SUMMER TRAINING MANUAL

Course Name: Reverse Engineering and CAD, CAM

CourseCode: 22MC024
Department:Mechatronics

Submitted By: Submitted To:

RISHURAJ CHAUBEY Dr. Gurdyal Singh Virk
2210994283
X2

Department of Mechatronics Engineering

Chitkara University Institute of Engineering & Technology
Chitkara University, Punjab
 INDEX

Signatur
S.No Program Title
e
Practice on constrained sketching and 3D solid
1
modelling for computer aided design of simple design.
Perform the complex 3D modelling using advanced
2
features of CAD.
Generate the assembly of different components with
3
assembly joints with constraint motion or mechanism.
Generate the assembly of different components with
assembly joints with constraint motion or mechanism
4
and component level technical drawings with all
specifications.
Generate the rendered images of the assembly of
5
components with realistic look and appearance.

6 Create the Surface model and sheet-metal model.

Introduction to the CNC machines and NC program

7 codes to generate the manual NC program for simple
VMC machining profiles.
Generate the CAM NC program of given profiles for
8
computer aided manufacturing on VMC.
Perform the CAM Machining on VMC as per the
9
generated NC program of given profiles.
Generate the manual and CAM NC program of given
10 profiles for computer aided manufacturing on CNC
Lathe Machine.
Perform the 3D printing of given CAD part on Polymer
11
3D Printer.
Perform the 3D scanning of given physical part for
12
reverse engineering.
 TASK:1
AIM – To practice on constrained sketching and 3D solid modeling for computer aided
design of simple design.

CAD is a technology used for creating precise drawings and technical illustrations,
primarily in engineering, architecture, and manufacturing. We are using Fusion 360
software for autocad.
A constrained sketch refers to a sketch where all geometric entities (lines, circles, arcs,
etc.) have specific rules or constraints applied to them to control their size, shape, and
position. Constraints help define the precise relationships between different parts of the
sketch, ensuring that the design behaves predictably when modified.
PROCEDURE –
1. Open Autodesk Fusion 360 from your desktop or start menu.
2. Click on "File" > "New Design" to start a new project.
3. Ensure you are in the "Design" workspace. Select “Sketch” > “Create Sketch”.
4. Choose a plane (e.g., XY plane) for the sketch.
5. Use tools like "Line", "Rectangle", and "Circle" from the sketch toolbar.
6. Use "Sketch Dimension" to set precise measurements. Apply
constraints like "Horizontal/Vertical", "Coincident", and "Equal" to control
geometry.
7. Click "Finish Sketch" to complete and exit the sketch mode.
8. Click "File" > "Save" and name your design.
TASK 2
AIM – To perform the complex 3D modeling using advance features of CAD.
3D modeling in Fusion 360 refers to the process of creating three-dimensional digital
representations of objects using the software's comprehensive set of tools. Fusion 360 is a
powerful CAD (Computer-Aided Design) software developed by Autodesk, which allows
designers, engineers, and architects to create, simulate, and visualize their designs in a 3D
environment.
We had created many 3D models like coffee mug, mouse, duster, etc.

View of duster

View of duster
PROCEDURE –
1. Create the sketch of the required component by following the procedure given in
previous task.
2. Now extrude it by selecting extrude option. Specify the height or depth to create a 3D
solid.
3. Select "Create" > "Sweep". Choose a profile and a path to follow. Similarly, select
"Create" > "Revolve". Choose a profile and an axis to revolve around.
4. Select "Modify" > "Fillet" or "Chamfer". Apply to edges to smooth or bevel them.
5. Select "Modify" > "Combine". Choose operation type (Join, Cut, Intersect, New Body,
New Component).
6. Use components to build assemblies. Apply joints and constraints.
 TASK3
AIM–To perform the assembly of different components with assembly joints with
constrained motion.
Assembling different components with constrained motion in a mechanical system
involves understanding the types of joints and constraints required. In this task we are
making a butterfly valve.

Side view of butterfly valve

Top view of the valve

PROCEDURE –
1. Create the sketch of the valve body by following the steps given in previous tasks.
Sketch the cross-section of the valve body and use the Revolve tool to create the
cylindrical shape. Add necessary features like flanges using the Extrude and Fillet tools.
2. Create a new sketch for the disc. Draw the shape of the disc and use the Extrude tool to
give it thickness. Add any holes or cutouts needed for mounting.
3. Sketch the stem on an appropriate plane. Use the Extrude tool to create the cylindrical
shape. Add threads or other necessary features.
4. Sketch and extrude the actuator components as needed. Ensure the design allows for
connection to the stem.
5. Use the Joint tool from the Assemble menu. Connect the disc to the valve body using
a Revolute Joint to allow rotation. Connect the stem to the disc and the actuator using
appropriate joints (e.g., Rigid Joint for fixed connections, Revolute Joint for rotational
connections).
6. Add any final details such as bolts, gaskets, and other small features. Perform a final
check for assembly and interference.
7. Generate detailed 2D drawings of the butterfly valve assembly.
By following these steps, we can create a functional butterfly valve model in Fusion 360.
 TASK 4
AIM – Generate the assembly of different components with assembly joints with
constraint motion or mechanism and component level technical drawings with all
specifications.
Generating an assembly of different components with assembly joints, constrained motion
or mechanisms, and component-level technical drawings involves several steps. In this
task we are making bolt and nut. And we also simulate them.
PROCEDURE –
1. Sketch a circle with the shaft diameter on the front plane. Extrude to desired length.

2. Sketch a polygon (e.g., hexagon) on the top face of the shaft. Extrude to desired height.

3. Select the bolt shaft. Use Create > Thread, check Modeled, and choose thread
type and size.

4. Sketch a polygon (e.g., hexagon) on the front plane with an internal circle for
the bolt. Extrude to desired thickness.

5. Select the nut hole. Use Create > Thread, check Modeled, and match the bolt
thread type and size.

6. Use Assemble > Joint to align the nut and bolt. Use the Slide joint type to position
the nut along the bolt.

7. Ensure proper alignment and fit. Use section analysis to check thread fit.
 TASK 5
AIM – Generate the rendered images of the assembly of components with realistic look
and appearance.
Rendered images in Fusion 360 are photorealistic images of your 3D models created
using the software's rendering tools. Rendering adds lighting, shadows, textures, and
realistic materials to your models, making them look as if they were real objects. This is
useful for presentations, marketing, and visualizations.

PROCEDURE –
1. Sketch: Draw the bolt profile (head and shank) on a plane. Extrude: Use the
Extrude tool to give it 3D shape. Add Threads: Apply the Thread tool to the shank.
2. Sketch: Draw a hexagon and an internal circle for the nut on a plane. Extrude: Use
the Extrude tool to give it 3D shape. Add Internal Threads: Apply the Thread tool to
the hole.
3. Switch to Render Workspace: Select Render from the workspace switcher.
4. Appearance: Apply materials using the Appearance tool (shortcut A).
Environment: Choose and adjust the environment from Scene Settings. Lighting:
Adjust lighting settings as needed.
5. Position Components: Arrange the nut and bolt as desired.
6. Render the Image: Click Render. Set render settings (quality, resolution). Click
Render to start rendering.
7. Save the Image: Save the rendered image from the Render Gallery.
 TASK 6
AIM – Create the Surface model and sheet-metal model.
In Fusion 360, surface and sheet metal tools are specialized toolsets designed for different
types of modeling, particularly useful for creating complex shapes and manufacturable
parts.
Surface Modeling: This involves creating and manipulating surfaces rather than solid
bodies. Surface modeling is typically used for creating complex, organic shapes that are
difficult to achieve with traditional solid modeling techniques.
Sheet Metal: This toolset is designed for creating parts that will be manufactured from
sheet metal. It provides tools to create sheet metal features that can be flattened for
fabrication.
PROCEDURE –
1. Open Fusion 360 and create a new design. Go to the Sheet Metal tab. Click on
"Sheet Metal Rules" in the toolbar. Create a new rule or edit an existing one to set the
parameters for your sheet metal, such as thickness, bend radius, K-factor, etc.
2. Click on "Create Sketch" and select a plane to draw on. Draw the base shape of
your box (typically a rectangle). Finish the sketch. Select "Create" > "Flange" from
the Sheet Metal tab. Choose the sketch you just created and define the thickness and
other properties in the dialog box. Click OK to create the base flange.
3. Select the edge of the base flange where you want to add a side flange. Click on
"Flange" in the Sheet Metal tab. Define the height and angle of the flange in the
dialog box. Repeat for all four sides of the box.
4. Ensure the bends and corners are properly defined. Use the "Bend" tool if you
need to create additional bends. Use the "Bend Relief" tool to add relief cuts where
necessary to avoid interference during bending.
5. Create new sketches on the faces where you want tabs or cutouts. Use the "Cut"
tool in the Sheet Metal tab to create openings, slots, or tabs.
6. Click on "Unfold" in the Sheet Metal tab. Select a stationary face and the bends to
unfold. This will flatten the box to see the sheet metal layout.
7. Once satisfied with the design, click on "Create Flat Pattern" in the Sheet Metal
tab. Select a face to start the flat pattern. Finish the flat pattern and the unfolded sheet
metal view will be generated. Export the flat pattern as a DXF file by right-clicking
on the Flat Pattern in the browser and selecting "Save as DXF".
8. Review the design to ensure all dimensions and features are correct. Save your
project in Fusion 360 for future reference or modification.
 TASK 7
AIM – Introduction to the CNC machines and NC program codes to generate the
manual NC program for simple VMC machining profiles.

CNC (Computer Numerical Control) machines are automated tools used for precise
machining and manufacturing processes. These machines are controlled by computer
software, which directs the movement and operation of the machine tools based on a
programmed set of instructions. CNC machines are used to cut, shape, and form
materials such as metal, plastic, wood, and composites into specific parts or products.
Here’s a brief overview:

Key Components of CNC Machines

1. Control Unit: The brain of the CNC machine, responsible for interpreting the
G-code (the programming language) and sending signals to the motors to
move the machine tools.
2. Machine Tool: The part of the CNC machine that performs the actual cutting,
drilling, milling, or other processes. Examples include lathes, mills, routers,
and grinders.
3. Drive System: Includes motors and mechanisms that move the machine tool
and workpiece in various directions (X, Y, and Z axes).
4. Bed/Table: The surface where the workpiece is fixed during machining.
5. Feedback System: Monitors and ensures the correct movement and
positioning of the machine tool.

Types of CNC Machines

1. CNC Milling Machines: Use rotary cutters to remove material from the
workpiece.
2. CNC Lathes: Rotate the workpiece while a single-point cutting tool shapes it.
3. CNC Routers: Used for cutting and engraving various materials, often in
woodworking.
4. CNC Plasma Cutters: Use a plasma torch to cut through conductive materials.
5. CNC Laser Cutters: Use a laser beam to cut or engrave materials with high
precision.
6. CNC Grinders: Use an abrasive wheel to remove material from the
workpiece’s surface.
NC (Numerical Control) codes, often referred to as G-codes, are a set of instructions
used to control CNC (Computer Numerical Control) machines. These codes direct the
machine's movements and operations to perform various machining tasks such as
cutting, drilling, milling, and more. NC codes are written in a programming language
specifically designed for CNC machining.
Key Components of NC Codes
1. G-Codes: Instructions that control the movement of the machine.
o G00: Rapid positioning.
o G01: Linear interpolation (cutting in a straight line).
o G02: Circular interpolation, clockwise.
o G03: Circular interpolation, counterclockwise.
2. M-Codes: Instructions that control miscellaneous functions of the machine.
o M00: Program stop.
o M03: Spindle on, clockwise.
o M05: Spindle stop.
 o M08: Coolant on.
o M09: Coolant off.

Key Components of NC Codes

1. G-Codes: Instructions that control the movement of the machine.

o G00: Rapid positioning.
o G01: Linear interpolation (cutting in a straight line).
o G02: Circular interpolation, clockwise.
o G03: Circular interpolation, counterclockwise.
2. M-Codes: Instructions that control miscellaneous functions of the machine.
o M00: Program stop.
o M03: Spindle on, clockwise.
o M05: Spindle stop.
o M08: Coolant on.
o M09: Coolant off.
 TASK 8
AIM – Generate the CAM NC program of given profiles for computer aided
manufacturing on VMC.

In the CAM we have printed the first letter of our name. So I have printed the letter ‘R’.
The machine on which this operation is done is HURCO V10.

Here is a simple G-code example for engraving the letter "Y" in a 20mm by 20mm area
on a metal surface. This assumes the use of a standard CNC milling machine setup. The
origin (0,0) is set at the bottom-left corner of the 20mm by 20mm square.

CODE –
 TASK 9
AIM – Perform the CAM Machining on VMC as per the generated NC program of
given profiles.

In the CAM we have printed the first letter of our name. So I have printed the letter ‘Y’. The
machine on which this operation is done is HURCO V10.
PROCEDURE –
1. Go to "Sketch" > "Create Sketch". Select a plane or face.
2. Use the "Text" tool to place and type the letter. Finish the sketch.
3. Switch to Manufacture Workspace.
4. Go to "Setup" > "New Setup". Define the work origin and material.
5. Select "2D" > "Trace". Choose the sketch text and appropriate tool (e.g., V-bit).
Set cutting parameters.

6. Go to "Post Process". Choose the appropriate post-processor for Hurco V10.

7. Transfer the N Code to the Hurco V10 via USB or network.

8. Load the material and secure it. Set the work origin on the machine.
9. Load and execute the NC code on the Hurco V10.
 TASK 10
AIM – Generate the manual and CAM NC program of given profiles for computer aided
manufacturing on CNC Lathe Machine.

To generate a manual and CAM NC program for CNC lathe machining, we need to
understand the specific profiles and operations required. For this example, let's assume
we have a basic profile to turn on a cylindrical workpiece with the following features:

 Facing the front of the workpiece.

 Turning the outer diameter to a specific dimension.
 Grooving at a certain position.
 Chamfering the edges.

Assumptions:
Material: Metal (e.g., aluminum), Stock Diameter: 50 mm, Stock Length: 100 mm, Final
Diameter: 40 mm, Groove Width: 5 mm, Groove Position: 30 mm from the front,
Chamfer: 2 mm at both ends, Feed Rate: 0.2 mm/rev, Spindle Speed: 1500 RPM

Manual NC Program
O1000 (Program Number)

G21 (Set units to millimeters)

G40 G18 G99 (Cancel cutter compensation, XZ plane selection, feed per
revolution) G28 U0 W0 (Return to home position)

(Spindle and Tool Setup)

T0101 (Select tool 1 and offset 1)
M03 S1500 (Start spindle at 1500 RPM)

(Facing)
G00 X52 Z2 (Rapid move to clearance
position) G01 X0 F0.2 (Feed to face)
G00 X52 (Rapid retract)

(Turning OD)
G00 X42 Z2 (Rapid move to clearance
position) G01 Z0 F0.2 (Feed to start position)
G01 X40 (Turn to final
diameter) G01 Z-100 (Turn
along length) G00 X52 Z2
(Rapid retract)
(Grooving)
G00 X42 Z-30 (Rapid move to groove
position) G01 X35 F0.2 (Feed to groove
depth)
G01 Z-35 (Cut groove
width) G00 X42 (Rapid
retract)
(Chamfering Front)
G00 X40 Z2 (Rapid move to clearance
position) G01 Z0 F0.2 (Feed to start position)
G01 X38 Z-2 (Chamfer front
edge) G00 X52 (Rapid
retract)
(Chamfering Back)
G00 X40 Z-98 (Rapid move to clearance
position) G01 Z-100 F0.2 (Feed to start
position)
G01 X38 Z-102 (Chamfer back
edge) G00 X52 (Rapid retract)
(Program
End) M05
(Stop spindle)
G28 U0 W0 (Return to home
position) M30 (End of program)
 TASK 12
AIM – Perform the 3D scanning of given physical part for reverse engineering.
Reverse engineering is the process of analyzing a product, component, or system to
understand its design, functionality, and construction in detail. This is typically done
with the goal of replicating, modifying, or improving upon the original design.
3D scanning is a technology used to capture the physical shape and dimensions of
objects and environments to create digital representations in three dimensions. It
involves using various scanning methods and devices to collect data points that describe
the object's surface geometry. This data is then processed to generate a detailed 3D
model that can be viewed, analyzed, modified, or used for
various applications. 3D scanning plays a crucial role in reverse engineering by
capturing the physical object's geometry and translating it into a digital 3D model.