement and strain measurement.

Strain gauges are primarily used as sensors for machine tools and safety in automotives. In particular,
they are employed for force measurement in machine tools, hydraulic or pneumatic press and as
impact sensors in aerospace vehicles.

3. Capacitive element based sensor

Capacitive sensor is of non-contact type sensor and is primarily used to measure the linear
displacements from few millimeters to hundreds of millimeters. It comprises of three plates, with the
upper pair forming one capacitor and the lower pair another. The linear displacement might take in
two forms:

(a) one of the plates is moved by the displacement so that the plate separation changes

(b) area of overlap changes due to the displacement.

Figure 2.2.5 shows the schematic of three-plate capacitive element sensor and displacement
measurement of a mechanical element connected to the plate 2.

4. Linear variable differential transformer (LVDT)

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Figure 2.2.6 Construction of LVDT sensor

Linear variable differential transformer (LVDT) is a primary transducer used for measurement of
linear displacement with an input range of about ± 2 to ± 400 mm in general. It has non-linearity error
± 0.25% of full range. Figure 2.2.6 shows the construction of a LVDT sensor. It has three coils
symmetrically spaced along an insulated tube. The central coil is primary coil and the other two are
secondary coils. Secondary coils are connected in series in such a way that their outputs oppose each
other. A magnetic core attached to the element of which displacement is to be monitored is placed
inside the insulated tube.

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5. Bimetallic strips

Figure 2.5.1 Construction and working of Bi-metallic strip

Bimetallic strips are used as thermal switch in controlling the temperature or heat in a manufacturing
process or system. It contains two different metal strips bonded together. The metals have different
coefficients of expansion. On heating the strips bend into curved strips with the metal with higher
coefficient of expansion on the outside of the curve. Figure 2.5.1 shows a typical arrangement of a
bimetallic strip used with a setting-up magnet. As the strips bend, the soft iron comes in closer
proximity of the small magnet and further touches. Then the electric circuit completes and generates
an alarm. In this way bimetallic strips help to protect the desired application from heating above the
pre-set value of temperature.

[Link]

Thermocouple works on the fact that when a junction of dissimilar metals heated, it produces an
electric potential related to temperature. As per Thomas Seebeck (1821), when two wires composed of
dissimilar metals are joined at both ends and one of the ends is heated, then there is a continuous
current which flows in the thermoelectric circuit. Figure 2.5.5 shows the schematic of thermocouple
circuit. The net open circuit voltage (the Seebeck voltage) is a function of junction temperature and
composition of two metals. It is given by,

ΔVAB = αΔT (2.5.2)

Where α, the Seebeck coefficient, is the constant ofproportionality.

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Figure 2.5.5 Schematic of thermocouple circuit

Generally, Chromel(90% nickel and 10% chromium)–Alumel(95% nickel, 2% manganese, 2%

aluminium and 1% silicon) are used in the manufacture of a thermocouple. Table 2.5.1 shows the
various other materials, their combinations and application temperature ranges.

Tachogenerator

Figure 2.4.1 Principle of working of Techogenerator

Tachogenerator works on the principle of variable reluctance. It consists of an assembly of a toothed

wheel and a magnetic circuit as shown in figure 2.4.1. Toothed wheel is mounted on the shaft or the
element of which angular motion is to be measured. Magnetic circuit comprising of a coil wound on a
ferromagnetic material core. As the wheel rotates, the air gap between wheel tooth and magnetic core
changes which results in cyclic change in flux linked with the coil. The alternating emf generated is
the measure of angular motion. A pulse shaping signal conditioner is used to transform the output into
a number of pulses which can be counted by a counter.

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Figure 2.4.2 Construction and working of AC generator

An alternating current (AC) generator can also be used as a techognerator. It comprises of rotor coil
which rotates with the shaft. Figure 2.4.2 shows the schematic of AC generator. The rotor rotates in
the magnetic field produced by a stationary permanent magnet or electromagnet. During this process,
an alternating emf is produced which is the measure of the angular velocity of the rotor. In general,
these sensors exhibit nonlinearity error of about ± 0.15% and are employed for the rotationsup to
about 10000 rev/min.

Strain Gauge as force Sensor

Figure 2.4.5 Strain gauge based Load cell

Strain gauge based sensors work on the principle of change in electrical resistance. When, a
mechanical element subjects to a tension or a compression the electric resistance of the material
changes. This is used to measure the force acted upon the element. The details regarding the
construction of strain gauge transducer are already presented in Lecture 2 of Module 2.

Figure 2.4.5 shows a strain gauge load cell. It comprises of cylindrical tube to which strain gauges are
attached. A load applied on the top collar of the cylinder compress the strain gauge element which

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changes its electrical resistance. Generally strain gauges are used to measure forces up to 10 MN. The
non-linearity and repeatability errorsof this transducer are ±0.03% and ±0.02% respectively.

4. Fluid pressure

Chemical, petroleum, power industry often need to monitor fluid pressure. Various types of
instruments such as diaphragms, capsules, and bellows are used to monitor the fluid pressure.
Specially designed strain gauges doped in diaphragms are generally used to measure the inlet
manifold pressure in applications such as automobiles. A typical arrangement of strain gauges on a
diaphragm is shown in figure 2.4.6. Application of pressurized fluid displaces the diaphragm. This
displacement is measured by the stain gauges in terms of radial and/or lateral strains. These strain
gauges are connected to form the arms of a Wheatstone bridge.

Figure 2.4.6 A diaphragm

Figure 2.4.7 Schematic of Capsule and Bellow

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Figure 2.4.8 Bellow with a LVDT

Capsule is formed by combining two corrugated diaphragms. It has enhanced sensitivity in

comparison with that of diaphragms. Figure 2.4.7 shows a schematic of a Capsule and a Bellow. A
stack of capsules is called as ‘Bellows’. Bellows with a LVDT sensor measures the fluid pressure in
terms of change in resultant voltage across the secondary coils of LVDT. Figure 2.4.8 shows a typical
arrangement of the same.

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VIVA VOCE QUESTIONS & ANSWERS
1. Expand CATIAV5?
Computer Aided Three Dimensional Interactive Application.
2. What is the save extension of sketcher file?
CAT Part
3. Does CATIA V5 work on UNIX Platform?
Yes
4. Is it possible to increase the size of plane boundary representation & how?
Yes, go for Tools-Options- Infrastructure-Part structure-Display
5. Is It Possible to directly enter in to Sketcher Workbench?
No, it is not possible to enter in to sketcher workbench directly. We have to go for any workbench
&form there we can enter the sketcher workbench…
6. Which is the tool used to exit from sketcher workbench to part design Workbench?
Exit Sketcher
7. What is the use of construction elements?
Construction elements assist in sketching the required profile in sketcher.
8. What are the default units of LMT (Length, Mass and Time)
mm, Kg, Second.
9. What is SKETCH TOOLS in sketcher work bench & Explain the Importance of it?
SKETCH TOOLS in sketcher workbench are the commands, which find very use in creating sketches.
SKETCH TOOLS are namely geometric and dimensional constraints, construction elements/standard
elements and Grid option. They play very important role in sketching, whenever we want to constrain
a sketch we use these options and if we want to convert any element into a construction element once
again these options come into picture.
10. Is it possible to hide specification tree?
Yes, with help of F3 button, but the option in Tools command must be checked to allow this.
11. What is SHOW/HIDE option?
Show mode enables us to see all the components presently opened and in Hide mode we can hide the
desired elements from the view for time being.
12. What is the use of Cut Part by Sketch Plane?
This task shows how to make some edges visible. In other words, we are going to simplify the sketch
plane by hiding the portion of the material that is not needed for sketching.
13. How do you measure arc length?
We can measure arc length by using MEASURE ITEM command. Sometimes we need to customize
the option for arc length if it is not checked earlier using customization in MEASURE ITEM
command.
14. What is the meaning of true dimension?
True dimension is the dimension desired after the machining. In other words, this is the value that
should be attained after the machining.
15. What do you mean by ISO-Constraints?
If all of the degrees of freedom of geometry have been takes up by a consistent combination of
dimensions & fixed geometry. That geometry is said to be ISO-CONSTRAINED. Geometry that still
has some degrees of freedom is said to be UNDER constrained.
16. Mention the color code of ISO-constrained, under, and over con strained elements?
The color code for these elements is Green, White and Magenta respectively.
17. What for the animated constraint command is used?
This task shows how constrained sketched element reacts when we decide to vary one constraint.

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18. How many dimensions are required to constrain the ellipse?
Three dimensions are required namely major axis, minor axis and the distance from the origin.
19. What are different conic sections?
Ellipse, Hyperbola and Parabola
20. What is RHO value for ellipse, Parabola and hyperbola?
Parabola has RHO values of 0.5, Ellipse has RHO value between 0 & 0.5 and Hyperbola has RHO
value b/w 0.5 &1.0.
21. What is NURBS?
Nurbs are the type of curves
22. How many types of Co-ordinate systems are there?
Three namely Cartesian, Polar and Spherical co-ordinate system.
23. What are project 3D silhouette edges?
Project 3D silhouette edges in sketcher will shows how to create silhouette edges to be used in as
geometry or reference elements.
24. What is use of sketch analysis?
To check whether the sketch is fully closed or not so that the sketch can be used or not so that the
sketch can be used for further operations in part design.
25. Where do we use axis?
Axis is used in creating shaft (revolved) feature
26. Can we redefine the sketches?
Yes.
27. Can axis be converted into line or vice versa?
We can convert line into axis but axis cannot convert into line.
28. How many axis can be created in a single sketch?
Only one axis can be created in a sketch, if more than one axis are drawn then only one of them, the
latest one, will be axis and others will be converted into reference elements.
29. How do we change, sketch’s reference plane?
Right click on the sketch whose reference plane is to be changed and select the change reference plane
and then select new reference.
30. What is the function of mirror command in sketch?
Mirror command in sketch will create a copy of the sketch about a reference plane.
31. If I donor want the relation b/w original and mirrored elements what should I do?
Explore and the relation b/w the original and mirror element doesn’t exit.
32. What is the use of isolate in sketcher workbench?
Isolated is used when 3D geometry is projected on to a sketch in order to be modified and used as part
of the sketch’s profile.
33. Can we select non-planer surf ace as sketch plane?
No, we cannot select a non-planar surface as sketch.
34. What are the different options available in quick trim command?
BREAK & RUBBER in removes part of the element, which is clicked. BREAK & RUBBER out
removes part of the element, which is not clicked. BREAK & KEEP keeps both parts of elements after
breaking.
35. What do CATIA P1, CATIA P2 AND CATIA P3 mean?
P1, P2 and P3 will indicate the different types of platforms of CATIA. Higher the number
sophisticated will be the software.

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36. What is kernel?
The kernel is the basic indispensable part of an operating system that allocates resources such as low-
level hardware interfaces & security.
38. What is the importance of sketch tools?
This tool bar only appears when you are in sketcher workbench. The four tools found in this tool bar
are toggle tools. When tool is highlighted the tool is on. This particular tool bar changes depending on
what other sketcher workbench tool is currently selected.
39 .How many degrees of freedom are there for points, lines, circles & ellipse in 2dimensions?
Degree of freedom for points & ellipse is 2 for circles it is 3 & for ellipse it is 5 in two dimensions.
40. What is the meaning of mean dimension?
Mean dimension is the dimension that should be mean of all the dimensions, which are tolerance.
41. How many types of environment are available to start CATIA?
1. From desktop (motif)
2. From console (dterm)

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