ADVANCED MANUFACTURING METHODS LAB

Paper Code: ETAT-455 (ELECTIVE)

For Session (2016-2017)

Lab Manual

Maharaja Agrasen Institute of Technology

PSP Area, Sector-22, Rohini, Delhi-110085
GENERAL INSTRUCTIONS

1. Every student should obtain a set of instruction sheets entitled Advanced

Manufacturing methods lab.
2. For reasons of safety, Students should ensure that floor around the machine is
clear and dry (not oily) to avoid slipping.
3. Instruments and tools will be issued from the tool room. Every student must
produce his identity card for the purpose. Tools, etc. must be retuned to the tool
room on the same day.
4. The student should take the permission of the Lab Staff / Tutor before handling
the machine.
5. The student should not lean on the machine when it is working.
6. Power to the machines will be put off 10 minutes before the end of laboratory
session to allow the students to return the tools.
7. Laboratory reports should be submitted on Hard bound Writing file.
 ADVANCED MANUFACTURING METHODS LAB

Paper Code: ETAT-455 (ELECTIVE)

Paper: Advanced Manufacturing Methods Lab

List of Experiments:

1. Study of electric discharge machining process.

2. Determination of material removal rate of the steel workpiece machined on

electric discharge machine (EDM).

3. Determination of surface roughness of the steel workpiece machined on

electric discharge machine (EDM).

4. Study of electrochemical machining process (ECM).

5. Study of flexible manufacturing system (FMS).

6. Study the effect of current on material removal rate on an EDM machined

work piece.

7. Study the effect of current on surface finish on an EDM machined work

piece.

8. Study of the effect of different tool material on material removal rate on an

EDM machined work piece.

9. Study of the effect of different tool material on surface finish on an EDM

machined work piece.

10.Study of a computer integrated manufacturing (CIM) system.

11.Optimization of Electric Dischagre machining parameters using taguchi

technique. (Research Practical, outside curriculum)
 LAB PRACTICAL NO. 1

Aim: Study of electric discharge machining process

LHS: Draw a labeled diagram of the EDM

Theory:

Electrical Discharge Machining (EDM) is a controlled metal-removal

process that is used to remove metal by means of electric spark erosion. In
this process an electric spark is used as the cutting tool to cut (erode) the
workpiece to produce the finished part to the desired shape. The metal-
removal process is performed by applying a pulsating (ON/OFF) electrical
charge of high-frequency current through the electrode to the workpiece.
This removes (erodes) very tiny pieces of metal from the workpiece at a
controlled rate.

Fig 1: Principle of EDM

Procedure: Write about the procedure to operate the EDM

PROCEDURE TO OPERATE EDM

1. Put MCB 'ON'.

2. Check R, Y and B lights are 'ON'.
3. Put mains switch (No. 1) 'ON' & check its light with sign curve is 'ON' and
check the level low light fluctuates.
4. Set the knob Machine-Set-Micro fin to 'Set' position.
5. See that buzzer switch (black switch) is 'ON'.
6. Put motor switch (No. 2) 'ON' and see buzzer working when 'up-down knob
is manipulated.
7. Put oil motor switch (No. 3) to 'ON' position.
8. Check level low light is off when sufficient oil is pumped into the tank.
9. Put Machine-Set-Micro fin knob to 'Machine' position and put 2 amps
switch to 'ON' position `initially and increase later on.
10.Put machining switch (No. 4) to 'ON' position and see its indicator is 'ON'
now.
11.For rough finish, put fineness knobs to 8 & 6 positions and bring 'Up- Down'
knob to down position. If you notice that dial needle fluctuates, turn the
adjacent knob in clockwise direction.
12.Set the knobs for 'Cycle OFF time' and 'Cycle ON time'.
13.When red light in the gap meter illuminates, increase the amperage.
14.For vertical axis setting, set the feed rate, to overpower it, there are 'creep'
and 'rapid' function buttons.
15.For final finish reduce the amperage and the gap.
16.At last put Cut-Off-Fine knob to 'Fine' position and reduce gap to 3-3 and
put 2 amps switch to 'ON' position.
 LAB PRACTICAL NO.2

Aim: Determination of material removal rate of the steel workpiece

machined on electric discharge machine (EDM).

Apparatus: Write the name of machine used and materials of tool and
workpiece.

Specification: Write about the specifications of workpiece, tool, non

electrical parameters and electrical parameters.

Procedure:

1. Weigh the workpiece by cleaning it properly

2. Set the workpiece and tool as described in experiment 1.
3. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 20 minutes.
4. Stop the machine and take out the workpiece from the machine.
5. Weigh the workpiece by cleaning it.
6. Calculate the difference in weight of the workpiece.
7. Use formula (1) for the calculation of material removal rate.

Observations and Calculation (LHS): Evaluate the Material removal rate

using mathematical expressions

S. No. Current Weight Weight Change in

(A) (intial)(gm) (Final)(gm) Weight(gm)
1.

Change in weight
MRR
Time (1)

Result:

Precautions: Discuss some precautions taken while performing the

experiment.
 LAB PRACTICAL NO. 3:

Aim: Determination of surface roughness of the steel workpiece machined

on electric discharge machine (EDM).

Apparatus: Write the name of machine used and materials of tool and
workpiece.

Procedure:

1. Set the workpiece and tool as described in experiment 1.

2. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 20 minutes.
3. Stop the machine and take out the workpiece from the machine.
4. Mark three locations on the machined area of the workpiece.
5. Measure the surface roughness at three marked points on the machined
area by using the taylor hobson talysurf machine.
6. Take mean of the surface roughness.

Observation: Measure surface roughness at three different areas of the

machined surface.

S. No. Surface Surface Surface

Roghness(m)1 Roghness(m)2 Roghness(m)3
1.
2.
3.

Calculation: Calculate the mean surface roughness.

Result:

Precautions: Discuss some precautions taken while performing the

experiment.
 LAB PRACTICAL NO. 4:

Aim: Study of electrochemical machining process (ECM).

Theory:

Electrochemical Machining (ECM) is a non-traditional machining (NTM)

process belonging to Electrochemical category. ECM is opposite of
electrochemical or galvanic coating or deposition process. Thus ECM can be
thought of a controlled anodic dissolution at atomic level of the work piece
that is electrically conductive by a shaped tool due to flow of high current at
relatively low potential difference through an electrolyte which is quite often
water based neutral salt solution. Fig. 1 schematically shows the basic
principle of ECM.

Figure 1: Basic principle of ECM

Modeling of MRR: Evaluate the expression for MRR in ECM.

Material removal rate (MRR) is an important characteristic to evaluate

efficiency of a non-traditional machining process. In ECM, material removal
takes place due to atomic dissolution of work material. Electrochemical
dissolution is governed by Faradays laws.
The first law states that the amount of electrochemical dissolution or deposition is
proportional to amount of charge passed through the electrochemical cell, which
may be expressed as:
mQ,

where m = mass of material dissolved or deposited

Q = amount of charge passed

The second law states that the amount of material deposited or dissolved further
depends on Electrochemical Equivalence (ECE) of the material that is again the
ratio atomic weigh and valency. Thus
mECEA/v

Thus
mQA/v

where F = Faradays constant = 96500 coulombs

m=ItA/Fv

MRR=m/t =IA/F v
where I = current
= density of the material.
Application of ECM:

Die sinking
Profiling and contouring
Drilling
 LAB PRACTICAL NO. 5:

Aim: To run the entire FMS system along with the Aristo robot and
conveyer.
Theory: Write about the flexible manufacturing system in brief with
advantages.

Procedure:
FMS Operating Procedure
1. Drain the Air compressor. Ensure that there is no water in the
Compressor tank.
2. Switch ON the compressor.
3. Check the air pressure is at 8 bar in all machines.
4. Turn ON the FMS Computer
5. Release the Emergency button in the CELL Controller.
6. Turn ON the XLTURN Computer & Control box of XLTURN
7. Type cd downloa~1 and Enter key in XLTURN Computer
8. Then type FLSTEP & Enter key
9. Release the Emergency button in XLTURN machine.
10.Press Alt + H in Xlturn PC .
11.Press X for homing the X axis
12.Press Z for homing the Z axis
13.Press Alt + J and the type M38 & Enter
14.Press Alt + A (Note: XLTURN is ready for FMS system)
15.Turn ON the XLMILL Computer & Control box of XLMill
16.Type cd downloa~1 and Enter key in XLMILL Computer
17.Then type FANUCMD & Enter key
18.Release the Emergency button in XLMILL machine.
19.Press Alt + H in Xlturn PC .
20.Press Z for homing the Z axis
21.Press Y for homing the Y axis
22.Press X for homing the X axis
23.Press Alt + J and the type M38 & Enter
24.Press Alt + A (Note: XLMILL is ready for FMS system)
(You can run the 100.fnc program in milling machine for ready position)

25.Turn ON the ASRS Controller.

26.Press NST(Home) key in ASRS Teach Pendant
27.Once the home is completed, Then Press Auto in the teach pendant.
28.Now the ASRS come to Ready Position. (Note: The ASRS ready for
FMS System)
29.Turn ON the Shuttle Conveyor Control Box.
30.The Pallet Holder will move to Home Position & then Stop at Infront of
Mill.
31.Check All Pallets are there in ASRS station.
32.Turn ON Robot Control & Release the E-Stop Button.
33.Double click aristo.exe in Desktop. Now the robot software screen will
open.
34.Physically verify the robot is in Home Position. If it is not in Home,
Slide the speed menu.
35.Slide J1+ upto 20degree from the Home sensor.
36.Slide J2- upto 20degree from the Home sensor.
37.Slide J3- upto 20degree from the Home sensor.
38.Slide J4+ upto 20degree from the Home sensor.
39.Slide J6+ upto 90degree from the Home sensor.
40.Now select Home ALL (Note: Now the robot will move to
HomePosition.
41.Select file FMS.PRG for the FMS Execution.
42.Click RUN button in the Menu.
43.Now the robot is ready for FMS system
44.Now Open FMSFull.exe in FMS computer. (Shortcut is available in the
Desktop)
45.Select Automode in the FMS system.
46.Select Full sequence in the MENU
47.Click Serial Port for Lathe (It will show Port is Open)
48.Click Serial Port for Mill (It will show Port is Open)
(Note : If it show any other message there is problem in the serial port or
Close any other application in the window)

49.Click RUN in the Menu

50.Enter the file name for XLTURN eg) 111 & enter
51.Enter the file name for XLMILL eg) 111 & Enter
52.Enter the starting position of the ASRS eg) 1 & Enter
53.Enter the no. of cycle e.g. 1
54.Now the FMS demo program will execute.

Result:
Precaution: List some precautions taken during experiment.
 LAB PRACTICAL 6
Aim: Study the effect of current on material removal rate on an EDM
machined work piece.

Apparatus: Write the name of machine used and materials of tool and
workpiece.

Procedure:

1. Weigh the workpiece by cleaning it properly

2. Set the workpiece and tool as described in experiment 1.
3. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 15 minutes.
4. Stop the machine and take out the workpiece from the machine.
5. Weigh the workpiece by cleaning it.
6. Calculate the difference in weight of the workpiece.
7. Use formula (1) for the calculation of material removal rate.
8. Repeat the steps 1 to 7 by considering three different values of current
and keeping all other inputs as constant (same value as on one).
Observation:

S. No. Current Weight Weight Change in

(A) (intial)(gm) (Final)(gm) Weight(gm)
1.
2.
3.

Calculation: Calculate the material removal rate for three readings by using
the relationship.

Change in weight
MRR
Time (1)

Result: Discuss the variation of MRR with current by using a graph

Precautions: Discuss some precautions taken while performing the

experiment.
 LAB PRACTICAL 7

Aim: Study the effect of current on surface finish on an EDM machined

work piece.

Apparatus: Write the name of machine used and materials of tool and
workpiece.

Procedure:

1. Set the workpiece and tool as described in experiment 1.

2. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 20 minutes.
3. Stop the machine and take out the workpiece from the machine.
4. Mark three locations on the machined area of the workpiece.
5. Measure the surface roughness at three marked points on the machined
area by using the taylor hobson talysurf machine.
6. Take mean of the surface roughness.
7. Repeat the steps 1 to 6 by considering three different values of current
and keeping all other inputs as constant (same value as on one).

Observation:

S. No. Current Surface

(A) Roghness(m)
1.
2.
3.

Result: Discuss the variation of Surface roghness with current by using a graph

Precautions: Discuss some precautions taken while performing the experiment.

 LAB PRACTICAL 8

Aim: Study of the effect of different tool material on material removal rate
on an EDM machined work piece.

Apparatus: Write the name of machine used and materials of tool and
workpiece.

1. Weigh the workpiece by cleaning it properly

2. Set the workpiece and tool as described in experiment 1.
3. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 15 minutes.
4. Stop the machine and take out the workpiece from the machine.
5. Weigh the workpiece by cleaning it.
6. Calculate the difference in weight of the workpiece.
7. Calculate of material removal rate.
8. Repeat the steps 1 to 7 by changing the material of the tool and keeping
all other inputs as constant (same value as on one).
Observation:

S. No. Tool Material Weight Weight Change in

(intial)(gm) (Final)(gm) Weight(gm)
1. Copper
2. Graphite

Result: Discuss the variation of material removal rate with tool material.

Precautions: Discuss some precautions taken while performing the

experiment.
 LAB PRACTICAL 9

Aim: Study of the effect of different tool material on surface finish on an

EDM machined work piece.

Apparatus: Write the name of machine used and materials of tool and
workpiece.

1. Set the workpiece and tool as described in experiment 1.

2. Start the machining of the workpiece by setting specific values for
current, tool, Ton, Toff and flushing pressure. Run the machine for a
fixed time of 20 minutes.
3. Stop the machine and take out the workpiece from the machine.
4. Mark three locations on the machined area of the workpiece.
5. Measure the surface roughness at three marked points on the machined
area by using the taylor hobson talysurf machine.
6. Take mean of the surface roughness.
7. Repeat the steps 1 to 6 by changing the tool material and keeping all
other inputs as constant (same value as on one).
Observation:

S. No. Tool Material Surface

Roughness
(m)
1. Copper
2. Graphite

Result: Discuss the variation of Surface Roughness with tool material.

Precautions: Discuss some precautions taken while performing the

experiment.
 LAB PRACTICAL 10

Aim: Study of a computer integrated manufacturing (CIM) system.

Theory:

Computer Integrated Manufacturing (CIM) encompasses the entire range of

product development and manufacturing activities with all the functions
being carried out with the help of dedicated software packages. The data
required for various functions are passed from one application software to
another in a seamless manner. For example, the product data is created
during design. This data has to be transferred from the modelling software to
manufacturing software without any loss of data. CIM uses a common
database wherever feasible and communication technologies to integrate
design, manufacturing and associated business functions that combine the
automated segments of a factory or a manufacturing facility. CIM reduces
the human component of manufacturing and thereby relieves the process of
its slow, expensive and error-prone component. CIM stands for a holistic
and methodological approach to the activities of the manufacturing
enterprise in order to achieve vast improvement in its performance.

CIM Hardware And CIM Software

CIM Hardware comprises the following:

i). Manufacturing equipment such as CNC machines or computerized work

centers, robotic work cells, DNC/FMS systems, work handling
and tool handling devices, storage devices, sensors, shop floor data
collection devices, inspection machines etc.

ii). Computers, controllers, CAD/CAM systems, workstations / terminals,

data entry terminals, bar code readers, RFID tags, printers, plotters and other
peripheral devices, modems, cables, connectors etc.,

CIM software generally comprises computer program to carry following

functions:

Management of Information System Sales

Marketing
Finance
Database Management
 Modeling and Design
Analysis
Simulation
Communications
Monitoring
Production Control
Manufacturing Area Control
Job Tracking
Inventory Control
Shop Floor Data Collection
Order Entry
Materials Handling
Device Drivers
Process Planning
Manufacturing Facilities Planning
Work Flow Automation
Business Process Engineering
Network Management
Quality Management

Elements of a CIM

Marketing
Product Design
Planning
Purchase
Manufacturing Engineering
Factory Automation Hardware
Warehousing
Logistics and Supply Chain Management
Finance
Information Management

Conceptual Model of Manufacturing

The computer has had and continues to have a dramatic impact on the
development of production automation technologies. Nearly all modern
production systems are implemented today using computer systems. The term
computer integrated manufacturing
(CIM) has been coined to denote the pervasive use of computers to design the
products, plan the production, control the operations, and perform the various
business related functions needed in a manufacturing firm.
CAD/CAM
(computer-aided design and computer-aided manufacturing) is another term
that is used almost synonymously with CIM.

Let us attempt to define the relationship between automation and CIM by

developing a conceptual model of manufacturing. In a manufacturing firm, the
physical activities related to production that take place in the factory can be
distinguished from the infor-mation-processing activities, such as product
design and production planning, that usually occur in an office environment.
The physical activities include all of the manufacturing processing, assembly,
material handling, and inspections that are performed on the product. These
operations come in direct contact with the product during manufacture. They
touch the product. The relationship between the physical activities and the
information processing activities in our model is depicted in Figure 1. Raw
materials flow in one end of the factory and finished products flow out the
other end. The physical activities (processing, handling, etc.) take place inside
the factory. The information-processing functions form a ring that surrounds
the factory, providing the data and knowledge required to produce the product
successfully. These information-processing functions include (1) certain
business activities (e.g., marketing and sales, order entry, customer billing,
etc.), (2) product design, (3) manufacturing planning, and (4) manufacturing
control. These four functions form a cycle of events that must accompany the
physical production activities but which do not directly touch the product. Now
consider the difference between automation and CIM. Automation is concerned
with the physical activities in manufacturing. Automated production systems
are designed to accomplish the processing, assembly, material handling, and
inspecting activities with little or no human participation. By comparison,
computer integrated manufacturing is (figure 1)
 Figure 1: Conceptual model of manufacturing

In the figure 1 Model of manufacturing, showing (a) the factory as a

processing pipeline where the physical manufacturing activities are
performed, and (b) the information-processing activities that support
manufacturing as a ring that surrounds the factory concerned more with the
information-processing functions that are required to support the production
operations. CIM involves the use of computer systems to perform the four
types of information-processing functions. Just as automation deals with the
physical activities, CIM deals with automating the information-processing
activities in manufacturing.
 LAB PRACTICAL 11

Aim: Optimization of Electric Dischagre machining parameters using

taguchi technique.

Equipments and Tools: Minitab software, EDM machine , MS workpiece,

Brass tool

Procedure:

1. Set the tool and workpiece on the EDM machine as explained in

experiment 1.
2. Select three different current readings, tool materials and Ton time.
3. Make an L9 orthogonal array using the MINITAB software.
4. Perform experimentation work by following the orthogonal array.
5. Calculate the surface roughness for each experimentation run.
6. Feed the output data to the taguchi table
7. Predict the optimum set of input parameter using the taguchi technique.

Optimization check

1. Use the predicted values of the taguchi technique and machine the
workpiece.
2. Measure the surface roughness
3. Calculate the error.

Result:

Precautions