CIM & Automation Lab Manual VTU

Sampoorna Institute of Technology and Research.

AS PER SYLLABUS
CIM & AUTOMATION LAB
Subject Code : 10MEL78

IA Marks : 25

Hours/Week : 04

Exam Hours : 03

Total Hours : 42

Exam Marks : 50
PART – A

CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling
operations. 3 typical simulations to be carried out using simulation packages like MasterCAM, or any equivalent software.
PART – B
(Only for Demo/Viva voce)
1. FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval
system (ASRS) and linear shuttle conveyor Interfacing CNC lathe, milling with loading
unloading arm and ASRS to be carried out on simple components.
2. Robot programming: Using Teach Pendent & Offline programming to perform pick and
place, stacking of objects, 2 programs.
PART – C
(Only for Demo/Viva voce)
Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these
topics to be conducted.
Scheme of Examination:
Two questions from Part A - 40 Marks (20 Write up +20)
Viva - Voce - 10 Marks
TOTAL: 50 MARKS

CIM and Automation Lab

1


1.0 INTRODUCTION
The first NC machines were built in the 1940s and 1950s, based on existing tools that were
modified with motors that moved the controls to follow points fed into the system on
punched tape. These early servomechanisms were rapidly augmented with analog and digital
computers, creating the modern CNC machine tools that have revolutionized the machining
processes.
1.1 Numerical control (NC) is the automation of machine tools that are operated by
abstractly programmed commands encoded on a storage medium, as opposed to controlled
manually via handwheels or levers, or mechanically automated via cams alone Fig No 01.

1.2 computer numerical control (CNC), Most NC today is CNC in which computers play
an integral part of the control. In modern CNC systems, end-to-end component design is
highly automated using computer-aided design (CAD) and computer-aided manufacturing
(CAM) programs. The programs produce a computer file that is interpreted to extract the
commands needed to operate a particular machine via a post-processor, and then loaded into
the CNC machines for production. Since any particular component might require the use of a
number of different tools – drills, saws, etc., modern machines often combine multiple tools
into a single "cell". In other cases, a number of different machines are used with an external
controller and human or robotic operators that move the component from machine to
machine. In either case, the complex series of steps needed to produce any part is highly
automated and produces a part that closely matches the original CAD design.
The position of the tool is driven by motors through a series of step-down gears in
order to provide highly accurate movements, or in modern designs, direct-drive stepper motor
or servo motors. Open-loop control works as long as the forces are kept small enough and

2


speeds are not too great. On commercial metalworking machines closed loop controls are
standard and required in order to provide the accuracy, speed, and repeatability demanded.

As the controller hardware evolved, the mills themselves also evolved. One change has been
to enclose the entire mechanism in a large box as a safety measure, often with additional
safety interlocks to ensure the operator is far enough from the working piece for safe
operation. Most new CNC systems built today are completely electronically controlled
Fig No 02.
CNC-like systems are now used for any process that can be described as a series of
movements and operations. These include laser cutting, welding, friction stir welding,
ultrasonic welding, flame and plasma cutting, bending, spinning, hole-punching, pinning,
gluing, fabric cutting, sewing, tape and fiber placement, routing, picking and placing (PnP),
and sawing.
Tools with CNC variant Machines
Drills, EDMs, Lathes, Milling machines, Wire bending machines, Plasma cutters, Water jet
cutters, Laser cutting, Surface grinders, Cylindrical grinders, 3D Printing etc..

1.3 Direct numerical control (DNC), also known as distributed numerical control (also
DNC), is a common manufacturing term for networking CNC machine tools. On some CNC
machine controllers, the available memory is too small to contain the machining program (for
example machining complex surfaces), so in this case the program is stored in a separate
computer and sent directly to the machine, one block at a time. If the computer is connected
to a number of machines it can distribute programs to different machines as required.

3


Usually, the manufacturer of the control provides suitable DNC software Fig No 03.
However, if this provision is not possible, some software companies provide DNC
applications that fulfill the purpose. DNC networking or DNC communication is always
required when CAM programs are to run on some CNC machine control.

1.4 What is Machining ? is any of various processes in which a piece of raw material is cut
into a desired final shape and size by a controlled material-removal process. The many
processes that have this common theme, controlled material removal, are today collectively
known as subtractive manufacturing, in distinction from processes of controlled material
addition, which are known as additive manufacturing.
The precise meaning of the term "machining" has evolved over the past two centuries as
technology has advanced. During the Machine Age, it referred to (what we today might call)
the "traditional" machining processes, such as turning, boring, drilling, milling, broaching,
sawing, shaping, planing, reaming, and tapping. In these "traditional" or "conventional"
machining processes, machine tools, such as lathes, milling machines, drill presses, or others,
are used with a sharp cutting tool to remove material to achieve a desired geometry. Since the
advent of new technologies such as electrical discharge machining, electrochemical
machining, electron beam machining, photochemical machining, and ultrasonic machining,
the retronym "conventional machining" can be used to differentiate those classic technologies
from the newer ones. In current usage, the term "machining" without qualification usually
implies the traditional machining processes.


4


1.5 Letter addresses

Variable

Description

A

Absolute or incremental position of A axis (rotational axis around X axis)

B

Absolute or incremental position of B axis (rotational axis around Y axis)

C

Absolute or incremental position of C axis (rotational axis around Z axis)

D

Defines diameter or radial offset used for cutter compensation. D is used for depth
of cut on lathes.

E

Precision feedrate for threading on lathes

F

Defines feed rate

G

Address for preparatory commands

H

Defines tool length offset;

I

Defines arc center in X axis for G02 or G03 arc commands.

J

Defines arc center in Y axis for G02 or G03 arc commands.

K

Defines arc center in Z axis for G02 or G03 arc commands.

L

Fixed cycle loop count;

M

Miscellaneous function

N

Line (block) number in program; System parameter number

O

Program name

P

Serves as parameter address for various G and M codes

Q

Peck increment in canned cycles

R

Defines size of arc radius, or defines retract height in milling canned cycles

S

Defines speed, either spindle speed or surface speed depending on mode

T

Tool selection

U

Incremental axis corresponding to X axis (typically only lathe group A controls)
Also defines dwell time on some machines (instead of "P" or "X").

V

Incremental axis corresponding to Y axis

W

Incremental axis corresponding to Z axis (typically only lathe group A controls)

X

Absolute or incremental position of X axis.

Y

Absolute or incremental position of Y axis

Z

Absolute or incremental position of Z axis


5


1.6 List of G-codes
Code

Description

Milling Turning
(M)

(T)

G00

Rapid positioning

M

T

G01

Linear interpolation

M

T

G02

Circular interpolation, clockwise

M

T

G03

Circular interpolation, counterclockwise

M

T

G04

Dwell

M

T

G05.1 Q1.

AI Advanced Preview Control

M

G06.1

Non Uniform Rational B Spline Machining

M

G07

Imaginary axis designation

M

G09

Exact stop check, non-modal

M

T

G10

Programmable data input

M

T

G11

Data write cancel

M

T

G12

Full-circle interpolation, clockwise

M

G13

Full-circle interpolation, counterclockwise

M

G17

XY plane selection

M

G18

ZX plane selection

M

G19

YZ plane selection

M

G20

Programming in inches

M

T

G21

Programming in millimeters (mm)

M

T

G28

Return to home position (machine zero, aka machine

M

T

M

T

reference point)
G30

Return to secondary home position (machine zero, aka
machine reference point)

G31

Skip function (used for probes and tool length measurement
systems)

G32

M

Single-point threading, longhand style (if not using a cycle,

T

e.g., G76)
G33

Constant-pitch threading

G33

T

M

Single-point threading, longhand style (if not using a cycle,

T

e.g., G76)
G34

Variable-pitch threading

M

G40

Tool radius compensation off

M


T
6


G41

Tool radius compensation left

M

T

G42

Tool radius compensation right

M

T

G43

Tool height offset compensation negative

M

G44

Tool height offset compensation positive

M

G45

Axis offset single increase

M

G46

Axis offset single decrease

M

G47

Axis offset double increase

M

G48

Axis offset double decrease

M

G49

Tool length offset compensation cancel

M

G50

Define the maximum spindle speed

G50

Scaling function cancel

G50

Position register

G52

Local coordinate system (LCS)

M

G53

Machine coordinate system

M

T

G54 to G59

Work coordinate systems (WCSs)

M

T

Extended work coordinate systems

M

T

G61

Exact stop check, modal

M

T

G62

Automatic corner override

M

T

G64

Default cutting mode (cancel exact stop check mode)

M

T

G70

Fixed cycle, multiple repetitive cycle, for finishing (including

G54.1 P1 to
P48

T
M
T

T

contours)
G71

Fixed cycle, multiple repetitive cycle, for roughing (Z-axis

T

emphasis)
G72

Fixed cycle, multiple repetitive cycle, for roughing (X-axis

T

emphasis)
G73

Fixed cycle, multiple repetitive cycle, for roughing, with

T

pattern repetition
G73

Peck drilling cycle for milling – high-speed (NO full
retraction from pecks)

G74

Peck drilling cycle for turning

G74

Tapping cycle for milling, lefthand thread, M04 spindle

M

direction
G75

Peck grooving cycle for turning


T
M
T
7


G76

Fine boring cycle for milling

G76

Threading cycle for turning, multiple repetitive cycle

G80

Cancel canned cycle

M

G81

Simple drilling cycle

M

G82

Drilling cycle with dwell

M

G83

Peck drilling cycle (full retraction from pecks)

M

G84

Tapping cycle, righthand thread, M03 spindle direction

M

G84.2

Tapping cycle, righthand thread, M03 spindle direction, rigid
toolholder

G84.3

Tapping cycle, lefthand thread, M04 spindle direction, rigid
toolholder

M
T
T

M
M

G85

boring cycle, feed in/feed out

M

G86

boring cycle, feed in/spindle stop/rapid out

M

G87

boring cycle, backboring

M

G88

boring cycle, feed in/spindle stop/manual operation

M

G89

boring cycle, feed in/dwell/feed out

M

G90

Absolute programming

M

G90

Fixed cycle, simple cycle, for roughing (Z-axis emphasis)

G91

Incremental programming

G92

Position register (programming of vector from part zero to
tool tip)

T (B)
T (A)

M

T (B)

M

T (B)

G92

Threading cycle, simple cycle

G94

Feedrate per minute

G94

Fixed cycle, simple cycle, for roughing (X-axis emphasis)

G95

Feedrate per revolution

G96

Constant surface speed (CSS)

G97

Constant spindle speed

M

G98

Return to initial Z level in canned cycle

M

G98

Feedrate per minute (group type A)

G99

Return to R level in canned cycle

G99

Feedrate per revolution (group type A)


T (A)
M

T (B)
T (A)

M

T (B)
T
T
T (A)

M
T (A)

8


List of M-codes
Code

Description

Milling

Turning

(M)

(T)

M00

Compulsory stop

M

T

M01

Optional stop

M

T

M02

End of program

M

T

M03

Spindle on (clockwise rotation)

M

T

M04

Spindle on (counterclockwise rotation)

M

T

M05

Spindle stop

M

T

M06

Automatic tool change (ATC)

M

T (some-times)

M07

Coolant on (mist)

M

T

M08

Coolant on (flood)

M

T

M09

Coolant off

M

T

M13

Spindle on (clockwise rotation) and coolant on (flood) M

M19

Spindle orientation

M

M21

Mirror, X-axis

M

M21

Tailstock forward

M22

Mirror, Y-axis

M22

Tailstock backward

M23

Mirror OFF

M23

Thread gradual pullout ON

T

M24

Thread gradual pullout OFF

T

M30

End of program, with return to program top

M41

Gear select – gear 1

T

M42


T

M43


T

M44


T

M48

Feedrate override allowed

M

T

M49

Feedrate override NOT allowed

M

T

M52

Unload Last tool from spindle

M

T

M60

Automatic pallet change (APC)

M

M98

Subprogram call

M

T

M99

Subprogram end

M

T


T
T

M
T
M

M

T

9


2.0 INTRODUCTION TO MASTERCAM
Founded in Massachusetts in 1983, CNC Software, Inc. is one of the oldest developers of
PC-based computer-aided design / computer-aided manufacturing (CAD/CAM) software.
They are one of the first to introduce CAD/CAM software designed for both machinists and
engineers.

Mastercam, CNC Software’s main product, started as a 2D CAM system with CAD
tools that let machinists design virtual parts on a computer screen and also guided computer
numerical controlled (CNC) machine tools in the manufacture of parts. Since then,
Mastercam has grown into the most widely used CAD/CAM package in the world. CNC
Software, Inc. is now located in Tolland, Connecticut.

Mastercam’s comprehensive set of predefined toolpaths—including contour, drill,
pocketing, face, peel mill, engraving, surface high speed, advanced multi axis, and many
more—enable machinists to cut parts efficiently and accurately. Mastercam users can create
and cut parts using one of many supplied machine and control definitions, or they can use
Mastercam’s advanced tools to create their own customized definitions.

Mastercam also offers a level of flexibility that allows the integration of 3rd party
applications, called C-hooks, to address unique machine or process specific scenarios.

Mastercam's name is a double entendre: it implies mastery of CAM (computer-aided
manufacturing), which involves today's latest machine tool control technology; and it
simultaneously pays homage to yesterday's machine tool control technology by echoing the
older term master cam, which referred to the main cam or model that a tracer followed in
order to control the movements of a mechanically automated machine tool.


10


2.1 WORKING IN MASTERCAM
The layout is the most important to understand MasterCAM, it consist of Main menu

Drawing tools

,

Zoom-fit
View methods

,
, and Value input methods

.
G-code generation and Animation

Match Group with complete setup of Machine Tool and Stock

Complete Layout of the MasterCAM


11


The most complex system will be simplified if you the concept of inter relation between
Computer and Machine Tool. The idea behind the MasterCAM is to understand the simplicity
in controlling a Machine Tool that is dependent on only electrical signals.
2.2 EXPERIMENT NO: 01 MILLING
There are simple three basic working in CNC milling they are Contour path,
Drilling, Pocketing still many more can be achieved like surface grinding, polishing,
embossing etc.
The difference between Milling and Turning is a creative idea which is made easy to the
learners in which the model will be created first in Milling using (X,Y, Z as zero) and then the
tool path setup is used to create contour, Drilling or Pocketting. In Milling the pattern is first
and the stock setup is the last but in Turning operation the stock setup is first and the pattern
is next based on different co-ordinates (D, -Z) this makes the work easy which will be
understood by any learner when they finish this manual. Most important the Cutting Tool
compensation is very much important along with Tool position, stock orientation, speed, feed
depth of cutting etc.
Let the Machining begin in Milling operation firs, basics to learn Couture, Pocketing,
Drilling.


12


2.2.1 Geometric Construction
Press F9 to see the coordinates on the screen, this is the basic need if you can’t understand
co-ordinates it is 0 to 360’ from each of the start point of a line to end point of the line as
worked in SolidEdge (Polar co-ordinate).

Step 01: The geometric construction is as follows first press F9 and use create > Rectangle by
two co-ordinate and enter (0, 0, 0) and (100, 100, 0) and construct rectangle to make the outline.

Step 02: Using arc by Polar co-ordinate and create four arc based on center of arc, start point,
and end point including sweep length.
(0, 50) 90,270; (50, 100) 0, 180; (100, 50) 270, 90; (50, 0) 180, 0;


13


Using trim command with break function

create the arc.

Step 03: create > Rectangle by two co-ordinates and enter (25, 25, 0) and (75, 75, 0) and
construct rectangle

Step 4: once the design is complete, bring the machine type and go with stock setup.

Step 5: in stock setup give the solid view and using “select corners” select whole geometry
and give the thickness in z-direction.

Note : the step 01 to 05 is the general method to create any geometric structure, now it’s the
time for operations.


14


2.2.2 Contour.
Select Toolpaths from the Menu and click on contour,

Select chain command and click on the line geometry in clock wise direction and if required
use change direction for unidirectional tool path.

Make sure the contour parameters are filled correctly and animate to see perfect tool path
before going with next operation.


15


2.2.3 Pocketing.
Same as done with contour, select Tool path as pocket and select partial command and click on the
contour and perfectly match all the cutting parameters.

Once the path is selected it will be seen like this.

Make sure the pocketing parameters are filled correctly and animate to see perfect tool path before
going with next operation.


16


2.2.4 Drilling.
Drilling is a special Machining operation in which one has to understand cutting tool
compensations, also one has to create center of drilling using create points in position.

Once the center of drill points are created, complete all the Toolpath parameters and cross
check for compensation errors.

Use polar co-ordinates if required to center the locations.

Make sure the Drilling parameters are filled correctly and animate to see perfect tool path before
going with next operation.

Run the entire program at a time to see all the function are perfectly done. Note the cutting
tool compensations are critical in the process and the knowledge is not in the software but only in the
mind of a Mechanist.


17


2.3 EXPERIMENT NO: 02TURNING
Turning Basics: Turning operation is the fundamental of all Machining and the meaning is known as
the “Mother of all Machine”, the operation conducted in Turning are many but the basic is as
mentioned below.

A simple geometry in Lathe Machine looks so easy but when parameters are to be considered the task
on each value will be very critical, let’s start this experiment.
Step 01: Design the schematic as shown in the figure.

Material properties, stock setup and chuck setup to be bone in the first place.

The stock set up with and without extra stock and clearance is based on Metrology.


18


Once the chuck is designed, facing operation is the first if the stock is handled in single stock.

Remember the parameters are they are important if any one value is mismatched then the
whole project is demolished within seconds.

Lead in and Lead out is the basic of the machining if marked with wrong position the
Program will never execute.


19


Simulate the direction and the working before the working.

Rough cut parameters are essential to be mentioned.

Simulate each and every step and visualize the simulation.

Setting up any number of the working routine, the simulation is a must to negotiate the error.


20


Finish parameters are the critical values which decides the work status.

Cut off or grooving is needed to separate either the work piece from the stock or finishing the required
stock.

Remember to visualize every feed and depth of cut during operation because the work cannot be
undone if once finished.


21


Simulate to know the result with efficiency, remember once done it has to be perfect if not the
effort is lost to the drain.

Simulate and gather the G-codes in printed format for both Milling and Turning.


22


Experiment No: 01:Milling
Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


23


Experiment No: 02 Milling
Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


24


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


25


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


26


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


27


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


28


Experiment No: 01 Turning
Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


29


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


30



Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


31



Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


32


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


33


Sl
No

Design

Remark

Date of Working
Date of Report
Internal Marks


34


Note to the Students:
a) Internal Assessment marks will be based on the performance of the student in the lab and the
punctuality of the student along with the behavior of the individual.
b) If found not punctual to the lab, the shortage of attendance will be coincided severely.
c) Every time the student should bring the lab Manual cum Record to the lab and should get
entered with the IA marks of the work they have learned and processed, along with the
signature of the respected Faculty or the lab in charge.
d) Students should behave according to the rules and procedure of the lab with all conditions.
e) Every day the student should get their Experiments evaluated for 10 marks and 5 Marks for
record writing and 10 marks for final Internal, altogether every students will be evaluated for
their respective 25 marks as prescribed in the syllabus.


35

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