DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

LAB MANUAL

CAD / CAM LAB

IV B. TECH I SEMESTER

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

INSTITUTE VISION

Striving continuously for global recognition through academic excellence

in higher education for the betterment of society.

INSTITUTE MISSION

We will achieve this vision by:

Education

Providing high quality, engaging career-based education at all levels of

higher education at VCE with flexible pathways, engaging and rigorous curriculum
and contemporary delivery; while maintaining rigorous standards and ensuring that
all students are supported to meet those standards.

Research & engagement

Undertaking high quality and innovative research projects which results in

healthier, smarter and sustainable communities and connecting deeply with
industry and the community, in turn enhancing the quality of teaching and learning
at our best engineering college.

Technical competency

To produce technically competent and socially responsible engineers with

ethical values through an innovative teaching-learning process. To promote
research and entrepreneurship culture among faculty and students
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

DEPARTMENT VISION

To create VCE students technologically predominant and ethically well-

qualified engineers.

DEPARTMENT MISSION

Imparting quality education to VCE students and enhancing their skills to

make them globally competitive mechanical engineers.

Maintaining vital, state-of-the-art research facilities with a standard of the

best engineering college to provide students and faculty with opportunities to
create, interpret, apply and disseminate knowledge.
 DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES

PEO 1. Be able to employable as hardware & software professionals in reputed

industries.

PEO 2. Be able to analyze the problems by applying the principles of Mechanical

Engineering, mathematics, scientific investigation to design and implement

industry accepted solutions by using latest technologies.

PEO 3. Be able to work productively in supportive and leadership roles on

multidisciplinary teams with effective communication and team work skills by

considering high regard to legal and ethical responsibilities.

PEO 4. Be able to embrace lifelong learning to meet ever changing developments in

Mechanical Engineering.
 DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

PROGRAM OUTCOMES

The following program outcomes are expected to be found in the

graduate students on their completion of the 4-year program.

PO 1. Engineering Knowledge: An ability to apply knowledge of mathematics,

computing, science, electrical and electronics engineering.

PO 2. Problem Analysis: Identify, formulate, research literature, and analyze

complex engineering problems reaching substantiated conclusions using first
principles of mathematics, natural sciences, and engineering sciences.

PO 3. Design / Development of Solutions: Design solutions for complex

engineering problems and design system components or processes that meet the
specified needs with appropriate consideration for public health and safety, and
cultural, societal, and environmental considerations.

PO 4. Conduct Investigations of Complex Problems: Use research-based

knowledge and research methods including design of experiments, analysis and
interpretation of data, and synthesis of the information to provide valid
conclusions.

PO 5. Modern Tool Usage: Create, select, and apply appropriate techniques,

resources, and modern engineering and IT tools including prediction and modeling
to complex engineering activities with an understanding of the limitations.

PO 6. The Engineer and Society: Apply reasoning informed by the contextual

knowledge to assess societal, health, safety, legal, and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
 DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

PO 7. Environment and Sustainability: Understand the impact of the professional

engineering solutions in societal and environmental contexts, and demonstrate the
knowledge of, and need for sustainable development.

PO 8. Ethics: Apply ethical principles and commit to professional ethics and

responsibilities and norms of the engineering practice.

PO 9. Individual and Team Work: Function effectively as an individual, and as

a member or leader in diverse teams, and in multidisciplinary settings.

PO 10. Communication: Communicate effectively on complex engineering

activities with the engineering community and with the society at large, such as,
being able to comprehend and write effective reports and design documentation,
make effective presentations, and give and receive clear instructions.

PO 11. Project Management and Finance: Demonstrate knowledge and

understanding of the engineering and management principles and apply these to
one’s own work, as a member and leader in a team, to manage projects and in
multidisciplinary environments.

PO 12. Life-Long Learning: Recognize the need for, and have the preparation and
ability to engage in independent and life-long learning in the broadest context of
technological change
 DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

PROGRAM SPECIFIC OUTCOMES

PSO 1. Apply their understanding in the realm of Design, Production and thermal
fluid sciences to solve engineering difficulties utilizing sophisticated
technology.

PSO 2. Fruitfully apply the values of design, analysis and execution of mechanical
systems/processes which have been fed as a part of the curriculum.

PSO 3. Extend and implement new thoughts on product design and development with
the aids of modern CFD and CAD/CAM tools, while ensuring best manufacturing
practices.
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

COURSE OUTCOMES

After the completion of this course, the students should be able to

CO 1. Draw the part drawings which are utilized in real time applications
CO 2. Understand the different types of stress analysis, load calculations by using
ANSYS software
CO 3. Analyze 2D and 3D part drawings using AutoCAD, CREO software
packages
CO 4. Develop and understand the NC part program generation by using CADEM
packages
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

CONTENTS

Exp. No CONTENT Page. No.

1 List of Experiments 1–1

2 Introduction to Creo 3.0 2–6

3 2D Drawing using PTC Creo 3.0 Sketcher 7 - 10

4 3D Part Modeling Introduction 11 - 13

5 3D Part Modeling using PTC Creo 3.0 14 – 20

6 3D Part Assembly using PTC Creo 3.0 21 - 27

7 Introduction to Ansys 16.2 28 - 29

Structural Analysis of Beam using Ansys

8 30 - 33
16.2
Structural Analysis of Truss using Ansys
9 34 - 37
16.2

10 Thermal Analysis of a 3D Block 38 - 40

11 Introduction to CAM 41 - 41

12 Step Turning using CNC Lathe 42 – 45

13 Face Milling using CNC 45 - 50

DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

LIST OF EXPERIMENTS
SKETCH:
1. Generation of 2D drawings.
PART MODELING:
1. Generation of various 3D Models through protrusion, Revolve, shell, sweep .
Creation of various features
2. Feature based and Boolean based modelling surface and Assembly Modelling.
3. Design simple components.
DRAFTING:
1. Development of part drawings for various components in the form of orthographic
and isometric.
2. Representation of Dimensioning and tolerances scanning and plotting.
ANSYS:
1. Determination of deflection and stresses in 2D and 3D trusses and beams.
2. Deflections component and principal and Von Misses stress, plane strain and
Axisymmetric components
3. Determination of stresses in 3D and shell structures.
4. Estimation of natural frequencies and mode shapes Harmonic response of 2D beam.
5. Steady state heat transfer Analysis of plane and axisymmetric components.
CAM :
1. Development of process sheets for various components based on tooling machines.
2. Development of manufacturing and tool management systems.
3. Study of various post processors used in NC machines.
4. Development of NC code for free form and sculptured surfaces using CAM packages.
5. Machining of simple components on NC lathe and mill by transferring NC code/from a
CAM package.
6. Quality control and inspection.

1
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

INTRODUCTION
What is CAD/CAM?
CAD/CAM (computer-aided design and computer-aided manufacturing) refers to
computer software that is used to both design and manufacture products.
CAD is the use of computer technology for design and design documentation.
CAD/CAM applications are used to both design a product and program manufacturing processes,
specifically, CNC machining. CAM software uses the models and assemblies created in CAD
software to generate tool paths that drive the machines that turn the designs into physical parts.
CAD/CAM software is most often used for machining of prototypes and finished parts.

Why CAD/CAM?
Computer Aided Design and Computer Aided Manufacture is the way things are made
these days. Without this technology we wouldn’t have the range and quality of products
available or, at least, they wouldn’t be available at a price most of us can afford. Hand-building
and manual techniques still very much have their place and Design Education needs to treasure
and foster these skills so that future generations will have the hands-on‟ skills to understand the
man-made world and provide the next generation of engineers, designers and technicians.
All of these professionals will be using CAD/CAM techniques or CAD/CAM products in
their work, alongside practical hands-on skill. Design and Technology education has to reflect
modern practice so it is crucial that students have the opportunity to use real CAD/CAM tools in
their designing and making.

DESIGN PROCESS AND ROLE OF CAD:

1. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation

2
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

COMPUTER AIDED DESIGN (CAD):

PTC PARAMETIC CREO 3.0
Creo3.0,PTC's parametric, integrated 3D CAD/CAM/CAE solution, is used by
discrete manufacturers for mechanical engineering, design and manufacturing. Created by Dr.
Samuel P. Geisberg in the mid-1980s, Creo 3.0 was the industry's first successful parametric, 3D
CAD modeling system. The parametric modeling approach uses parameters, dimensions,
features, and relationships to capture intended product behavior and create a recipe which
enables design automation and the optimization of design and product development processes.
This powerful and rich design approach is used by companies whose product strategy is
family-based or platform-driven, where a prescriptive design strategy is critical to the success of
the design process by embedding engineering constraints and relationships to quickly optimize
the design, or where the resulting geometry may be complex or based upon equations. Creo3.0
provides a complete set of design, analysis and manufacturing capabilities on one, integral,
scalable platform. These capabilities include Solid Modeling, Surfacing, Rendering, Data
Interoperability, Routed Systems Design, Simulation, Tolerance Analysis, and NC and Tooling
Design. Companies use Creo 3.0 to create a complete 3D digital model of their products. The
models consist of 2D and 3D solid model data which can also be used downstream in finite
element analysis, rapid prototyping, tooling design, and CNC manufacturing.
All data is associative and interchangeable between the CAD, CAE and CAM modules
without conversion. A product and its entire bill of materials (BOM) can be modeled accurately
with fully associative engineering drawings, and revision control information. The associatively
in creeo3.0 enables users to make changes in the design at any time during the product
development process and automatically update downstream deliverables.
This capability enables concurrent engineering — design, analysis and manufacturing
engineers working in parallel — and streamlines product development processes.Creo3.0 is an
integral part of a broader product development system developed by PTC. It seamlessly connects
to PTC’s other solutions including Wind chill, Product View, MathCAD and Arbor text.

DIFFERENT MODULES IN CREO3.0 :

 SKETCH
 PART DESIGN
 ASSEMBLY
 DRAWING
 MANUFACTURING

3
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Advantages of PTC Creo3.0

1. It is much faster and more accurate. Once a design is completed. 2D and 3D views are
readily obtainable.
2. The ability to incorporate changes in the design process is possible.
3. It provides a very accurate representation of model specifying all other dimensions
hidden geometry etc.
4. It provides a greater flexibility for change. For example if we like to change the
dimensions of our model, all the related dimensions in design assembly, manufacturing
etc. will automatically change.
5. It provides clear 3D models, which are easy to visualize and understand.
6. Creo3.0 provides easy assembly of the individual parts or models created it also
decreases the time required for the assembly to a large extent.

Sketcher introduction
sketcher is an application that offers the easiest way for anyone too quickly sketch out
product design ideas and share them electro quickly with customers it lets you add colour
and other visual enchantments to transform fix sketcher into finished art work.
Sketcher commands:
Line:
it is the joining of two points are more than two points
There are two types of line command
Line chain:
it is a command which can create a chain of two points lines.
Line tangent:
it is a command which can create lines tangents to 2 greater than entities.
Rectangle:
There are four types of rectangle commands used to create rectangle in different ways.
Corner rectangle
Slant rectangle
Centre rectangle
Parallelogram
Circle:
There are four commands to form
a circle such as
Centre and point
Concentric
Three point

4
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Three tangent.
Arc:
It is a command used to form a arc we have five types of command for making arc.
Three point are tangent end.
Centre and ends.
Three tangent
Concentric
Conic.
Ellipse:
It is a command used to create ellipse by using a different command such as
Axis and ellipse
Centre and axis ellipse
Spline:
it is a command used to create a spline curve

Trimming:
it is a command used to remove the unwanted part it is done by 4 different types of
commands
Circular
Circular trim
Elliptical
Electrical trim
Chamfer:
it is a command to create a chamfer between two entities and create construction lines extension.
Chamfer Trim:
this is a command used to create a chamfer between two entities.
Global co-ordinate systems:
Datum: it is a command which are used to create
Central line
Point
Co-ordinate system
Editing:
It is a command used to simplify the required design with the following different commands.
Modify:
This is a command used to modify the values of dimensions, geometry of splice and text entities.
Mirror:
It is a command used to mirror the selected entities.

5
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Divide:
It is a command used to divide an entity at the point of selection.
Delete segment:
It is a command used to delete unwanted lines.
Corner:
It is a command to trim entities two other entities or geometry.
Other constraints are used in sketcher environment
 Vertical
 Horizontal
 Perpendicular
 Tangent
 Midpoint
 Coincident
 Symmetric
 Equal
 Parallel
 Dimensions
 Normal
 Perimeter
 Baseline
 References.
Generation of 2D drawings:

6
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 1
AIM:
To create a 2D view of the given diagram using PTC creo parametric 3.0 M030.
SOFTWARE REQUIRED:
PTC creo parametric 3.0 M030
Windows 8.1
HARDWARE REQUIREMENT:
2GB ram, 500 hard disk
PROCEDURE:
Create the horizontal axis and vertical Axis on the plane
Draw a circle as shown in the diagram with the specified dimensions use the circle straight lines
by using the line command at lost use the let command in the required parts.
delete unwanted lines for required shape or given object.

Result: The given 2D drawing is sketch by using PTC creo 3.0 M030.

7
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 2

AIM:
To create a 2D view of the given diagram using PTC creo parametric 3.0 M030.
SOFTWARE REQUIRED:
PTC creo parametric 3.0 M030
Windows 8.1
HARDWARE REQUIREMENT:
2GB ram,500 hard disk
PROCEDURE:
Create the horizontal axis and vertical Axis on the plane
Draw a circle as shown in the diagram with the specified dimensions use the circle straight lines
by using the line command at lost use the let command in the required parts.
Delete unwanted lines for required shape or given object.
Result: The given 2D drawing is sketch by using PTC creo 3.0 M030.

8
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 3

AIM:
To to create a 2D view of the given diagram using PTC creo parametric 3.0 M030.
SOFTWARE REQUIRED:
PTC creo parametric 3.0 M030
Windows 8.1
HARDWARE REQUIREMENT:
2GB ram, 500 hard disk
PROCEDURE:
Create the axis by using centerline command draw the constructional lines by using the
construction mode.
Use the required sketching command such as circle and Arcs and draw the diagram according to
the given specifications.
Delete unwanted lines for required shape or given object.
Result: The given 2D drawing is sketch by using PTC creo 3.0 M030.

9
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 4

AIM:
To to create a 2D view of the given diagram using PTC creo parametric 3.0 M030.
SOFTWARE REQUIRED:
PTC creo parametric 3.0 M030
Windows 8.1
HARDWARE REQUIREMENT:
2GB Ram, 500 Hard disk
PROCEDURE:
Create the axis by using centerline command draw the constructional lines by using the
construction mode.
Use the required sketching command such as circle and Arcs and draw the diagram according to
the given specifications. Delete unwanted lines for required shape or given object.
Result:
The given 2D drawing is sketch by using PTC creo 3.0 M030.

10
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

CREO 3.0 PART DESIGN INTERFACE:

PART MODELING:
Extrude:
Adding the material normal to the surface.(or) remove the material normal to the surface

Revolve:
Adding the material about the axis. (or) remove the material about the axis

11
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Sweep:
Adding or removing the material
A profile passing through the trajectory or

Editing Features in Part Modeling:

Round: Modify the sharp edge to curved edge

Chamfer: Modify the sharp edge to flat edge.

Shell: Removes a surface or surfaces from the solid then hollows out the inside of the solid,
leaving a shell of a specified wall thickness.

12
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Rib: Special type of protrusion to create a thin fin or web

Hole: Remove cylindrical portion from the basic part

Pattern:
Create instances of the selected feature by varying some specified dimensions
Direction:

Axis:

13
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 1

AIM:
To create the isometric model with help of given orthographic projections by using
software creo3.0.
SOFTWARE REQUIRED:
Windows8.1, creo3.0
COMMANDS USED:
 Sketch tools like centerline, line, rectangle, circle and delete segment.
 Extrude.
PROCEDURE:
PART MODELING:
Sketch --draw a rectangle 100mm*63mm
Extrude-given depth value 75mm.--OK.
As per the given dimensions to adding or removing the material.
To get required shape using only extrude command.
DRAWING:
New-drawing--browse--standard size (A4)-landscape Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given press tool assembly.
RESULT:
Thus the detail view of the given isometric model and then its respective views have been
drawn.
Detail view of the given isometic object:

14
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

15
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 2
AIM:
To create the isometric model with help of given orthographic projections by using software
creo3.0.
SOFTWARE REQUIRED:
Windows8.1, creo3.0
COMMANDS USED:
 Sketch tools like centerline, line, rectangle, circle and delete segment.
 Extrude
PROCEDURE:
PART MODELING:
Sketch --draw a rectangle 62mm*50mm
Extrude-given depth value--44mm--OK.
As per the given dimensions to adding or removing the material.
To get required shape using only extrude command.

DRAWING:
New-drawing--browse--standard size (A4)-landscape Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given press tool assembly.

RESULT:
Thus the detail view of the given isometric model and then its respective views have been drawn.

Detail view of the given isometric object:

16
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

17
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 3
AIM:
To create the master rod model with help of given orthographic projections by using
software creo3.0.
SOFTWARE REQUIRED:
Windows8.1, creo3.0
COMMANDS USED:
 Sketch tools like centerline, line, rectangle, circle and delete segment.
 Extrude, round and mirror.
PROCEDURE:
Part Modeling:

18
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

DRAWING:
New-drawing--browse--standard size (A4)-landscape Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given press tool assembly.
RESULT:
Thus the detail view of the given master rod model and then its respective views have
been drawn.
Detail view of the given isometric object:

19
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

20
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 4

AIM:
To draw the detail view of the Press Tool assembly and assemble the parts by using the
creo3.0 software and obtain its respective views.
SOFTWARE REQUIRED:
Windows8.1, creo3.0
COMMANDS USED:
Sketch, Extrude, Revolve, Pattern, Mate, Align, Hole, Chamfer etc.
PROCEDURE:
Part Modeling
Top plate:
Sketch-- >Extrude-
Bottom plate:
Sketch >Extrude
Guide Pillar:
Sketch >Extrude
Guide Bush:
Sketch >Extrude >
ASSEMBLY:
New>Assembly>Ok>mmns-asm-design>assembly
By using assembly constraints like align, mate, coincident, Distance etc., performed the
assembly for the given press tool assembly.
DRAWING
New>drawing>browse>standard size (A4)>landscape>Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given press tool assembly.
RESULT:
Thus the Detail View of the Press Tool assembly and then its respective views have been
drawn.
Detail view of the given assembly:

21
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

22
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 5

AIM:
To draw the detail view of the Wheel support assembly and assemble the parts by using
the creo3.0 software and obtain its respective views.
SOFTWARE REQUIRED:
Windows8.1, creo3.0
COMMANDS USED:
Sketch, Extrude, Revolve, Mate, Align, Hole, Chamfer etc.
PROCEDURE:
Part Modeling
Base:
Sketch >Extrude
Support:
Sketch >Extrude >
Wheel:
Sketch >Revolve >
Shoulder screw:
SketchExtrude
Bolt:
Sketch-- > Extrude
Nut:
SketchExtrude-Helical sweep  remove material
Bush:
Sketch >Extrude >Hole>Chamfer
Washer:
Sketch >Extrude >Hole
ASSEMBLY:
New>Assembly>Ok>mmns-asm-design>assembly
By using assembly constraints like align, mate, coincident, Distance etc., performed the
assembly for the given press tool assembly.
DRAWING:
New>drawing>brows>standard size (A4)>land scape>Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given Wheel support assembly.
RESULT:
Thus the Detail View of the Wheel support assembly and then its respective views have
been drawn.
23
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Detail view of the given assembly:

ASEEMBLY VIEW

24
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPLODE VIEW

25
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT: 6

AIM:
To draw the detail view of the Knuckle joint and assemble the parts by using the pro-e
software and obtain its respective views.
COMMANDS USED:
Sketch, Extrude, Revolve, Pattern, Mate, Align, Hole, Chamfer etc.
PROCEDURE:
PART MODELING
Fork:
Pin:
Collar:
Taper pin:
ASSEMBLY
New>Assembly>Ok>mmns-asm-design>assembly
By using assembly constraints like align, mate, coincident, Distance etc., performed the
assembly for the given Knuckle joint.
DRAWING
New>drawing>brows>standard size (A4)>landscape>Ok
In first angle projection, generated different views like front view, side view, top view and
isometric view and applied the dimensions to the given Knuckle joint.
RESULT:
Thus the Detail View of the Knuckle joint and then its respective views have been drawn.
Detail view of the given assembly:

26
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

27
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

ANSYS

INTRODUCTION:
ANSYS is general-purpose finite element analysis (FEA) software package. Finite
Element Analysis is a numerical method of deconstructing a complex system into very small
pieces (of user-designated size) called elements. The software implements equations that govern
the behaviour of these elements and solves them all; creating a comprehensive explanation of
how the system acts as a whole. These results then can be presented in tabulated or graphical
forms. This type of analysis is typically used for the design and optimization of a system far too
complex to analyze by hand. Systems that may fit into this category are too complex due to their
geometry, scale, or governing equations.
ANSYS is the standard FEA teaching tool within the Mechanical Engineering
Department at many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as
the Physics and Chemistry departments.
ANSYS provides a cost-effective way to explore the performance of products or
processes in a virtual environment. This type of product development is termed virtual
prototyping. With virtual prototyping techniques, users can iterate various scenarios to optimize
the product long before the manufacturing is started. This enables a reduction in the level of risk,
and in the cost of ineffective designs. The multifaceted nature of ANSYS also provides a means
to ensure that users are able to see the effect of a design on the whole behavior of the product, be
it electromagnetic, thermal, mechanical etc.
GENERIC STEPS TO SOLVING ANY PROBLEM IN ANSYS
Like solving any problem analytically, you need to define (1) your solution domain, (2)
the physical model, (3) boundary conditions and (4) the physical properties. You then solve the
problem and present the results. In numerical methods, the main difference is an extra step called
mesh generation.
This is the step that divides the complex model into small elements that become solvable
in an otherwise too complex situation. Below describes the processes in terminology slightly
more attune to the software.
Build Geometry
Construct a two or three dimensional representation of the object to be modeled and
tested using the work plane coordinate system within ANSYS.
Define Material Properties
Now that the part exists, define a library of the necessary materials that compose the
object (or project) being modeled. This includes thermal and mechanical properties.
Generate Mesh
At this point ANSYS understands the makeup of the part. Now define how the modeled system
should be broken down into finite pieces.
28
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Apply Loads
Once the system is fully designed, the last task is to burden the system with constraints,
such as physical loadings or boundary conditions.
Obtain Solution
This is actually a step, because ANSYS needs to understand within what state (steady
state, transient… etc.) the problem must be solved.
Present the Results
After the solution has been obtained, there are many ways to present ANSYS’ results,
choose from many options such as tables, graphs, and contour plots.
TYPES OF ANALYSIS
 Structural Analysis
 Thermal Analysis
 Modal Analysis
 Transient Analysis
 CFD

29
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Structural Analysis
EXPERIMENT 1
TWO DIMENSIONAL STATIC LINEAR ANALYSIS OF A CANTILEVER BEAM
AIM:
To determine the stresses acting on a cantilever beam with a point load of 500 N acting
at
one of its ends and perpendicular to the axis of the beam.
GIVEN DATA:
 Young’s modulus = 2e5
 Poisson’s ratio = 0.3
 Length of the beam = 15 m = 1500 mm
 Breadth of the beam = 100 mm
 Height of the beam = 100 mm
 Load=500N
SOFTWARE REQUIRED:
Ansys 16.2, Windows8.1,
PROCEDURE:
Pre processing
STEP 1: From the Main menu select preferences
Select structural and press OK.
STEP 2:
From the main menu select Pre-processor
Element type Add / edit/Delete Add BEAM3D infinite Apply Close
Material properties material models Structural Linear Elastic Isotropic
EX = 2e5; PRXY = 0.3.
STEP 3:
From the main menu select Pre-processor
Sections Beam Common Sections Select subtype as Rectangular section Enter B =
100, H = 100 Apply ok.
STEP 4: From the main menu select Pre-processor Modeling
Create the key points in the Workspace
Create Key points in active CS

X 0 1500

Y 0 0

30
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Click APPLY to all the points and for the last point click OK
Create LINES using the Key points
Create Lines Lines Straight Line Click on Key points to generate lines
Select Plot controls from menu bar Capture image file save as and save your file.

Figure: Model
STEP 4: Meshing the Geometry
From the main menu select Meshing
Meshing Size controls Manual size Lines All lines – Number of element
divisions = 25 .Click OK
Meshing MeshLines – pick all
SOLUTION PHASE: ASSIGNING LOADS AND SOLVING
STEP 5: From the ANSYS main menu open Solution
SolutionAnalysis typenew analysis – Static
STEP 6: Defining loads at the Key points
SolutionDefine LoadsApply Structural Displacement On key points
Left end – ALL DOF arrested

31
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Loads Define loadsApplyStructural force/moment On key Points

Right end – Apply a load of FY = -500 N
Select Plot controls from menu bar Capture image file save as and save your file.

Figure: Model with boundary conditions

STEP 7: Solving the system
Solution SolveCurrent LS
GENERAL POSTPROCESSING: VIEWING THE RESULTS
1. Deformation
Nodal solution
From the Utility menu select PLOT
PLOT Results Contour plot Nodal solution – DOF solution – Y component of
displacement – OK

32
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

RESULT:
DMX =0.331522mm
SMN =0.331092N/mm2
SMX=0.36788 N/mm2

33
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 2
2-D STATIC LINEAR ANALYSIS OF A TRUSS STRUCTURE

AIM:
To determine the nodal deflections, reaction forces, and stress of the indeterminate truss
System when it is subjected to a load of 2000 N.
SOFTWARE REQUIRED:
Ansys 16.2, windows 8.1
GIVEN DATA:
 Young’s modulus = 2e5
 Cross sectional area = 3250mm2
 Poisson’s ratio = 0.3
PROCEDURE:
Preprocessing
STEP 1: From the Main menu select preferences
Select structural and press OK
STEP 2: From the main menu select Preprocessor
Element type Add / edit/Delete Add Link – 2D spar 8ok close
Real constants . Add Geometric Properties Area = 3250
Material properties material models Structural Linear Elastic Isotropic
EX = 2e5; PRXY = 0.3
STEP 3: From the main menu select Pre-processor Modeling
Create the key points in the Workspace.
Pre-processor Modeling Create NodesIn active CS

34
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Click APPLY to all the points and for the last point click OK

FIG: TRUSS (KEY POINTS MODEL)

Create LINES using the Elements
Pre-processor ModelingCreate ElementsAuto numbered through nodes
select node 1&2 apply 2&3apply3&4apply1&5 apply5&2 apply
2&6apply6&3apply 3&7 apply 7&4 apply5&6 apply6&7
ok close.

FIG: TRUSS (LINE MODEL)

SOLUTION PHASE: ASSIGNING LOADS AND SOLVING
STEP 5: From the ANSYS main menu open Solution
Solution Analysis type new analysis – Static
STEP 6: Defining loads at the Key points
Solution Define Loads Apply Structural Displacement On nodes select
node 1&4 ok select All DOFok

35
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Left end – ALL DOF arrested

Solution Define loads Apply Structural Force/moment On nodes
Select node 2&3 ok FY direction Give force value as 1000 N ok close

Figure: Model with boundary conditions

STEP 7: Solving the system
Solution Solve Current LS
POSTPROCESSING: VIEWING THE RESULTS
Nodal solution
From the Utility menu select PLOT
PLOT Results Contour plot Nodal solutionDOF solution Y component of
displacement OK

36
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Figure: Y-Component displacement of the Model

RESULT:
DMX =0.577E-04 mm
SMX =0.641E-05 N/mm2
SMN=0.577E-04 N/mm2

37
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 3

AIM:
To determine the nodal temperature for given Thermal - Mixed Boundary
(Conduction/Convection/Insulated).
SOFTWARE REQUIRED:
Ansys 16.2, Windows8.1,
GIVEN DATA:
Thermal - Mixed Boundary (Conduction/Convection/Insulated)

1. Open preprocessor menu

ANSYS Main Menu Preprocessor
2. Create geometry
Preprocessor Modeling Create Areas Rectangle By 2 Corners
X=0, Y=0, Width=1, Height=1
3. Define the Type of Element
Preprocessor Element Type Add/Edit/Delete... click 'Add' Select
Thermal Mass Solid, Quad 4Node 55
As in the conduction example, we will use PLANE55 (Thermal Solid, Quad 4node 55).
This element has 4 nodes and a single DOF (temperature) at each node. PLANE55 can only be
used for 2 dimensional steady-state or transient thermal analysis.
4. Element Material Properties
Preprocessor Material Props Material Models Thermal Conductivity
Isotropic KXX = 10
This will specify a thermal conductivity of 10 W/m*C.
5. Mesh Size
Preprocessor Meshing Size Cntrls ManualSize Areas All Areas 0.05

38
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Mesh
Preprocessor Meshing Mesh Areas Free Pick All

6. Define Analysis Type

Solution > Analysis Type > New> Analysis> Steady-State
7. Apply Conduction Constraints
In this example, all 2 sides of the block have fixed temperatures, while convection
occurs on the other 2 sides.
1. Solution > Define Loads> Apply > Thermal> Temperature.> On Lines
2. Select the top line of the block and constrain it to a constant value of 500 C
3. Using the same method, constrain the left side of the block to a constant value of
100 C
8. Apply Convection Boundary Conditions
1. Solution > Define Loads > Apply > Thermal > Convection > On Lines
2. Select the right side of the block.
3. Fill in the window as shown. This will specify a convection of 10 W/m2*C and an
ambient temperature of 100 degrees Celcius.
Note that VALJ and VAL2J have been left blank. This is because we have uniform convection
across the line.
9. Apply Insulated Boundary Conditions
1. Solution > Define Loads > Apply > Thermal > Convection > On LinesSelect the
bottom of the block.
2. Enter a constant Film coefficient (VALI) of 0. This will eliminate convection
through the side, thereby modeling an insulated wall.

39
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Note: you do not need to enter a Bulk (or ambient) temperature

10. Solve the System

Solution Solve Current LS
11. Result:
Plot Temperature
General Postproc> Plot Results> Contour Plot> Nodal Solu > DOF solution, Temperature
TEMP

40
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

CAM
MTAB Make XL Turn specifications:
CAPACITY
Chuck Size: 100 mm
Maximum turning Diameter: 32 mm
Maximum turning Length: 120 mm
Bed Type: 45 deg Slant bed
No. of axes: 2 mm
Swing over way covers: 132 mm
Swing over cross slide: 50 mm
SPINDLE
Spindle nose taper: A2-3
Bore through spindle: 20 mm
Spindle motor: 1 HP AC Induction
Control system: PC based 2 axis continuous paths
Turret
Tool cross section: 12 x 12
No. of Station: 8 no
Boring bar size (capacity): 16 mm
Axes
X- axis travel: (160 in dia)mm Z - axis Tavel:180 mm
Axis motor: Stepper
Slides: Hardened ground guide ways
Tailstock
Tailstock base travel: 150 mm
Power source
Main supply: 230V, Single Ph, 50 Hz

41
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 1
STEP TURNING USING TURNING CYCLE

AIM:
To develop the given model by using CNC machine.
SOFTWARE REQUIRED:
CNC Turn
TOOLS REQUIRED:
1. Tool
2. Mild Steel shaft
3. Micro meter
4. Vernier
PROCEDURE:
1. For the given dimensions of the work piece to be machined write the program using G codes
and M codes
2. Using the simulation software or by running the machine in test mode check the Program and
if there is any error make the correction in the program.
3. Fix the work piece on the chucks.
4. Move the tool to the start point of the work piece by manual mode.
5. Reset the Machine.
6. Change the machine from manual mode to single block mode or auto mode.
7. Execute the program to get the required shape of the work piece.
8. Remove the machined work piece from the chuck .

CNC PROGRAMME:
N010 G21 G40 G98
N020 G28 U0 W0
N030 M06 T0404
N040 M03 S1200
N050 G00 X30 Z5

42
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

N060 G00 Z1
N070 G71 U0.5 R1
N080 G71 P90 Q150 U0.1 W0.1 F50
N090 G01 X0
N100 G01 Z0
N110 G03 X10 Z-5 R5
N120 G01 Z-15
N130 X20 Z-25
N140 G01 Z-35
N150 G02 X30 Z-40 R5
N160 G70 P90 Q150
N170 G28 U0 W0
N180 M05
N190 M30

RESULT:
Thus the given job is manufactured.

43
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 2
AIM:
To develop the given model by using CNC machine.
SOFTWARE REQUIRED:
CNC Turn
TOOLS REQUIRED:
1. Tool
2. Mild Steel shaft
3. Micro meter
4. Vernier
PROCEDURE:
1. For the given dimensions of the work piece to be machined write the program using G codes
and M codes .
2. Using the simulation software or by running the machine in test mode check the Program and
if there is any error make the correction in the program.
3. Fix the work piece on the chucks.
4. Move the tool to the start point of the work piece by manual mode.
5. Reset the Machine.
6. Change the machine from manual mode to single block mode or auto mode.
7. Execute the program to get the required shape of the work piece.
8. Remove the machined work piece from the chuck.

CNC PROGRAMME:
N010 G21 G98
N020 G28 U0 W0
N030 M06 T0404
N040 M03 S1200
N050 G00 X31 Z5
N060 G00 Z1

44
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

N070 G72 W0.5 R1

N080 G72 P90 Q180 U0.2 W0.2 F30
N090 G01 Z-22.5 F40
N100 X30
N110 X26
N120 Z-17.5
N130 X20 Z-15
N140 Z-10
N150 G02 X10 Z-5 R5 F40
N160 G01 Z-2.5 F50
N170 X5 Z0
N180 Z0
N190 G70 P90 Q180
N200 G28 U0 W0
N210 M05
N220 M30
RESULT:
Thus the given job is manufactured.
HYTECH MAKE MT 250 CNC MILLING SPECIFICATIONS:
Axes
Axis Motor and Drive Servo Motor with Servo Drives
X Axis 300 mm
Y Axis 225 mm
Z Axis 250 mm
Ball Screw X / Y / Z Ø25 x 5 – C4 Class
4th Axis Provision (Optional) Provided
Distance between Table top and Spindle
70 – 370 mm
Nose
Distance between Spindle to Column 270 mm
Feed Rate 0 to 1,200 mm/min
Rapid Travel 0 to 1,200 mm/min
Table
Table Size 600 X 160 mm
T Slot 3 x 10 x 50
Load On Table 120 Kg
Spindle
Spindle Motor Capacity 2 HP

45
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

Motor Type AC Motor with VFD

Spindle Nose Taper ISO 30 / BT 30

Spindle RPM
100 to 3000 RPM

CNC Controller Details:

Cut Viewer-United Kingdom with Emulation
of
Controller

Fanuc, Siemens , Traub and Heidenhain

Control System PLC Based Control System
Operating Software Cut Viewer – United Kingdom
Keyboard Type Fanuc Emulated / Standard
Accuracy
Positioning 0.015 mm
Repeatability +- 0.010 mm
Resolution 0.010 mm
4th Axis Resolution (Optional) 0.02 Degrees
Tool Changer (ATC)
Tool Changer Automatic
No. of Tools 8
Maximum Tool Length 40 mm
Maximum Tool Dia. 16 mm
Type of ATC Umbrella Type
Actuation Pneumatic / Hydraulic
Machine Details
Run Speed Control Computer Controlled with Software
Real Time tool path simulation Provided
Vice Type Pneumatic/ Manual

Master CAM, EDGE CAM, Solid Edge, Bob

Compatible Soft wares
CAD

Dimension in mm 1540 x 1200 x 1700 mm

Power Supply 230V, Single Phase

46
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 1

AIM:
To develop the given model by using CNC MILLING machine.
SOFTWARE REQUIRED:
Cut Viewer mill.
TOOLS REQUIRED:
1. Tool
2. ALUMINUM
3. Micro meter
4. Vernier
PROCEDURE:
1. Switch on the cnc mill machine.
2. Open cutmill viwer nill simulation in the PC.
3. keep the machinein simulation mode .
4. Enter the CNC programme and run it
5. Check for errors and make any changes if required
6. Install the work piece on the table
7. Install the tools required in the turret
8. Check all the miscellaneous parameters
9. Change the machine to machining mode
10. Close the door and run the programme
11. After completing the machining process change the machine to simulation mode
12. Remove the completed work piece and check for dimensions
13. Turn off the PC and switch off the CNC machine.

CNC PROGRAMMING:
O01 BILLET 120 X 120 X 30 MM
N01 G21 G94 G90
N02 G28 X0 Y0 Z0
47
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

N03 T0101
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G01 X25 Y35 F35
N07 G01 Z-10 F40
N08 G01 Y55
N09 G01 X35 Y65
N10 G01 Y75
N11 G03 X45 Y85 R10 F35
N12 G02 X55 Y95 R10 F35
N13 G01 X85 F40
N14 G02 X95 Y85 R10 F35
N15 G01 Y35 F40
N16 G02 X85 Y25 R10 F35
N17 G01 X35
N18 G02 X25 Y35 R10 F35
N19 G00 Z5
N20 M05
N21 G28 X0 Y0 Z0
N22 M30

RESULT:
Thus the given job is manufactured.

48
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

EXPERIMENT 2

AIM:
To develop the given model by using CNC MILLING machine.
SOFTWARE REQUIRED:
Cut Viewer mill.
TOOLS REQUIRED:
1. Tool
2. ALUMINUM
3. Micro meter
4.Vernier
PROCEDURE:
1. Switch on the cnc mill machine.
2. Open cutmill viwer nill simulation in the PC.
3. keep the machinein simulation mode .
4. Enter the CNC programme and run it
5. Check for errors and make any changes if required
6. Install the work piece on the table
7. Install the tools required in the turret
8. Check all the miscellaneous parameters
9. Change the machine to machining mode
10. Close the door and run the programme
11. After completing the machining process change the machine to simulation mode
12. Remove the completed work piece and check for dimensions
13. Turn off the PC and switch off the CNC machine.

CNC PROGRAMMING:
O02
BILLET 150 X 150 X 30 MM
N01 G21 G94 G90
N02 G28 X0 Y0 Z0
49
DEPARTMENT OF MECHANICAL ENGINEERING VAAGDEVI COLLEGE OF ENGINEERING

N03 M06 T01

N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G00 X25 Y25 Z5
N07 G01 Z-10 F40
N08 G01 X25 Y100
N09 G02 X85 Y100 R30 F30
N10 G01 X105 Y50 F40
N11 G01 X125 Y40
N12 G01 Y25
N13 G01 X25 Y25
N14 G00 Z5
N15 M05 M09
N16 G28 X0 Y0 Z0
N17 M30

RESULT:
Thus the given job is manufactured.

50