Exercise No.

10 Write a manual part programming for the component shown in figure below with and without Canned Cycle

Without canned cycle O4 N1 G28 U ! W ! " 1 1#$C%N% 2&2&' ( ) !8* G& +2 G(, +2 '4 #$%-.N /-C0* G 1& ! 2,! '3 1&4! 22! G1 142! / !2 G 141! 22!& 1&4! 2 ! G1 142! / !2 G 15! 22!& 1& ! #CON"OU) "U)N* 22! 1&4! G1 14,! / !2

With canned cycle O4 N1 G28 U ! W ! " 1 1#$C%N% 2&2&' ( ) !8* G& +2 G(, +2 '4 #$%-.N /-C0* G 1& ! 2,! '3 1&4! G32 W2! ) !& G32 $2 6, U ! W ! / !2 N2 G 2 ! N5 G1 1& ! 2 ! N4 142! N& 24! N, G G4 142! 2,! G 1& ! #CON"OU) "U)N* 22! 1&4! G31 U2! ) !&

2444!33& G5 14,!258 2444!881 )1!5 G1 14(!&51 244,!&23 1& ! G 22! G1142!/ !2 2444!& 144!4 G5 14,! 2444!33& )1!5 G 22! G1 158! / !2 2444!& 142! G 22! G1 154! / !2 241!2,2 15&!258 241!881 G5 15,! 242!8 )1!5 G1 2444!& 158! G 22! G1 151!(4, / !2 24 !254 154! 241!2,2 G 15&! 24 !3,1 1&4! G42 22! G1 151! / !2 G(, +22 2 ! / !1& 15&! 242! 244&! 14,! 1& ! 2443! 1&4! G G4 1& ! '( N2 G28 U ! W ! ' & " 2 2 #121127 2! W7 !2 )7 880$"97 %9* G& +2 G(3 +2 '4 #01"0)N-% G)OO:0* G 1& ! 245 !& '3 15(! G1 12(! / !1& G4 11! 2451! G 15(! 2451!&

G31 $3 61& U1! W !& / !2 N3 G 151! N8 G1 151! 2 ! N( 15&! 242 N1 2428!& N11 2451!&! N12 244&! N15 14,! N14 1& ! 2443! N1& G G4 1& ! 2 ! G G42 22! G1 151! / !2 G(, +22 2 ! / !1& 15&! 242! 244& 14, 1& ! 2443 1&4! G G4 1& ! '( N2 G28 U ! W ! ' & " 2 2 #121127 2! W7 !2 )7 880$"97%9* G& +2 G(3 +2 '4 #01"0)N-% G)OO:0* G 1& ! 245 !& '3 15(! G1 12(! / !1& G4 11! 2451 G 15(! 2451!& G1 12(! / !1& G4 11! 2451! G 15(! 1& ! '( N5 G28 U ! W ! ' & " 5 5 #"9)0-8 2& 1 2&7, 80G!7 80$"9 5! 7 )9* G& +2 G(3 +( ( '5 #"9)0-8.NG* G 1& ! 2 ! '3 15(!

G1 12(! / !1& G4 11! 2451! G 15(! 1& ! '( ' & N5 G28 U ! W ! ' & " 5 5 #"9)0-8 2& 1 2&7 , 80G!7 80$"9 5! 7 )9* G& +2 G(3 +( ( '5 #"9)0-8.NG* G 1& ! 2 ! '3 154!25 22! G(2 154!252 245 !& /1!& 155!(1& 155!,31 155!4,& 155!284 155!12 155!1 G 15(! 1& ! '( G28 U ! W ! ' & '5

G3, $ 2 , 6 ) ! G3, 155!12 245 !& ) ! $(4 6585 /1!& 1& '( G28 U ! W ! ' & '5

Problem No. 01 Write a manual part programming for step ;oring operation for the component shown in figure below!

Problem No. 02 Write a manual part programming for step ;oring operation for the component shown in figure below!

Problem No.03 Write a manual part programming for $ec< 8rilling operation for the component shown in figure below!

Problem No 04 Write a manual part program for the profile gi=en below using C-NN08 C>C%0

Problem No.05 :
Write a manual part program for the profile gi=en below!

Problem No.6: Write a manual part program for 8rilling operation for the component shown in
figure

P !" #$ No.0%: Write a manual part program for the profile gi=en below!

P !" #$ No.0&: Write a manual part program for the profile gi=en below!

P !" #$ No.0': Write a manual part program for the profile gi=en below!

Exercise (ased on )#P*mill Exercise No. 01 : Obtain NC $rogram for the following ob?ect

*te+s
1! *tart a ne, +art .f you ha=e ?ust started C-$+mill7 +elect Create a new part in the startup dialog bo@ and clic< on OA! .f you ha=e already started C-$+mill7 select /ile B New! 2! Wor- setu+ "he Wor< setup dialog bo@ appears automatically when you start a new part! +etup data C 0nter the following data7 lea=ing the rest unalteredD /or Units select E''F! /or Wor< piece material select any material! 8ocumentation C Clic< on the 8ocumentation tab and enter suitable data!

-ll the data e@cept the )emar<s will appear in the NC program and in other documents li<e the cycle time sheet! >ou can omit any or all of them! -ny field that you do not enter appears blan< in the shop documents generated by the program! C Clic< on EOAF to e@it from the Wor< setup dialog bo@! +a=e the /ile C +elect /ile B +a=e! C 0nter the /ile name as E$lateF! "he file will now be sa=ed as $late!cpm! -ll ?ob files that you create in C-$+mill will be stored with the e@tension7 dot cpm! C Clic< on the Geometry button at the bottom left of the screen!

3. .ra, blan8raw rectangle C +elect 8raw B +hapes B )ectangle #Center G %ength G Width*! C 0nter the following dataD %ength H 2 ;readth H 1& Corner radius H )otation angle H C Clic< on OA! C -t the prompt +pecify the center point of the rectangle7 enter the coordinates 7 through the <eyboard and press the 0nter <ey or 8one! 4. .ra, +art 8raw points for 1 mm diameter holes C +elect 8raw B $oint pattern B $oints on Circle! C 0nter the following data and clic< on OA! 8iameter H 1 -ngle of first hole H Number of holes H 12 C -t the prompt 0nter the center point for this pattern enter 7 press 0nter!

through the <eyboard and

Zoom picture C +elect :iew B2oom all to e@pand the =iew! "he part has now been definedI your drawing should appear as shown!

5. .e/ine blan- sha+e C +elect 8raw B 8efine blan< ! C Clic< on +elect contour button in the dialog bo@ that appears! C -t the prompt select a contour clic< on the 2 @ 1& rectangle drawn earlier!

C 0nter the following data in the dialog bo@ that appears and clic< on OA! ;lan< thic<ness H 8 ! 2 coordinate at bottom H 43&! "he 'inimum and 'a@imum 17 > coordinates are pic<ed up automatically from the selected rectangle! %ea=e them unaltered! Note D "he blan< definition is optional! .f it is not defined7 it is automatically assumed as a rectangular bloc< surrounding the area that is cut! +teps in performing a machining operationD +elect the operation +elect the tool +pecify the area to be machined +pecify the machining parameters >ou will find this seJuence of steps repeated for e=ery operation 6. $achinin0

Get into the machining mode by clic<ing on the 'achining button at the bottom left of the screen!

/ace milling +elect the operation C +elect 'achining K 'illing K /ace mill! +elect the tool C Clic< on New tool! C .n the +elect tool type list7 select a face mill type with a sJuare shoulder! C .n the +elect tool list7 clic< on the 12&! mm! dia! face mill!
C Clic< on OA!

Specify the area to be machined C -t the prompt +elect a contour clic< on the rectangle7 which was defined as the blan< earlier! C +elect )ectangle4Center point7 length and breadth from the select entity list and clic< on done! Specify the machining parameters - machining parameters dialog bo@ appears with default =alues! C 0nter & for 'aterial thic<ness! C Clic< on OA! C -t the prompt +elect a circle to specify the machining start point clic< on the top right circle!

NoteD While defining the blan< you specified the blan< thic<ness as 8 ! and 2 coordinate at bottom as 43&! "he e@tra &! material is remo=ed in face milling7 and the top of the face milled surface of the part becomes 2 after this! 8efault =alues and cutting parameters are automatically selected from the database for the selected tool type7 tool material and wor< piece material! Drilling C +elect 'achining B 9ole B 8rilling! C Clic< on New tool! .n the "ool type bo@ e@pand theL8rillL list and select L"wist drillL!

C +elect a (!8mm dia! drill and clic< on OA! C -t the prompt +elect the points to be machined clic< on any point on the point pattern7 clic< on 8one! +ince the hole is part of a pattern7 all the points in the pattern get selected!

C +elect No for the prompt 8o you want to omit any holesM C /or Wor< surface 2 enter 7 and for 9ole depth enter 52! ! C Clic< on OA! %.View tool path

C Clic< on the "oolpath button at the bottom left of the screen! C Clic< on to simulate till the end! C +elect to start simulation! C -fter =iewing the simulation try out the other simulation optionsD 'odesD +olid or line mode :iewsD .sometric7 1>7 >2 or 12! +imulate tillD Ne@t motion7 ne@t tool7 ne@t operation or end of the program! NC program C Clic< on NC program on the menu bar! Clic< on OA in the dialog bo@ that appears! C Clic< on 0dit to =iew the NC program! C +elect /ile B 0@it to e@it from the editor!

Exercise (ased on )#P*mill $roblem No! 1 D Obtain NC $rogram for the following ob?ect

$roblem No! 2D Obtain NC $rogram for the following ob?ect.

$roblem No! 5D Obtain NC $rogram for the following ob?ect

Exercise (ased on )#P*turn 0@ercise No! 1 D ! Obtain NC $rogram for the following ob?ect

1. *tart a ne, 1ob .f you ha=e ?ust started C-$+turn7 +elect Create a new part in the startup dialog bo@ and clic< on OA! .f you ha=e already started C-$+turn7 select /ile B New 2. Wor- setu+ "he Wor< setup dialog bo@ appears automatically when you start a new part! +etup data 1 C +elect mm for Units7 select any Wor< piece material7 and enter this data7 lea=ing the rest unalteredD Oaw position absolute 2 H 421 Clearance 2 H & Clearance O8 H 2 +etup data 2 %ea=e the default data unaltered! 8ocumentation C Clic< on the 8ocumentation tab and enter suitable data! -ll the data e@cept the )emar<s will appear in the NC program and other documents li<e the cycle time sheet! >ou can omit any or all it! -nything that you do not enter appears as a blan< in the documents! C Clic< on OA to e@it from the Wor< setup dialog bo@! +a=e the /ile C +elect /ile B +a=e! C 0nter the /ile name as +haft! "he file will now be sa=ed as +haft!C$"! :alues can be entered as fractions! 0!g!7 3!& can be entered as 3P1Q2! 3. .ra, the +art C Clic< on the Geometry button at the bottom left of the screen!

C +elect 8raw B 6uic< shaft! C -t the prompt +pecify the start point enter 7 and press 0nter! C -t the prompt +elect the direction clic< on the arrow pointing =ertically up! C -t the prompt +pecify 1 coordinate enter , and press 0nter! C -t the prompt +pecify 2 coordinate enter G8 and press 0nter!

C 0nter the following co4ordinates in seJuenceD 12 411 18 42 C Clic< the right mouse button and then select 8one! Define the part "hrough this step you are telling C-$+turn R"his set of lines is the partS! C +elect 8rawB 8efine $art! C -t the prompt +elect the first ob?ect clic< on the line shown! C Clic< on >es at the prompt Create part shapeM Define the blank C +elect 8raw B 8efine ;lan<! C 0nter the following data and clic< on OAD %ength H 24 8iameter H 184 +tart 2 H &

.f the blan< shape is a comple@ shape and not a plain cylinder7 8raw its shape! .n the blan< definition screen clic< on +elect contour and then select the contour! "hrough this step you are telling C-$+turn R"his set of lines is the blan<S! 5. $achinin0 C Clic< on the 'achining button at the bottom left of the screen!

We will now do the following machining operationsD )ough facing using the $lain face operation )ough turning using the Contour turn operation /inish facing using the /inish face operation /inish turning using the /inish turn operation "o perform a machining operation in C-$+turnD +elect the operation +elect the tool +elect the area to be machined +pecify the machining parameters >ou will find this seJuence of steps repeated for e=ery operation! Rough facing

+elect the operation C +elect 'achining B "urning B $lain face +elect the tool C Clic< on New tool! C Clic< on OA to accept the default tool that C-$+turn has already selected! +elect the area to be machined C When you are prompted for the +tart 1 and 0nd 1 clic< on the points shown7 on the ;%-NA! ! C +pecify the machining parameters7 and in the operation dialog bo@ clic< on OA to accept the default data!

Rough turning C +elect 'achining B "urning B Contour turn! C .n the +elect an e@isting tool Q new tool dialog bo@ clic< on the tool selected earlier for facing and clic< on OA! C When you are prompted for the +tart point and 0nd point of machining clic< on the points shown7 on the $-)"! C .n the operation dialog bo@ clic< on OA to accept the default data!

Finish facing C +elect 'achining B "urning B /inish face! C Clic< on New tool! Clic< on OA to accept the default tool that has been selected! C /or the +tart point and 0nd point of machining clic< on the points shown7 on the $-)"! C 0nter this data in the operation dialog bo@7 lea=ing the rest unaltered! O=ershoot 1 H 4 !&! "his is 2& T more than the tool nose radius!

Finish turning C +elect 'achining B "urning B /inish turn! C .n the +elect an e@isting tool Q new tool dialog bo@7 clic< on the tool selected earlier for finish facing and clic< on OA! C /or the +tart point and 0nd point of machining clic< on the points shown7 on the $-)"! C .n the operation dialog bo@ clic< on OA to accept the default data! +a=e the file!

6. 2ie, tool +ath C Clic< on the "oolpath button at the bottom left of the screen!

C +elect "oolpath B +tart! "he mode can be solid or line mode! +imulation can be till the ne@t motion7 ne@t tool7 ne@t operation or end of the program! "he simulation can also be =iewed in +ingle step mode! "he tool mo=es one step at e=ery clic< of the mouse or space bar on the <eyboard! Use the 2oom and $an functions for closer inspection of the tool path. Generate NC program C Clic< on NC program on the menu bar! C Clic< on OA in the dialog bo@ that appears! C Clic< on 0dit to =iew the NC program! C +elect /ile B 0@it to e@it from the editor! "he NC program is sa=ed as a te@t file with a !$)G e@tension in the folder where C-$+turn is installed!

Exercise (ased on )#P*turn $roblem No! 1! Obtain NC $rogram for the following ob?ect

Problem No. 02 Obtain NC Program for the following object

$roblem No! 5! Obtain NC $rogram for the following ob?ect

34E56(4E $#N73#)87 6N" *9*8E$* :3$*; 6ntroduction .n the middle of the 1(, s7 mar<et competition became more intense! 8uring 1(, to 1(3 cost was the primary concern! %ater quality became a priority! -s the mar<et became more and more comple@7 speed of delivery became something customer also needed! - new strategy was formulatedD Customizability! "he companies ha=e to adapt to the en=ironment in which they operate7 to be more flexible in their operations and to satisfy different mar<et segments #customiUability*! "hus the inno=ation of /'+ became related to the effort of gaining competiti=e ad=antage! /irst of all7 /'+ is a manufacturing technology! +econdly7 /'+ is a philosophy! V+ystemV is the <ey word! $hilosophically7 /'+ incorporates a system =iew of manufacturing! "he buUU word for todayFs manufacturer is VagilityV! -n agile manufacturer is one who is the fastest to the mar<et7 operates with the lowest total cost and has the greatest ability to VdelightV its customers! /'+ is simply one way that manufacturers are able to achie=e this agility! -n '." study on competiti=eness pointed out those -merican companies spent twice as much on product inno=ation as they did on process inno=ation! Germans and Oapanese did ?ust the opposite! .n studying /'+7 we need to <eep in mind what $eter 8ruc<er saidD VWe must become managers of technology not merely users of technologyV! +ince /'+ is a technology7 well ad?usted to the en=ironmental needs7 we ha=e to manage it successfully!
1. 3lexibility conce+t. .i//erent a++roaches

"oday flexibility means to produce reasonably priced customized products of high quality that can be quickly delivered to customers. 8ifferent approaches to fle@ibility and their meanings are shown "able 1!

+o7 what is fle@ibility in manufacturingM While =ariations abound in what specifically constitutes fle@ibility7 there is a general consensus about the core elements! "here are three le=els of manufacturing fle@ibility

#++roach $anu/acturin0

3lexibility meanin0 "he capability of producing different parts without ma?or retooling - measure of how fast the company con=erts its process #es* from ma<ing an old line of products to produce a new product "he ability to change a production schedule7 to modify a part7 or to handle multiple parts "he ability to efficiently produce highly customiUed and uniJue products "he ability to e@ploit =arious dimension of speed of deli=ery "he ability of a company to offer a wide =ariety of products to its customers "he ability to rapidly increase or decrease production le=els or to shift capacity Juic<ly from one product or ser=ice to another

!+erational )ustomer *trate0ic

)a+acity

#a* ;asic fle@ibilities

Machine flexibility 4 the ease with which a machine can process =arious operations Material handling flexibility 4 a measure of the ease with which different part types can be transported and properly positioned at the =arious machine tools in a system Operation flexibility 4 a measure of the ease with which alternati=e operation seJuences can be used for processing a part type

#b* +ystem fle@ibilities Volume flexibility 4 a measure of a systemFs capability to be operated profitably at different =olumes of the e@isting part types Expansion flexibility 4 the ability to build a system and e@pand it incrementally

outing flexibility 4 a measure of the alternati=e paths that a part can effecti=ely follow through a system for a gi=en process plan !rocess flexibility 4 a measure of the =olume of the set of part types that a system can produce without incurring any setup !roduct flexibility 4 the =olume of the set of part types that can be manufactured in a system with minor setup

#c* -ggregate fle@ibilities

!rogram flexibility 4 the ability of a system to run for reasonably long periods without e@ternal inter=ention

!roduction flexibility 4 the =olume of the set of part types that a system can produce without ma?or in=estment in capital eJuipment Market flexibility 4 the ability of a system to efficiently adapt to changing mar<et conditions

2. *ee-in0 bene/its on /lexibility "odayFs manufacturing strategy is to see< benefits from fle@ibility! "his is only feasible when a production system is under complete control of /'+ technology! 9a=ing in mind the !rocess" !roduct Matrix you may realiUe that for an industry it is possible to reach for high fle@ibility by ma<ing inno=ati=e technical and organiUational efforts! +ee the :ol=oFs process structure that ma<es cars on mo=able pallets7 rather than an assembly line! "he process gains in fle@ibility! -lso7 the :ol=o system has more fle@ibility because it uses multi4s<ill operators who are not paced by a mechanical line! +o we may search for benefits from fle@ibility on mo=ing to the ?ob shop structures! -ctually7 the need is for flexible processes to permit rapid low cost switching from one product line to another! "his is possible with flexible #orkers whose multiple s<ills would de=elop the ability to switch easily from one <ind of tas< to another! -s main resources7 fle@ible processes and fle@ible wor<ers would create flexible plants as plants which can adapt to changes in real time7 using mo=able eJuipment7 <noc<down walls and easily accessible and re4routable utilities! 3. 3$*< an exam+le o/ technolo0y and an alternati=e layout "he idea of an /'+ was proposed in 0ngland #1(, s* under the name V+ystem 24V7 a fle@ible machining system that could operate without human operators 24 hours a day under computer control! /rom the beginning the emphasis was on automation rather than the VreorganiUation of wor<flowV! 0arly /'+s were large and =ery comple@7 consisting of doUens of Computer Numerical Controlled machines #CNC* and sophisticate material handling systems! "hey were =ery automated7 =ery e@pensi=e and controlled by incredibly comple@ software! "here were only a limited number of industries that could afford in=esting in a traditional /'+ as described abo=e! Currently7 the trend in /'+ is toward small =ersions of the traditional /'+7 called fle@ible manufacturing cells #/'C*!

"oday two or more CNC machines are considered a flexible cell and two ore more cells are considered a fle@ible manufacturing system! "hus7 a 3lexible $anu/acturin0 *ystem #/'+* consists of se=eral machine tools along with part and tool handling de=ices such as robots7 arranged so that it can handle any family of parts for which it has been designed and de=eloped! 8ifferent /'+s le=els areD $lexible Manufacturing Module #/''*! 0@ample D a NC machine7 a pallet changer and a part bufferI $lexible Manufacturing %&ssembly' Cell #/#'Q-*C*! 0@ample D /our /''s and an -G:#automated guided =ehicle*I $lexible Manufacturing (roup #/'G*! 0@ample D "wo /'Cs7 a /'' and two -G:s which will transport parts from a $art %oading area7 through machines7 to a $art Unloading -reaI $lexible !roduction )ystems #/$+*! 0@ample D - /'G and a /-C7 two -G:s7 an -utomated "ool +torage7 and an -utomated $artQassembly +torageI $lexible Manufacturing *ine #/'%*! 0@ample D multiple stations in a line layout and -G:s! 4. #d=anta0es and disad=anta0es o/ 3$*s im+lementation #d=anta0es

/aster7 lower4 cost changes from one part to another which will impro=e capital utiliUation %ower direct labor cost7 due to the reduction in number of wor<ers )educed in=entory7 due to the planning and programming precision Consistent and better Juality7 due to the automated control %ower costQunit of output7 due to the greater producti=ity using the same number of wor<ers +a=ings from the indirect labor7 from reduced errors7 rewor<7 repairs and re?ects

.isad=anta0es

%imited ability to adapt to changes in product or product mi@ #e@! machines are of limited capacity and the tooling necessary for products7 e=en of the same family7 is not always feasible in a gi=en /'+* +ubstantial pre4planning acti=ity 0@pensi=e7 costing millions of dollars "echnological problems of e@act component positioning and precise timing necessary to process a component +ophisticated manufacturing systems

/'+s comple@ity and cost are reasons for their slow acceptance by industry! .n most of the cases /'Cs are fa=ored! obot Pro0rammin0D "he methods used for de=elopment of robot programs or more generally called as teaching a robot is as follows 1! %ead by nose 2! "ech pendant 5! Offline programming

)6$ > #78!$#86!N 4#(: 262# ?7E*86!N*

1. 8efine the term C-8 W C-'! 2. Gi=e the abbre=iations of 3. C-8 W C-' 4. C.' 5. C-$$ 6. C-6C 7. CNC 8. 0.. -CC W -CO 10. 11. 12. 13. 14. %ist some of the commonly used 'odeling pac<ages! 8ifference between +olid W Wire frame modeling! What are the ad=antages of solid modeling o=er wire frame modeling! 8ifferentiate between C4rep and ;4rep! %ist the benefits of C-8

15. 16. 17. 18. 1 . 20. 21. 22. 23. 24. 25. 26. 27. 28. 2 . 30. 31. 32. 33. 34. 35. 36. 37. 38. 3 . 40. 41. 42. 43. 44. 45. 46. 47. 48. 4 . 50.

%ist the achie=ements of C-8 8ifferentiate between topology and geometry! 8efine the term Numerical control 8ifferentiate between NC and CNC! %ist the operation de=ices that are commonly used in a C-8 system! 8istinguish between -CC and -CO 0nlist the commonly used NC words! What are the different NC motion controllers! Configuration of hardware components in a C-8 systems! Gi=e basic configuration of the system for usages of C-8QC-'! %ist some of the commonly used analysis pac<ages! Where NC is most -ppropriate -d=antages and 8isad=antages of NC machines! What is /i@ed Uero and /loating Uero! What is -bsolute W .ncrementalI NC machine tool system! What are G Codes W ' Codes! Gi=e the General procedure for NC programming Gi=e the general procedure for 'anual part programming for turning What is /'+ What are the benefits of /'+ What are the ma?or elements of /'+ 8iscuss the importance of material handling system in /'+ Gi=e the name of materials handling de=ices in a /'+ 9ow is /'+ optimiUed What are different type s of data associated with /'+ 9ow are ?obs scheduled in /'+ 9ow NC program control is effecti=e in a /'+ What are the significant ad=antages of using a robot in a computer integrated manufacturing system 8escribe the elements of a robot system 9ow do you ?ustify the use of a robot 9ow do you classify robot What are the different types of deri=es used in robot What are the different type of control system used in robots 9ow do you specify a robot 8iscuss the basic types of robot programming languages ;riefly describe significant application areas of robot!