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LABORATORY MANUAL

MEC 469



NON TRADITIONAL AND COMPUTER
AIDED MANUFACTURING
LABORATORY



1







Table of contents

S. No NAME OF THE EXPERIMENT
Page No
1 Part Program for step turning 3
2 Part Programming of Taper and radius turning 7
3 Part Programming for grooves and reliefs 11
4 Part Programming for threading of single and multi start threads 15
5 Part Programming for Milling operation on machining centre 19
6 Roughing CAM Program generation for 3 axis Milling 23
7 Z level profile CAM Program generation for 3 axis Milling 26
8 Surface Finish CAM Program for 3 axis Milling 29
9 Cutting of simple cavity on EDM Machine and estimating MRR
for different Parameters
32



























2
3
Experiment 1: Part Programming for step turning

Machines/Equipments/tools used: CNC Turning Machine, Carbide Cutting
tools, Micrometers, vernier caliper.

Material required: Aluminium bars

Learning objectives: To instil Knowledge about the codes and functions used in
part programs in students.





Outlines of the Procedure:

1. Write the program as per the drawing.

2. Set the tool offset.

3. Simulate on the machine controller.

4. Execute the actual cutting.

5. Check for the dimensions as per the sketch

6. Analyze the surface finish.

Cautions:

1. Dont operate the machine without the presence of faculty member or lab
instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.
4
4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.



































5

Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:

































S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





6







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained







7

Experiment 2: Part Programming of Taper and radius turning.

Machines/Equipments/tools to be used: CNC Turning Machine, Carbide
Cutting tools, Micrometers, vernier calipers, radius gauge, bevel protector.

Material required: Aluminium bars.

Learning objectives: To learn CNC program generation and execution on the
Turning machine.



Outlines of the Procedure:

1. Write the program as per the drawing.

2. Set the tool offset.

3. Simulate on the machine controller.

4. Execute the actual cutting.

5. Check for the dimensions as per the sketch

6. Analyze the surface finish.

Cautions:

1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.

4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.
8
6. Dont keep any sharp tool in your pocket.

7. Tools being used should be well sharpened.




































9
Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:






























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





10







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained







11
Experiment 3: Part Programming for grooves and reliefs.

Machines/Equipments/tools to be used: CNC Turning Machine, Carbide
Cutting tools, Micrometers, vernier calipers.

Material required: Aluminium bars.

Learning objectives: To learn CNC program generation and execution on the
machine to create grooves and reliefs.



Outlines of the Procedure:

1. Write the program as per the drawing.

2. Set the tool offset.

3. Simulate on the machine controller.

4. Execute the actual cutting.

5. Check for the dimensions as per the sketch

6. Analyze the surface finish.

Cautions:

1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.

4. Be careful and attentive while working on this job.
12
5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.
































13


Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:



























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





14







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained







15

Experiment 4: Part Programming for threading of single and multi start
threads.

Machines/Equipments/tools to be used: CNC Turning Machine, Carbide
Cutting tools, Micrometers, vernier calipers, thread gauges.

Material required: Aluminium bars.

Learning objectives: The objective is to learn CNC program generation and
execution on the machine.



Outlines of the Procedure:

1. Write the program as per the drawing.

2. Set the tool offset.

3. Simulate on the machine controller.

4. Execute the actual cutting.

5. Check for the dimensions as per the sketch

6. Analyze the surface finish.

Cautions:

1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.
16
4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.


































17

Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:





























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





18







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained







19

Experiment 5: Part Programming for Milling operation on machining centre.

Machines/Equipments/tools to be used: CNC Milling Machine, Carbide Cutting
tool, Micrometer, vernier caliper, thread gauge.

Material required: Aluminium bars.

Learning objectives: To learn procedures for CNC program generation and
execution on the machine for milling operation.



Outlines of the Procedure:

1. Write the program as per the drawing.

2. Set the tool offset.

3. Simulate on the machine controller.

4. Execute the actual cutting.

5. Check for the dimensions as per the sketch

6. Analyze the surface finish.

Cautions:

1. Dont operate the machine without the presence of faculty member or
lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.
20
4. Be careful and attentive while working on this job.

5. Use proper tools for each operation.

6. Dont keep any sharp tool in your pocket.

7. Tools being used should be well sharpened.
































21
Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:






























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





22







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained






23
Experiment 6: Roughing CAM Program generation for 3 axis Milling.

Machines/Equipments/tools to be used: Computer with Pro-E W ildfire
software.

Material required: none.

Learning objectives: To practice CAM program generation and simulation on
machine.

Outlines of the Procedure:

1. Make the CAD Model.

2. Make CAM Program.

3. Simulate the CAM program.

Required results: Check for Gauging of the tools in simulation.

Cautions:

1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.

4. Be careful and attentive while working on this job.



























24
Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:





























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





25







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained








26
Experiment 7: Z level profile CAM Program generation for 3 axis Milling.

Machines/Equipments/tools to be used: Computer with Pro-E W ildfire
software.

Material required: none.

Learning objectives: to write and CAM program generation and simulation it
on 3 axis machine.

Outlines of the Procedure:

1. Make the CAD Model.

2. Make CAM Program.

3. Simulate the CAM program.

Required results: Check for Gauging of the tools in simulation.

Cautions:

1. Dont operate the machine without the presence of faculty member
or lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.

4. Be careful and attentive while working on this job.













27
Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:































S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





28







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained






29
Experiment 8: Surface F inish CAM Program for 3 axis Milling.

Machines/Equipments/tools to be used: Computer with Pro-E W ildfire
software.

Material required: none.

Learning objectives: To learn steps required for CAM program generation and
simulation on machine.

Outlines of the Procedure:

1. Make the CAD Model.

2. Make CAM Program.

3. Simulate the CAM program.

Required results: Check for Gauging of the tools in simulation.

Cautions:

1. Dont operate the machine without the presence of faculty member or
lab instructor.
2. Make sure the simulation does not show any gauging off tool.

3. Wear apron, shoes and tight fitted clothes.

4. Be careful and attentive while working on this job.

30
Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:






























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension





31







Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained







32
Experiment 9: Cutting of simple cavity on EDM Machine and estimating MRR
for different Parameters.

Equipment required: EDM, Vernier caliper, Tool holder, Copper Electrode,
Micrometer etc.

Material Required: Workpiece and EDM oil.



Learning object: To study Non- Conventional machining equipment and the
metal removal process and better understand the relationship between time
for which the current is supplied and metal removed.

Outline of procedure:

1. Take a work piece and submerge it into EDM oil before switching
on the power supply to EDM.

2. Switch on the machine in the presence of operator and Set the
proper current value. Set the proper voltage value. See the depth
of material removed as indicated on the m/c)

3. Switch off the power supply to the machine when the desired
depth of material is removed.
33


Material removal rate Vw versus the surface current density

Result Scope: Notice the time taken for the material removed with different
current settings.

Cautions:

1. Keep in mind that machinery capable of cutting metal is inherently
dangerous.

2. Operator should be present at the time of operation of the machine.

3. Make sure the work piece is adequately clamped .

4. Make sure the tool holder and electrode is adequately clamped for the job
being performed.

5. Always wear safety glasses when around the machine.

6. Loose clothing, rings or watches should not be worn when operating
machine.

7. Use extreme caution while operating the machine as high current is used.































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Process Sheet
Workshop Name: Date:
Name of Student: Section:
Roll No.: Registration No.:
Job:

Drawing:




























S. Job Operations Tools Used Equipment/Machine Remark
No. Specification Used
/ Dimension






35






Learning Outcome:





To be filled in by Faculty
Parameter (Scale from 1-10, 1 for very poor and
S.No. 10 Marks Max. Marks
excellent) obtained
1 Understanding of the student about the 20
procedure/apparatus. (process sheet)

Dimensional Accuracy, Finishing and Learning
2 Outcome. 20

3 Completion of experiment/job, Discipline and 10
Cleanliness

Signature of Faculty Total marks
obtained