COMPUTER AIDED DESIGN (DRAFTING)

Introduction to CAD:

The use of interactive graphics programs to develop 2D and 3D models,

assemblies, part lists, and dimensional drawings of various components,
structures or objects with the help of a computer is called Computer-Aided
Design(CAD). The data generated by a CAD system can be directly utilized by
a CAM (Computer Aided Manufacturing) system. Thus CAD and CAM are
interrelated to each other.

CAD can be defined as the use of computer system to assist in the

creation, modification, analysis or optimization of design. Computer aided
design (CAD) is the process of doing design with the aid of computers. This
includes generation of computers models, analysis of design data, and creation
of drawings. CAD is relatively a new and rapidly expanding area in mechanical
engineering. AutoCAD is used for design and mainly drafting activities.
AutoCAD is developed by Autodesk Inc. in 1982.

AutoCAD is the most widely used CAD software and one of the most
powerful and user friendly. AutoCAD is ideal for architects, construction
engineers, managers and other professionals within the building and designing
industry.

Drawing is a language of engineers. Graphic language is used among the

engineers. An effective communicating tool is graphic language. Engineering
drawing is widely used in mechanical, production, automobile, aeronautical,
chemical, marine and electrical engineering to describe an engineering
machine. Picture is better than a million words. Picture is represented by
pixels. Pixel is the smallest picture on screen.

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 Now-a-days, Computer Aided Drafting (CAD) is becoming popular
because of its simplicity and accuracy in drawing, repeatability and fast work.
As per the latest method, geometric model of the object with all dimensions
with physical properties can be prepared by using computers. The computer
software commonly used for drafting are Auto CAD 2016, Mini CAD etc.
PRO/Engineer, Unigraphics, Integrated Engineering Analysis Software(IDEAS),
Computer Aided 3-Dimensional Interactive applications(CATIA), solid works,
IronCAD, Mechanical Desktop(MDT) with AutoCAD 2016 are leading modelling
(design) cum drafting software packages are commonly used engineering
packages.

Computer Aided Design and Drafting is a technology that is about the

use of computers in the application of engineering design and development.
This technology came into the market during early 80's. Since the inception,
the technology has grown to a very large extent and today any engineering
project is nearly impossible to think of without this technology.

No need to make an expensive prototype and test it, by putting it into

actual working conditions. This saves a lot of time and money that is involved
in the design process. Based on the test results, in no time the design can be
modified and analysed once again.

If you are into the architectural design project, you can build a full size
model of your work on the computer screen, add lights and even have a walk
through the model that you are dreaming of no brick, no paint, nothing. Today,
the technology has grown to that extent.

Merits of CAD over manual drafting:

1) Design can be consistently accurate, clear and faster.
2) Drawings are stored in electronic format in computers. With sufficient
backup space required for is far lesser that required for storing the man
made paper drawings.

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 3) Documents can be maintained safely for a longer period. No natural
factors such as moisture could spoil the documents.
4) Retrieval of documents is faster than that of manual drawings.
5) Editing and modification of drawing is easy.
6) Directly we can construct and visualise a 3D model. The CAD software
can quickly produce the orthographic views of component or assembly.
7) Repetitive and time consuming activities such as cross-hatching,
dimensioning can be done much faster care at any time.
8) We can simulate real life situations such as wind, sun light, pressure and
temperature and visualise how the model or design would react in a given
situation.
9) There is flexibility in design.
10) Design analysis is made
11) Fewer design errors.
12) There is improvement in design with shorter lead time.

AutoCAD has several features:

• Group related parts of the drawing together and turn their display on or off
at will.
• Manipulate drawing entities separately or in groups as though they were a
single drawing entity.
• Create an unlimited library of custom made drawing entities and symbols
and insert them into different drawings at will.
• Add dimension information to your drawing easily by selecting relevant
points on a drawing entity.
• AutoCAD by means of command scripts that execute a series of commands
in sequence. This can also be done by programming AutoCAD with Auto
LISP.
• Create drawings that can be exported and used in other graphics programs.
• Construct 3D wire-frame models of objects in 3D space and view them from
any angle.

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• Create sectional views of 3D entities automatically by using an AutoCAD
feature called clipping planes to temporarily block out selected portions of
the drawing.
• Advanced versions of AutoCAD is icon based and provides solid modeling
features like other high end CAD packages.
Advantages of CAD
1. Increased and accuracy and productivity compared to traditional method
2. Cost effective and flexible, even small scale fabrication industries can
take advantage of it.
3. Can be e-transmitted.
4. Changes can be incorporated very fast.
5. Production drawings can be created very fast
6. Area, Mass properties, Centre of gravity, Moment of Inertia can be
calculated.
7. Easy visualisation and hence customer satisfaction.
8. Templates and programming for consistency and drafting standards.
9. See the model before the equipment is actually manufactured.
10. Analysis and tests can be performed on the model like destructive test,
heat and cold test etc.
11. Latest version of AutoCAD has the power of interaction of Drawings over
the internet.

Select Object Options

a) Single entity.
b) All. (All entities in the drawing)
c) Window. (Totally covered in the window)
d) Crossing. (Cut by the window)
e) Last. (Last selected)
f) Previous. (Object previously stored)
g) Fence. (Range)
h) Window Polygon.
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 i) Crossing Polygon.

Function keys

F1 Help
F2 Toggle (Graphic and Character screen)
F3 Osnap off (Object Snap)
F4 Tablet ON/OFF
F5 Iso-plane change (for isometric view
F6 Co-ordinate ON / OFF
F7 Grid ON / OFF
F8 Ortho ON / OFF
F9 Snap ON / OFF
F 10 Polar On/OFF
F 11 toggle Object Snap Tracking on or off

Transparent Commands:
These commands are used when we are in the middle of another
command, like zoom, view, pan, redraw, resume, grid A command started while
another is in progress. Precede transparent commands with an apostrophe.
Many commands can be used transparently: that is, they can be entered
on the command line while you use another command. Transparent commands
frequently change drawing settings or display options. In the Command
Reference, transparent commands are designated by an apostrophe in front of
the command name.
To use a command transparently, choose its toolbar button or enter an
apostrophe (') before entering the command at any prompt. On the command
line, double angle brackets (>>) precede prompts that AutoCAD displays for
transparent commands. After you complete the transparent command, the
original command resumes. In the following example, you turn on the dot grid
and set it to one-unit intervals while you draw a line, and then you continue
drawing the line.

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Snapping to Points on Objects
During drawing commands, you can snap the cursor to points on objects
such as endpoints, midpoints, centers, and intersections. For example, you can
turn on object snaps and quickly draw a line to the center of a circle, the
midpoint of a polyline segment, or the apparent intersection of two lines. You
turn on object snaps in one of two ways:
Single point (or override) object snaps: Sets an object snap for one use.
Running object snaps: Sets object snaps until you turn them off.
To snap to a point on an object:
1 Start a command requiring you to specify a point (for example, ARC,
CIRCLE, COPY, LINE or MOVE).
2 When the command prompts you to specify a point, choose an object snap
using one of the following methods:
Click a toolbar button on the Standard toolbar Object Snap flyout or on the
Object Snap toolbar. Press SHIFT and right-click in the drawing area, and
choose an object snap from the shortcut menu. Enter an object snap
abbreviation on the command line.
3. Move your cursor over the snap location and click.

After you click to the snap point, the object snap clears. If you select any point
other than the object snap point, AutoCAD displays an invalid point message.
The following table shows the AutoCAD object snaps, the toolbar buttons, and
command line abbreviations you can use to start them.
Object snaps
S. Object snap Symbol Comman Snaps to
No. d line
1 Endpoint END Object endpoints
2 Midpoint MID Object midpoints
3 Intersection INT Object intersections
4 Apparent APP Apparent intersection of
Intersection objects

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5 Extension EXT Object extension paths
6 Center CEN Center points of circles,
arcs, or ellipses
7 Node NOD Point objects drawn with
the POINT command
8 Quadrant QUA Closest quadrant of arcs,
circles, or ellipses
9 Insertion INS Insertion point of a
block, shape, text,
attribute, or attribute
definition
10 Perpendicul PER Object points forming a
ar perpendicular (normal)
alignment
11 Parallel PAR Point on an alignment
path that is parallel to
the selected object
12 Tangent TAN Point on a circle or arc
that, when connected to
the last point, forms a
line tangent to the object
13 Nearest NEA Object snap point
closest to the selection
point
14 None NON Turns off object snaps
for the next point
selection
15 From FRO Snap from a distance of
existing object

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8
Commands in AutoCAD
Draw commands: MODIFY COMMANDS VIEW COMMANDS &
OTHERS
LINE MOVE REDRAW
CIRCLE COPY REGEN
ARC OFFSET ZOOM
PLINES TRIM PAN
RECTANGLE EXTEND 3DORBIT
ELLIPSE ROTATE HIDE
MLINE SCALE SHADE
XLINE CHAMFER RENDER
RAY LENGTHEN VIEWPORT
DONUT ARRAY DDEDIT
SPLINE BREAK SNAP
MLSTYLE MEASURE GRID
MLEDIT DIVIDE OSNAP
POLYGON MIRROR LIMITS
TEXT PROPERTIES EXPLODE
DTEXT ERASE LIST
MTEXT FILLET AREA
LINETYPE BLOCK TIME
LTSCALE WBLOCK STATUS
HATCH INSERT DIM
LAYERS PEDIT PLOT

EXERCISE #1

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 PRACTICE ON 2D COMPONENTS
AIM : To create a 2D view of the given diagram using Auto CAD.

PROCEDURE:
1. Type limits in command menu & set value to 297,290.
2. Change the units to millimeters from inches and also precision to 0 by
clicking format -> units -ok.
3. To set the paper size type zoom -> enter and type a -> enter in Command
bar.
4. Draw the 3 concentric circles with diameters 94, 74 & 54
5 .Draw the two axis lines from centre of circles
6 .Draw the vertical line from the centre of circle
7 .From the modify tool bar, use the array command to draw the 6holes with
12dia from centre of circles
8. Now draw the 300 line by use the vertical line
9. Then mirror the 300 line, with vertical line
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10. Again draw the concentric of radius 100 from centre of circle
11. From the modify toolbar, use the offset command to draw the 12 & 23
distance circle.
12. Draw 2 circles. With radius 23 & 12 on the 100R circle where the 30 0 line
co-inside.
13 . From modify toolbar, mirror these circle to represent the another side.
14 . And offset vertical line from centre of circle with a distance both side of
vertical line.
15 . From modify toolbar, use the fillet command to represent fillet of radius
10 & 9 to the offset line.
16 . Trim the unwanted lines to get required 2D drawing

RESULT:

INFERENCE

VIVA QUESTIONS
1. What is the difference between line and Spline?
2. What is the difference between chamfer and fillet?
3. What are different ways to draw a circle?
4. What are the possible ways to draw an arc?
5. How to extend a line?
6. What is the procedure to enter into AutoCAD?

EXERCISE #2
PRACTICE ON 2D COMPONENTS

AIM: To create a 2D view of the given diagram using Auto CAD.

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PROCEDURE:
1. Type limits in command menu & set value to 297,290.
2. Change the units to millimeters from inches and also precision to 0 by
clicking format -> units -> ok.
3. To set the paper size type zoom -> enter and type a -> enter in Command
bar.
4. Draw the 2 axes lines
5. Draw 2 concentric circles of diameter 58 and 40 above the axes
6. Draw the 10dia circle on the 40dia of the circle
7. And use the array command from modify tool bar to represent the 8 holes
with 10dia from centre of the circles.
8. Draw the 2 concentric circles of diameter 58 & 36 below the axes
9. Draw the circles of the diameter 8 on the circle of 36dia
10. Use the array command from the modify tool bar to represent the 6 holes
with 8dia
11. Draw the 2 concentric circles of diameter 22 and 20 radius at the right
side of the vertical line from the vertical axes.
12. Fillet the circles of radius 20 with 15 radiuses.

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13. And again draw the circles of diameter 16& 20R at left side of the vertical
line from the vertical axes.
14. And chamfer the circles of radius 20 with 58dia circle
15. Then trim the unwanted lines to get the required 2D drawing.

RESULT:

INFERENCE

VIVA QUESTIONS
1. What are the possible ways to draw arc?
2. How to extend line?
3. What is the purpose of command trim?
4. How to convert 2D drawings to 3D drawings?
5. How to give dimension?

EXERCISE #3
PRACTICE ON 3D COMPONENTS
AIM: To create a 2D isometric view of the given drawings using Auto CAD.

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PROCEDURE FOR FIG.1:
1. Type limits in command menu & set value to 297,290.
2. Change the units to millimeters from inches and also precision to 0 by
clicking format -> units ->ok.
3. To set the paper size type zoom -> enter and type a -> enter in Command
bar.
4. Go to drafting settings and turn on isometric snap. Use the F5 key to change
between the views of isometric planes.
5. Start from the front view and draw the the line of length of line 54.
6. Draw the semi circle using the Iso circle option from the ellipse command.
7. Continue drawing using F5 and F8 snap keys.
8. Give proper dimensions.
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PROCEDURE FOR FIG. 2:
1. Type limits in command menu & set value to 297,290.
2. Change the units to millimeters from inches and also precision to 0 by
clicking format -> units -> ok.
3. To set the paper size type zoom -> enter and type a -> enter in command bar.
4. Go to drafting settings and turn on isometric snap..
5. Use the F5 key to change between the views of isometric planes.
6. Start from the front view and draw the the line of length of line 104 using
the F8 key (O snap key) and continue with the 48 length line.
7. Change to top plane and draw the 72mm line.
8. Continue in the same fashion to complete the whole figure.
9. Give the dimensions from the dimension tool bar as in diagram.

RESULT

INFERENCE

VIVA QUESTIONS
1. What is the difference between metric unit and English unit?
2. What is the shortcut key for Ortho ON/OFF ?
3. What is the shortcut key for help?
4. What are the various ways to draw a measured line?
5. .What are object snap command.

2. MODELING

Pro/ENGINEER CREO-2 is a 3D Computer Aided Design software package

created by Parametric Technology Corporation. It is a feature-based,
parametric, and associative solid modeling software package, which helps to

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create 3D designs for mechanical engineering. A model designed in
Pro/ENGINEER Wildfire 4.0 incorporates the following modeling approaches:
∗Feature-based: A model is made up of a combination of various features, such
as extrusions, holes, cuts, rounds, sweeps, and slots. A feature is the smallest
building block of a model.
∗Parametric: A model consists of various features that are interrelated to each
other and every feature consists of certain attributes. This approach ensures
that modification of an attribute of a feature affects the complete model.
∗Associative: A model design passes through three modes Sketch, Part and
Assembly. This approach ensures that modifications made in one mode of a
model should be reflected in other modes of the same model.
∗Solid Modeling: This approach ensures that the model must have properties
of a solid object, such as volume and surface area.
There are four modes a solid model passes through during designing phase
namely;
∗Sketch Mode: Used to sketch geometry for a model.
∗Part Mode: Used to create features of a model.
∗Assembly Mode: Used to create an assembly design.
∗Drawing Mode: Used to generate the drawing of the parts and assemblies
created in part or assembly mode.

Features of Pro/ENGINEER CREO-2:

∗User-Interface
∗Auto-Round
∗Remove Surface
∗Shell
∗Dimension Attributes
∗View Manager
∗Surface Manipulation
∗Rendering
∗Electro-Mechanical Components

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∗Import data doctor
∗Feature Recognition Tool kit
Starting Pro/ENGINEER CREO-2:
Start ⇒
All Programs ⇒
PTC ⇒
Pro ENGINEER ⇒
Pro ENGINEER
Modes in Pro/ENGINEER
Sketch mode: The sketch mode in Pro/E Creo 2.0 is used to draw 2-D sketch
to a 3-D feature. To draw a sketch, various sketching entities are available in
Sketch Tool bar. Combination of various sketching entities leads into a
complete sketch.
Various Sketching Entities: Line, Circle, Arc, Circular fillet, Elliptical fillet,
Splines, Text
Dimensions: Whenever a sketching entity is created, some dimensions are
automatically applied on that entity. These dimensions are weak dimensions
and are gray in color. Dimensions that we apply on sketched entities are called
strong dimensions. When we apply strong dimensions, then weak dimensions
are automatically deleted.
Other Commands in Sketcher:
∗Applying Constraints
∗Modify
∗Trimming Entities
∗Mirroring Entities
∗Deleting Entities

Part Mode:
The part mode is used to build 3D solid features, such as holes, cuts , round
etc and has properties such as mass, volume and surface area. The files saved
in part mode are saved with .part extension.
The following tools are therein part mode namely,
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Extrude
Revolve
Sweep
Blend
Extrude: Extrusion is the process of defining a volume by protruding/removing
the sketched cross-section along an axis to the normal section plane. There are
various pick and place features. Pick and place features, are construction
features that operate on existing feature. The pick and place features are
•Draft
•Loft
•Hole
•Rib
•Shell
•Round
•Chamfer

Revolve: The revolve tool revolve/rotates the sketched section through the
specified angle about
the centerline.
Sweep: The Sweep option extrudes a section along a defined path. For creating
a sweep we have to define a cross-section and path, the path (Trajectory) can
be opened or closed one.
Types of Sweep:
•Constant Section Sweep
•Helical Sweep
•Variable Section Sweep

Blend:
The blend command creates a feature, by joining two or more planar sections
at their edges, to form a continuous feature. The number of entities in each
section should be the same.
There are three types of blend

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•Parallel Blend
•Rotational Blend
•General Blend

Assembly Mode:
An assembly is a collection of parts, oriented and positioned together. The
assembly mode provides the designers a set of smart tools, to assemble several
parts effectively, into a perfect design. The full associativity of Pro/ENGINEER
reflects any changes, made on a part, in all assemblies where the part is used.
The general procedure for creating assembly is as follows:
1.Import files into the assembly file.
2.Create additional parts in the assembly mode.
3.Add constraints to the parts.
4.Perform assembly operations if required.
5.Create an exploded view.
There are two types of assembly,
•Top-down Assembly
•Bottom-up Assembly

Top-down Assembly:
In the top-down approach of assembling the components, are created in the
assembly file itself, and then assembled, using the assembly constraints. The
parts created in assembly mode are saved as .prt files.

Bottom-up Assembly:
In this method, the parts are created in the part mode and assembled in the
assembly mode, using assembly constraints. Assembly files created in this
method, occupies less disc space as they contain only the information related
to the assembly of components. However, if any of the assembly components is
moved from its original location, the assembly will not open.

2.1 Mouse Functions

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Before we start with the hard job (modeling), you should know about some
tricks of the mouse. Wildfire is meant to be used with a 3-button mouse. If it
has a middle scroll, it is actually better and you are lucky. If your mouse is a
2-button one, try to use the <shift> key plus the left mouse button (LMB)
simultaneously as an equivalent to the middle mouse button (MMB). If it
doesn’t work, talk to your system administrator.

Most selections of menu commands, shortcut buttons, and so on are performed

by clicking the left mouse button (LMB). In this tutorial, whenever you “select”,
“click”, or “pick” a command or entity, this is done with the LMB unless
otherwise directed.
The functions controlling the view of the object in the graphics window are all
associated with the MMB. These are the important Spin, Pan, and Zoom
functions. The following table summarizes different uses of mouse buttons
that can make your job easier and more fun. Note: if you know previous
versions of Pro/E, you will find the mouse functions are quite different! Learn
the new functions and don’t let your experience frustrate you.

Table 1 Common mouse functions in Pro/E Wildfire.

Function Operation Action

Selection (click left Entity or command
button) LMB under
cursor selected
View Control (drag
holding MMB Spin

<Shift>+MMB Pan
<Ctrl>+MMB Zoom
(drag vertical)
<Ctrl>+MMB Rotate around axis

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 perpendicular to
screen
(drag horizontal)
Roll MMB scroll wheel (if Zoom
available)
RMB with cursor over Launch context-
Pop-up Menu (click right blank sensitive
button) graphics window pop-up menus
HINT: If you mouse seems “dead”, and so are the menus and toolbars, check
the message window; Pro/E is probably waiting for you to answer its prompts.
How to Get On-line Help
Oops, there is one more thing to say. As any tutorial may not cover everything
and some of the problems in the lab are very creative, both you and your
TA/tutor will sometimes need to get the online-help. The Help function gets
more important as you work on your own assignments and projects. OK, there
are several ways to do this.

Choose Help > Help Center to launch a browser, which lists many help items,
including tutorials and step-by-step description of all the commands.
Click the Context Sensitive Help button towards the right end of the top
toolbar. Its equivalent is Help > What is this? Then click on any command or
dialog window. (Can you find the button? If not, you didn’t browse through the
buttons. Please use your mouse cursor to go through those top toolbar buttons
and read their description in the message window.)
If your problem gets very tricky, you might need to register on-line at
www.ptc.com as a user and get help from the knowledge base created by the
Pro/E user group. Before you go through this route, talk to your TA as he/she
may know the answer to your problem.

2.3 Begin to work in Pro/E

The main graphics windows shows three orthogonal planes, named TOP,
FRONT and RIGHT, and a coordinate system. These planes are called datum
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planes, representing the 3-D world. These planes are very useful as reference
planes when creating features and assembling components. Their
advantages are not obvious when modeling simple parts, and in fact new
users find these planes annoying. Whatever you feel now, my advice is to get
yourself used to these “annoying” planes.
1) Prepare for sketching

Extrusion

Sweep
Blend
Style

Figure 4 The Sketched Features toolbar.

draw two lines to connect the respective endpoints. You should have an
enclosed profile with two concentric arcs and two vertical lines. The graphics
window should look like that in Figure 10 (don’t worry about the dimensions!).

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 Figure : The sketch plane with grid on.

EXERCISE #4
EXERCISE ON PART MODELING 1
AIM: To create 3D model of given drawing by using Pro/E Creo

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PROCEDURE:
1. Identify various parts to be created.
2. First enter into part environment and create the main part and create the
main part of the assembly.
3. First identify whether the main part or the first to be created by protrusion
or by revolution.
4. Select the sketch tool and then select the coincidental plane option and select
any one of the standard 3 planes (i.e. front, right &top).
5. Create the cross-section profile as a closed one using the 2D commands
available after completing the sketch, click open or return button and then click
finish button.
6. For creating other parts, select sketch both parallel plane option or plane by
3points option and then select the required plane.
7. Construct the full cross section for portion and construct the half of the cross
section and an axis line for revolution.
8. Do the protrusions by using protrusion command.
9. Use revolved cutout command whenever needed.
10. Use the distance between option to maintain accurate distance between one
edge and other edge or between one edge and to center the hole.

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11. After constructing each part save it as a separate part file with extrusion*
par.
12. Enter into assembly environment.
13. Assembly the various parts construct parts construct using the various
assembly constrains available (planer, design, mate, axial align, connect etc).
14. After finishing assembly, check whether the various parts have been
connected properly or not by rotating the view.
15. Save the assembly as a file with extrusion*asm.

RESULT
Thus the 3D assembly of the universal coupling has been modeled on the
software Pro-e creo with accurate dimension and withal respects.

INFERENCE:

VIVA-VOCE QUESTIONS
1. What is coupling?
2. What are the types of couplings?
3. What is protected type flange coupling?
4. What is use of protected type flange coupling?
5. What is the specification of protected type flange coupling?

EXERCISE # 5
PART MODELLING AND ASSEMBLING OF UNIVERSAL COUPLING

AIM: To create the universal coupling assembly as a 3D solid model.

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PROCEDURE :
1. Identify various parts to be created.
2. First enter into part environment and create the main part and create the
main part of the assembly.
3. First identify whether the main part or the first to be created by protrusion
or by revolution.
4. Select the sketch tool and then select the coincidental plane option and select
any one of the standard 3 planes (i.e. front, right &top).
5. Create the cross-section profile as a closed one using the 2D commands
available after completing the sketch, click open or return button and then click
finish button.
6. For creating other parts, select sketch both parallel plane option or plane by
3points option and then select the required plane.
7. Construct the full cross section for portion and construct the half of the cross
section and an axis line for revolution.
8. Do the protrusions by using protrusion command and the revolution by
revolved protrusion command.
9. For constructing holes and cutout, used hole command and cutout
command.

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10. If we use hole command, change the diameter of the hole by using modify
menu, resize hole option.
11. Use revolved cutout command whenever needed.
12. Use the distance between option to maintain accurate distance between one
edge and other edge or between one edge and to center the hole.
13. After constructing each part save it as a separate part file with extrusion*
par.
14. Enter into assembly environment.
15. Assembly the various parts construct parts construct using the various
assembly constrains available (planer, design, mate, axial align, connect etc).
16. After finishing assembly, check whether the various parts have been
connected properly or not by rotating the view.
17. Save the assembly as a file with extrusion*asm.
RESULT
Thus the 3D assembly of the universal coupling has been modeled on the
software Pro-e creo with accurate dimension and withal respects.
INFERENCE:

VIVA-VOCE QUESTIONS
1. What is universal coupling?
2. What are the parts of universal coupling?
3. What are the applications of universal coupling?
4. What are advantages of universal coupling?

EXERCISE # 6
PART MODELLING AND ASSEMBLING OF KNUCKLE JOINT
AIM: To create the knuckle joint assembly as a 3D solid model.

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PROCEDURE
1. Identify various parts to be created.
2. First enter into part environment and create the main part and create the
main part of the assembly.
3. First identify whether the main part or the first to be created by protrusion
or by revolution.
4. Select the sketch tool and then select the coincidental plane option and select
any one of the standard 3 planes (i.e. front, right &top).
5. Create the cross-section profile as a closed one using the 2D commands
available after completing the sketch, click open or return button and then click
finish button.
6. For creating other parts, select sketch both parallel plane option or plane by
3points option and then select the required plane.
7. Construct the full cross section for portion and construct the half of the cross
section and an axis line for revolution.
8. Do the protrusions by using protrusion command and the revolution by
revolved protrusion command.

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9. For constructing holes and cutout, used hole command and cutout
command.
10. If we use hole command, change the diameter of the hole by using modify
menu, resize hole option.
11. Use revolved cutout command whenever needed.
12. Use the distance between option to maintain accurate distance between one
edge and other edge or between one edge and to center the hole.
13. After constructing each part save it as a separate part file with extrusion*
par.
14. Enter into assembly environment.
15. Assembly the various parts construct parts construct using the various
assembly constrains available (planer, design, mate, axial align, connect etc).
16. After finishing assembly, check whether the various parts have been
connected properly or not by rotating the view.
17. Save the assembly as a file with extrusion*asm.
RESULT
Thus the 3D assembly of the universal coupling has been modeled on the
software Pro-e creo with accurate dimension and withal respects.
INFERENCE:

VIVA-VOCE QUESTIONS
1. What is knuckle joint?
2. What are the types of knuckle joint?
3. What are the parts of knuckle joint?
4. What are the applications of knuckle joint?
5. What are advantages of knuckle joint?
FINITE ELEMENT ANALYSIS

INTRODUCTION TO ANSYS

29
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.

The ANSYS 11.0 Family of Products continues ANSYS, Inc.'s commitment to

provide the highest quality engineering tools to help you with all of our design
and analysis needs. This release of the products contains all of the capabilities
from previous releases, plus many new features to enhance our productivity.
Some important areas where we will find new capabilities include the following:

TYPES OF ANALYSIS

1. Structural
2. Coupled-Field
3. Thermal
4. Modal
5. Contact
6. Solvers
7. Usability
8. ANSYS Commands
9. ANSYS Elements

Performing a Typical ANSYS Analysis:

30
The ANSYS program has many finite element analysis capabilities, ranging
from a simple, linear, static analysis to a complex, nonlinear, transient
dynamic analysis. The analysis guide manuals in the ANSYS documentation
set describe specific procedures for performing analyses for different
engineering disciplines. The next few sections of this chapter cover general
steps that are common to most analyses.
A typical ANSYS analysis has three distinct steps:
• Build the model.
• Apply loads and obtain the solution.
• Review the results.

Build the model:

1. Defining the Jobname:
The jobname is a name that identifies the ANSYS job. When you define a
jobname for an analysis, the jobname becomes the first part of the name of all
files the analysis creates. (The extension or suffix for these files' names is a file
identifier such as .DB.) By using a jobname for each analysis, you ensure that
no files are overwritten.
2. Defining an Analysis Title:
The TITLE command (Utility Menu> File> Change Title), defines a title for the
analysis. ANSYS includes the title on all graphics displays and on the solution
output. You can issue the /STITLE command to add subtitles; these will appear
in the output, but not in graphics displays.
3. Defining Units:
The ANSYS program does not assume a system of units for your analysis.
Except in magnetic field analyses, you can use any system of units so long as
you make sure that you use that system for all the data you enter. (Units must
be consistent for all input data.)
4. Defining Element Types:
The ANSYS element library contains more than 150 different element types.
Each element type has a unique number and a prefix that identifies the element

31
category: BEAM4, PLANE77, SOLID96, etc. The following element categories
are available:
BEAM MESH
CIRCUit Multi-Point Constraint
COMBINation PIPE
CONTACt PLANE
FLUID SHELL
SOLID LINK
MASS
The element type determines, among other things:
• The degree-of-freedom set (which in turn implies the discipline -
structural, thermal, magnetic, electric, quadrilateral, brick, etc.)
• Whether the element lies in 2-D or 3-D space.
5. Defining Element Real Constants:
Element real constants are properties that depend on the element type, such
as cross-sectional properties of a beam element. For example, real constants
for BEAM3, the 2-D beam element, are area (AREA), moment of inertia (IZZ),
height (HEIGHT), shear deflection constant (SHEARZ), initial strain (ISTRN),
and added mass per unit length (ADDMAS). Not all element types require real
constants, and different elements of the same type may have different real
constant values.
6. Defining Material Properties:
Most element types require material properties. Depending on the application,
material properties can be linear (see Linear Material Properties) or nonlinear
(see Nonlinear Material Properties).
As with element types and real constants, each set of material properties has
a material reference number. The table of material reference numbers versus
material property sets is called the material table. Within one analysis, you may
have multiple material property sets (to correspond with multiple materials
used in the model). ANSYS identifies each set with a unique reference number.
7. Creating the Model Geometry:

32
Once you have defined material properties, the next step in an analysis is
generating a finite element model - nodes and elements - that adequately
describes the model geometry. The graphic below shows some sample finite
element models.
There are two methods to create the finite element model: solid modeling and
direct generation. With solid modeling, you describe the geometric shape of
your model, then instruct the ANSYS program to automatically mesh the
geometry with nodes and elements. You can control the size and shape in the
elements that the program creates. With direct generation, you "manually"
define the location of each node and the connectivity of each element. Several
convenience operations, such as copying patterns of existing nodes and
elements, symmetry reflection, etc. are available.

Sample Finite Element Models

Apply Loads and Obtain the Solution:

In this step, you use the SOLUTION processor to define the analysis type and
analysis options, apply loads, specify load step options, and initiate the finite
element solution. You also can apply loads using the PREP7 preprocessor.
1. Defining the Analysis Type and Analysis Options:
You choose the analysis type based on the loading conditions and the response
you wish to calculate. For example, if natural frequencies and mode shapes are

33
to be calculated, you would choose a modal analysis. You can perform the
following analysis types in the ANSYS program: static (or steady-state),
transient, harmonic, modal, spectrum, buckling, and sub structuring.
Not all analysis types are valid for all disciplines. Modal analysis, for example,
is not valid for a thermal model. The analysis guide manuals in the ANSYS
documentation set describe the analysis types available for each discipline and
the procedures to do those analyses.
Analysis options allow you to customize the analysis type. Typical analysis
options are the method of solution, stress stiffening on or off, and Newton-
Raphson options.
2. Applying Loads: The word loads as used in ANSYS documentation includes
boundary conditions (constraints, supports, or boundary field specifications)
as well as other externally and internally applied loads. Loads in the ANSYS
program are divided into six categories:
DOF Constraints
• Forces
• Surface Loads
• Body Loads
• Inertia Loads
• Coupled-field Loads

You can apply most of these loads either on the solid model (keypoints, lines,
and areas) or the finite element model (nodes and elements).
3. Specifying Load Step Options:
Load step options are options that you can change from load step to load step,
such as number of substeps, time at the end of a load step, and output
controls. Depending on the type of analysis you are doing, load step options
may or may not be required. The analysis procedures in the analysis guide
manuals describe the appropriate load step options as necessary.
4. Initiating the Solution:
To initiate solution calculations, use either of the following: Command(s):
SOLVE
34
GUI: Main Menu> Solution> Solve> Current LS Main Menu> Solution>
solution_method

When you issue this command, the ANSYS program takes model and loading
information from the database and calculates the results. Results are written
to the results file (Jobname.RST, Jobname.RTH, Jobname.RMG, or
Jobname.RFL) and also to the database. The only difference is that only one
set of results can reside in the database at one time, while you can write all
sets of results (for all substeps) to the results file.
Review the Results:
Once the solution has been calculated, you can use the ANSYS postprocessors
to review the results. Two postprocessors are available: POST1 and POST26.
You use POST1, the general postprocessor, to review results at one substep
(time step) over the entire model or selected portion of the model. The command
to enter POST1 is /POST1 (Main Menu> General Postproc), valid only at the
Begin level. You can obtain contour displays, deformed shapes, and tabular
listings to review and interpret the results of the analysis. POST1 offers many
other capabilities, including error estimation, load case combinations,
calculations among results data, and path operations.
You use POST26, the time history postprocessor, to review results at specific
points in the model over all time steps. The command to enter POST26 is
/POST26 (Main Menu> TimeHist Postpro), valid only at the Begin level. You
can obtain graph plots of results data versus time (or frequency) and tabular
listings. Other POST26 capabilities include arithmetic calculations and
complex algebra.
Result:
Thus the basic steps to perform the analysis in ANSYS like
• Build the model.
• Apply loads and obtain the solution.
• Review the results. are studied.

35
 EXERCISE # 7
DETERMINATION OF DEFLECTION AND STRESSES IN 2D TRUSS.

AIM: To find the maximum deflection of a following truss by using ANSYS

software.

Young’s Modulus = 200 GPa

Poisson’s Ratio = 0.3
Cross sectional Area = 3250mm2.

PROCEDURE
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing

36
 Start - All Programs – ANSYS 17.0 - Mechanical APDL Product Launcher –
Set the Working Directory as E Drive, User - Job Name as Roll No., Ex. No. –
Click Run.
PRE PROCESSING
1. Element Type: Preprocessor Menu, select: Element Type >
Add/Edit/Delete> 2D spar.
2. Define Geometric Properties: Preprocessor menu, select Real Constants >
Add/Edit/Delete> 'Type 1 LINK1' >'OK'.
3. Element Material Properties: 'Preprocessor' menu select Material Props >
Material Models >Double click on Structural > Linear > Elastic > Isotropic
> EX Value, 'PRXY value>. Click 'OK'
4. Enter Keypoints: From the 'ANSYS Main Menu' select: Preprocessor >
Modeling > Create > Keypoints > In Active CS.
5. Form Lines: Main menu select: Preprocessor > Modeling > Create > Lines >
Lines > In Active Coord. >select key points>ok.
6. Mesh Size: Preprocessor menu select Meshing > Size Cntrls > ManualSize
> Lines > All Lines
7. Mesh: 'Preprocessor' menu select Meshing > Mesh > Lines and click 'Pick
All'.
8. Define loads: Solution menu, select Define Loads > Apply > Structural >
Displacement > On Keypoints.
9. Select Define Loads > Apply > Structural > Force/Moment > on Keypoints.
> 'OK'

SOLUTION
10. Solving the System: 'Solution' menu select Solve > Current LS.

POST PROCESSING
11. Viewing the Results: Main Menu select General Postproc > List Results
> Reaction Solu. Select 'All struc forc F' as shown above and click 'OK'
Deformation: In the General Postproc menu, select Plot Results > Deformed
Shape> Select 'Def + undef edge' and click 'OK'.

37
RESULT
Thus the stress analysis of truss is done by using the ANSYS Software. The
Max Deflection is: 7.409

INFERENCE:

VIVA QUESTIONS
1. Ansys needs the final element model(FEM) for its final solution.(T/F)
2. Element attributes must be set before meshing the solid model. (T/F)
3. In a plane strain, the strain in the direction of thickness is assumed to be
zero.(T/F)
4. The elements are used for in-plane bending problems.
5. Which one of the following elements is required to define the thickness as a
real constant?
a. Beam b. Shell c. Solid d. None

38
 EXERCISE # 8
DETERMINATION OF DEFLECTION, PRINCIPAL AND VON-MISES
STRESSES IN PLANE STRESS AND PLAIN STRAIN AND AXI - SYMMETRY
COMPONENT.

AIM: To conduct the analysis in a plate with a circular hole using ANSYS
software.

Young’s Modulus = 200 GPa

Poisson’s Ratio = 0.3
PROCEDURE
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 17.0 - Mechanical APDL Product Launcher –
Set the Working Directory as E Drive, User - Job Name as Roll No., Ex. No. –
Click Run.

39
PRE PROCESSING
1. Preference - Structural- h-Method - Ok.
2. Preprocessor - Element type - Add/Edit/Delete – Add – Solid, 8 node 82 –
Ok – Option – Choose Plane stress w/thk - Close.
3. Real constants - Add/Edit/Delete – Add – Ok – THK 0.5 – Ok - Close.
4. Material props - Material Models – Structural – Linear – Elastic – Isotropic -
EX 2e5, PRXY 0.3 - Ok.
5. Modeling – Create – Areas – Rectangle - by 2 corner - X=0, Y=0, Width=100,
Height=50 - Ok. Circle - Solid circle - X=50, Y=25, Radius=10 - Ok. Operate
–Booleans – Subtract – Areas - Select the larger area (rectangle) – Ok – Ok -
Select Circle – Next –Ok - Ok.
6. Meshing - Mesh Tool – Area – Set - Select the object – Ok - Element edge
length 2/3/4/5 – Ok - Mesh Tool -Select TRI or QUAD - Free/Mapped – Mesh
- Select the object - Ok.

SOLUTION
7. Solution – Define Loads – Apply – Structural – Displacement - On lines -
Select the boundary where is going to be arrested – Ok - All DOF - Ok.
Pressure - On lines - Select the load applying area – Ok - Load PRES valve = 1
N/mm2- Ok.
8. Solve – Current LS – Ok – Solution is done – Close.

POST PROCESSING

General post processor- plot result- element solution.

40
RESULT
Deflection:______________________
Principal stress :___________________
Von-mises stress: ________________________
Plane Stress: _______________________
Plain Strain: ______________________

INFERENCE:

VIVA QUESTIONS
1. If a cantilever beam has a uniformly distributed load, will the bending
moment diagram be quadratic or cubic?
2. Name the element type used for beams?
3. Define Analysis and its Purpose?
4. What are the modules in Ansys Programming?
5. What are the Real Constants & Material Properties in Ansys? Explain?

41
 EXERCISE # 9
DETERMINATION OF DEFLECTION AND STRESSES IN 3D BEAMS

AIM: Compute the Deflection, Stress, Shear force and bending moment
diagrams for the beam shown and find the maximum deflection.

Rectangular c/s area of 100mm * 100m m,

Young’s modulus of 2.1×105 N/mm2,
Poisson’s ratio= 0.27.

PROCEDURE
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 17.0 - Mechanical APDL Product Launcher –
Set the Working Directory as E Drive, User - Job Name as Roll No., Ex. No. –
Click Run.

PRE PROCESSING
1. Ansys Main Menu – Preferences-Select – STRUCTURAL- h method- ok
2. Element type – Add/Edit/Delete – Add – BEAM – 2 nodes Beam 188 – ok –
close.
3. Material Properties – material models – Structural – Linear – Elastic –
Isotropic – EX – 2.1e5– PRXY – 0.27 –ok – close.

42
 4. Sections-Beams-common sections- sub type- rectangle (1st element) -
enter b=100, h=100- preview-ok.
5. Modeling – Create – Nodes – In Active CS – Apply (first node is created) –
x,y,z location in CS– 3000 (x value w.r.t first node) – apply (second node
is created) – 4500 (x value w.r.t first node) –apply (third node is created) –
6000 (x value w.r.t first node) – ok (forth node is created).
6. Create – Elements – Auto numbered – Thru Nodes – pick 1 & 2 – apply –
pick 2 & 3 – apply –pick 3 & 4 – ok (elements are created through nodes).
7. Loads – Define loads – apply – Structural – Displacement – on Nodes- pick
node 1 & 4 – apply –DOFs to be constrained – all DOF – ok.
8. Loads – Define loads – apply – Structural – Pressure – on Beams – pick
element between nodes 1 & 2–apply–pressure value at node I– 0 (value)–
pressure value at node J – 40000–k.
9. Loads – Define loads – apply – Structural – Force/Moment – on Nodes-
pick node 3 –apply – direction of For/Mom – FY – Force/Moment value –
(-80000) (-ve value) – ok.

SOLUTION
10. Solve – current LS – ok (Solution is done is displayed) – close.
11. Displacement: Plot Results – Contour plot – Nodal solution – DOF solution
– displacement vector sum – ok.
12. Stress: Plot Results – Contour plot – Nodal solution – stress – von mises
stress – ok.
13. Element table – Define table – Add – ‘Results data item’ – By Sequence num
– SMISC –SMISC,6 – apply, By Sequence num – SMISC – SMISC, 19 – apply,
By Sequence num –SMISC- SMISC, 3 – apply, By Sequence num – SMISC –
SMISC, 16 – ok – close.
14. Plot results – contour plot – Line Element Results – Elem table item at
node I – SMIS6 – Elem table item at node J – SMIS19 – ok (Shear force diagram
will be displayed).

43
15. Plot results – contour plot – Line Element Results – Elem table item at
node I – SMIS3 – Elem table item at node J – SMIS16 – ok (bending moment
diagram will be displayed).
16. Reaction forces: List Results – reaction solution – items to be listed – All
items – ok (reaction forces will be displayed with the node numbers).
17. Animation: PlotCtrls – Animate – Deformed results – DOF solution –
deformed + undeformed – ok.

RESULT

Deflection:______________________
Shear force: ________________________
Bending moment:___________________
Stress:_____________________________

INFERENCE:

EXERCISE # 10:
44
 DETERMINATION OF STRESSES IN 3D SHELL STRUCTURE

AIM: To determine stresses in given 3D shell structure

PROCEDURE
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 17.0 - Mechanical APDL Product Launcher –
Set the Working Directory as E Drive, User - Job Name as Roll No., Ex. No. –
Click Run.

PRE PROCESSING

1. Ansys Main Menu – Preferencesselect – STRUCTURAL – ok

2. Element type – Add/Edit/Delete – Add – Solid – Quad 8 node – 82 – ok –
option – element behavior K3 – Plane stress with thickness – ok – close.

45
 3. Real constants – Add – ok – real constant set no – 1 – Thickness – 0.5 –
ok.
4. Material Properties – material models – Structural – Linear – Elastic –
Isotropic – EX 30e6 –PRXY – 0.27 – ok – close.
5. Modeling – Create – Area – Rectangle – by dimensions – X1, X2, Y1, Y2 –
0, 6, 0, 2 – apply –Create – Area – Rectangle – by dimensions – X1, X2,
Y1, Y2 – 4, 6, -2, 2 – ok. Create – Area –Circle – solid circle – X, Y, radius
– 0, 1, 1 – apply – X, Y, radius – 5, -2, 1 – ok.
6. Operate – Booleans – Add – Areas – pick all.
7. Create – Lines – Line fillet – pick the two lines where fillet is required –
apply – fillet radius – 0.4 – ok. Create – Areas – Arbitrary – by lines – pick
filleted lines – ok. Operate – Booleans – Add – Areas – pick all. Create –
Area – Circle – solid circle – X, Y, radius – 0, 1, 0.4 apply –X, Y, radius –
5, -2, 0.4 – ok.
8. Operate – Booleans – Subtract – Areas – pick area which is not to be
deleted (bracket) apply – pick areas which is to be deleted (pick two
circles) – ok.
9. Meshing – Mesh Tool – Mesh Areas – Quad – Free – Mesh – pick all – ok.
Mesh Tool – Refine– pick all – Level of refinement – 3 – ok.
Solution
1. Loads – Define loads – apply – Structural – Displacement – on Lines –
select the inner lines of the upper circle – apply – DOFs to be constrained
– ALL DOF – ok.
2. Loads – Define loads – apply – Structural – Pressure – on Lines – Pick
line defining bottom left part of the circle – apply – load PRES value – 50
– optional PRES value – 500 – ok. Structural – Pressure – on Lines – Pick
line defining bottom right part of the circle – apply – load PRES value –
500 – optional PRES value – 50 – ok.
3. Solve – current LS – ok (Solution is done is displayed) – close.
POST-PROCESSOR
1. Plot Results – Deformed Shape – def+undeformed – ok.

46
RESULT

Deflection:______________________

INFERENCE:

EXERCISE # 11
STUDY STATE HEAT TRANSFER ANALYSIS OF PLANE AND AXI-
SYMMETRIC COMPONENT.
AIM: Solve the 2-D heat conduction problem for the temperature distribution

47
within the rectangular plate.
Thermal conductivity of the plate, KXX=401 W/(m-K).

PROCEDURE
The three main steps to be involved are
1. Pre Processing
2. Solution
3. Post Processing
Start - All Programs – ANSYS 17.0 - Mechanical APDL Product Launcher –
Set the Working Directory as E Drive, User - Job Name as Roll No., Ex. No. –
Click Run.
PRE PROCESSING
1. Ansys Main Menu – Preferences-select – THERMAL- h method– ok
2. Element type – Add/Edit/Delete – Add – Solid – Quad 4 node – 55 – ok –
option – element behavior K3 – Plane stress with thickness – ok – close.
3. Material Properties – material models – Thermal – Conductivity – Isotropic –
KXX – 401.
4. Modeling – Create – Area – Rectangle – by dimensions – X1, X2, Y1, Y2 – 0,
10, 0, 20 – ok.
5. Meshing – Mesh Tool – Mesh Areas – Quad – Free – Mesh – pick all – ok.
Mesh Tool – Refine – pick all – Level of refinement – 3 – ok.
6. Loads – Define loads – apply – Thermal – Temperature – on Lines – select
48
1000 C lines – apply – DOFs to be constrained – TEMP – Temp value – 1000
C – ok.
7. Loads – Define loads – apply – Thermal – Temperature – on Lines – select
1000 C lines –
SOLUTION
8. Solve – current LS – ok (Solution is done is displayed) – close.
9. Read results-last set-ok
10. List results-nodal solution-select temperature-ok
11. Observe the nodal solution per node.
12. From the menu bar-plot ctrls-style-size and shape-display of the element-
click on real constant multiplier=0.2, don’t change other values-ok.
13. Plot results-contour plot-nodal solution-temperature-deformed shape only-
ok
14. Element table-define table-add-enter user label item=HTRANS, select by
sequence no SMISC,1-ok-close.
15. Element table-list table-select HTRANS-ok

RESULT : Conducted the steady state thermal analysis and monitored the
temperature distribution.
INFERENCE:

VIVA QUESTIONS
1. Define Heat flux, Heat flow & Heat generation
2. Define Density, film coefficient
3. Define Thermal gradient & Thermal conductivity
4. Define Specific heat
COMPUTER AIDED MANUFACTURING (CAM)

G- CODES
G00: POSITIONING
G01: LINEAR INTERPOLATION
G02: CIRCULAR INTERPOLATION CW G03: CIRCULAR
49
INTERPOLATION CCW G04: DWELL
G10: OFF SET VALUE SETTING (O) G20: INCH
G21: METRIC
G22: STORED STROKE CHECK ON (O) G23: STORED STROKE
CHECK OFF (O) G25: SPINDLE SPEED DETECT OFF G26: SPINDLE
SPEED DETECT ON G27: REF. POINT RETURN CHECK G28: REF.
POINT RETURN
G30: 2ND (3,4) REF. POINT RETURN G31: SKIP CUTTING
G33: THREAD CUTTING
G34: VARIABLE LEAD THREAD CUTTING (O) G36: AUTO TOOL OFF STE X-
AXIS (O)
G37: AUTO TOOL OFF SET Z-AXIS (O)
G40: TOOL NOSE RADIUS COMPENSATION CANCEL
G41: TOOL NOSE RADIUS COMPENSATION LEFT (O)
G42: TOOL NOSE RADIUS COMPENSATION RIGHT (O)
G53: SUPPRSSION OF ZERO OFFSET G54: SETTABLE ZERO
OFFSET
G55: SETTABLE ZERO OFFSET
G56: SETTABLE ZERO OFFSET
G57: SETTABLE ZERO OFFSET G65: MACRO CALL (O)
G68: DOUBLE TURRETS MIRROR ON (O) G69: DOUBLE TURRETS
MIRROR OFF G70: FINISHING CYCLE (O)
G71: ROUGH CUTTING (TURNING) (O) G72: ROUGH CUTTING
(FACING) (O) G73: ROUGH CUTTING (PROFILE) (O) G74: GROOVING
(FACING) (O)
G75: GROOVING TURNING (O)
G76: THREAD CUTTING CYCLE (MULTI) (O) G77: TURNING CYCLE
G78: THREAD CUTTING CYCLE G79: FACING CYCLE
G90: ABSOLUTE
G91: INCREMENTAL
G92: COORDINATE SYSTEM SETTING OR
MAX. SPINDLE SPEED SETTING G94: PER MINUTE FEED

50
G95: PER REVOLUTION FEED
G96: CONSTANT SURFACE SPEED (O) G97: REVOLUTION PER MINUTE
(RPM)

M-CODES
M00: PROGRAM STOP
M01: OPTIONAL STOP
M02: PROGRAM END AND RESTART M03: SPINDLE ROTATION CW
M04: SPINDLE ROTATION CCW M05: SPINDLE STOP
M07: COOLANT ON
M09: COOLANT OFF M10: CHUCK DECLAMP M11: CHUCK
CLAMP
M16: CHUCK 1D SELECTION
M18: CHUCK 0D SELECTION
M19: SPINDLE ORIENTATION
M20: SPINDLE ORIENTATION CANCEL M30: END OF MAIN PROGRAM
M32: TAILSTOCK QUIL FORWARD M33: TAILSTOCK QUIL RETRACT
M35: PARTS CATCHE RETRACT M46: DOOR OPEN
M47: DOOR CLOSE M50: SPINDLE LOCK M51: SPINDLE
UNLOCK
M78: STEADY REST OPEN
M79: STEADY REST HOLD M82: TAIL STOCK BODY FWD /
UNCLAMP
M83: TAILSTOCK BODY RET / CLAMP M84: TOUCH PROBE ARM
FORWARD M85: TOUCH PROBE ARM RETRACT M98: SUB PROGRAM
CALL
M99: SUB PROGRAM END

51
 EXERCISE # 11
STUDY OF VARIOUS POST PROCESSORS USED IN NC MACHINES.

Aim: To Study of various post processors used in NC Machines.

The large amount of data is generated in the solution phase (several thousand of nodal values

in complex problems). These are often too much to be understood without further processing.

The post processor presents the output of the problem in a manner which is easily understood

and interpreted by the user.

52
The postprocessor performs tasks:

(i) Extraction of significant information: The information may be related to local quantities

(magnetic flux density, stress distribution) or global quantities (heat flux, electromagnetic

forces, etc.).

(ii) Synthetic presentation of the numerical data via graphics facilities: This makes

the data more understandable and easier to interpret (stress plots, displacement plots,

isothermal plots, temperature Vs time curves, magnetic field along a line, etc.).

(iii) Post processor statements: It is necessary to specify the cutter details, spindle

speed, feed rate, tolerances etc., and these are included in the post processor

statements. FEDRAT, COOLNT, CUTTER, TOLER, etc., were the typical postprocessing

statements

The APT processor will create a cutter location data file (CL Data file) which is

basically a text file containing the co-ordinates of the points to be visited by the tool. It

is necessary to modify this and convert it into a NC program to suit a particular

combination of a machine tool and a control system. Since the specifications and

capabilities of machine tools and the features of the control systems vary widely it is

essential to develop separate post processors to create NC programs for each machine

tool and control system combination.

APT was the forerunner of the present CAD/CAM technology. The developments

in CAD and CAM has made this approach of program creation obsolete. Today the

geometry of the component can directly be obtained from the 3-D CAD model. CAM

softwares can create the NC program from the geometry data. The steps involved in the

part program development using CAM softwares are described in the next section.

53
EXERCISE # 12

54
 DEVELOPMENT OF CNC PART PROGRAM FOR MILLING

AIM: Development of CNC part program for given fig:

TOOLS AND EQUIPMENTS

1. CNC simulation software FANUC
2. CNC turning machine.

PROCEDURE
1. To write the program for given job.
2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM
PARTNO / APT-1
CLPRNT
UNITS / MM
NOPOST
CUTTER / 10.0
$$GEOMETRY DEFINITION
SETPT = POINT / 0.0, 0.0, 0.0
STRTPT = POINT / 70,70,0
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P1 = POINT / 50, 50, 0
P2 = POINT / 20, -20, 0
C1 = CIRCLE / CENTER, P2, RADIUS, 30
P3 = POINT / -50, -50, 0
P5 = POINT / -30, 30, 0
C2 = CIRCLE / CENTER, P5, RADIUS, 20
P4 = POINT / 50, -20, 0
L1 = LINE / P1, P4
L2 = LINE / P3, PERPTO, L1
L3 = LINE / P3, PARLEL, L1
L4 = LINE / P1, PERPTO, L1
PLAN1 = PLANE / P1, P2, P3
PLAN2 = PLANE / PARLEL, PLAN1, ZSMALL, 16
$$MOTION COMMANDS
SPINDL / 3000, CW
FEDRAT / 100, 0
FROM / STRTPT
GO/TO, L1, TO, PLAN2, TO, L4
TLLFT, GOFWD / L1, TANTO, C1
GOFWD / C1, TANTO, L2
GOFWD / L2, PAST, L3
GORGT / L3, TANTO, C2
GOFWD / C2, TANTO, L4
GOFWD / L4, PAST, L1
NOPS
GOTO / STRTPT
FINISH

RESULT: Developed the CNC program for given figure and executed in CAM
software then created part

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INFERENCE:

Viva Questions:
1. What is mean by M05?
2. What is mean by U00?
3. What is mean by W00?
4. What is mean by M30?
5. What is N series?
6. What is the difference between Manufacturing and Production?
7. What is Counter?
8. What is ASP?
9. What is F30 command?
10. How you fix the tool?
.

EXERCISE # 13
DEVELOPMENT OF CNC PART PROGRAM FOR TURNING

AIM: To write the part programming and simulation them to the given job.
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TOOLS AND EQUIPMENTS
1. CNC simulation software FANUC
2. CNC turning machine.

PROCEDURE
1. To write the program for given job.
2. To type G and M CODES.
3. To give the tool size and stock dimensions.
4. Finally to run the machine to the operation.

PROGRAM
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X26 Z1
G71 U0.5 R1.0
G71 P01 Q02 U0.2 W0.2 F50
N01 G01 X8
G01 Z0
G01 X10 Z-2

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G01 X10 Z-12
G02 X15 Z-14.5 R2.5
G01 X15 Z-24.5
G03 X20 Z-27 R2.5
G01 X20 Z-32
N02 G01 X25.4 Z-32
G70 P01 Q02 F40
G28 U0 W0
M05
M30

RESULT: Developed the CNC program for given figure and executed in CAM
software then created part.

INFERENCE:

Viva Questions:
1. What is NC part programming?
2. In NC part programming “BLOCK” means?
3. In NC part programming data contains in the form of?
4. How many types NC part programming is prepared?
5. Manual part programming is prepared on?

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