UNIVERSITI MALAYSIA PAHANG

PROJECT REPORT
BFF3622: COMPUTER AIDED
MANUFACTURING

PROJECT TITLE:

NO NAME ID NUMBER

1 PRAVEEN VARMAN KOLANDAVELOO FA18027

2 SARSIKUMAR EASWARAN FB18060

3 ANISSHWARAN SAMBANTHAN FB18090

4 DARSHEN NITHIYANDNANDNAN FB18093

5 MUGILAN GANESAN FB18096

6 YAP HOCK HUAT FB18101
 TABLE OF CONTENTS
No Title Page
.
1. Introduction 1

2. Objective 1

3. Experimental set up 2-7

4. Result and discussion 8-9

5. Conclusion 10
 1. INTRODUCTION
In this project, we are going to design and fabricate our own product. After the
preparation of specimen is finished, the work will be continued using CATIA V21
software. The material used for fabrication are aluminum alloys. The work piece is cut
for desired dimension and then ready to undergo material removing by using Makino
CNC milling machine.

The report of this project has been compiled in documents form on the processes
involved during conducting this project. A mechanical component design has been
chosen as an image to draw by using the CATIA V21 software. The purpose of this
project is to understand and learnt the operating machine to produce the desired final
product as shown in simulation that been done in CATIA.

A CAD/CAM system is a computer-based platform used for manufacturing

component parts on fully automated Computer Numerically Controlled (CNC)
production machines such as milling machines or lathes. The CAD software produces
geometries on PCs or laptops, the CAD file is exported to a CNC machine and a
finished part is produced at the click of button. The primary purpose of CAD/CAM is
to describe the geometric form of objects that are to be manufactured. CAD is
primarily a visual representation of an object while CAM deals with the physical tool
movements required producing the object. As a result, the geometric form of the object
is different in CAD than it is in CAM. Therefore, in order to transfer information
between the two systems there must be some means of translating the CAD model into
the CAM.
2. OBJECTICE
 To learn how the NC and CNC programming works.
 To learn the function of programming and NC code in CATIA.
 To master on how to design a 3D model in CATIA with unique shape and
program it with the NC code.
 To identify and troubleshoot on the problems if the NC code is not functioning
when designing the project.
 To ensure that the NC code of the design is correct while transmitting it on
milling machine.
3. EXPERIMENTAL SET UP
3.1 Manual process plan.
3.1.1 Methodology

START

SEARCHING FOR
PRODUCT DESIGN

DESIGN THE SPECIMEN

USING CATIA V5
SOFTWARE

SIMULATE THE DESIGN

USING CATIA V5 IN
ADVANCED MACHINING
PART

GENERATE NC-CODE

MACHINE THE
SPECIMEN USING
MILLING MACHINE

START
 3.1.2 CATIA Software
CATIA is an acronym for Three-Dimensional Interactive Technology Assisted by
Computers. This is one of the leading 3D applications companies using in various
industries automotive, to consumer goods. CATIA provides the capability to visualize
designs in 3D. CATIA can be used at different stages of the design - ideate, draw, test
and iterate. The software comes with different workbenches that allow CATIA to be
used across varied industries from parts design, surface design and assembly to sheet
metal design. CATIA can also be used for CNC.
A few of the important workbenches and their brief functionality description is given
below:
-Part Design
This CATIA module allows the design of specific 3D mechanical parts with an
intuitive and versatile user interface, from sketching in the sense of the assembly to
iterative detailed design.
-Generative Shape Design
The wireframe and surface features allow you to easily model both simple and complex
shapes. It offers a broad variety of software to build and edit shape designs.
-Assembly
The basics of the structure of the component, constraints and moving assemblies and
parts can be quickly learned. This is the workbench where all the parts can be attached
to form a system or a piece.
-Kinematic stimulation
Kinematics involves assembling parts that are joined together by a set of joints, called a
mechanism. Those joints determine how movement can be done by an assembly. This
workbench illustrates how, in the real world, a computer works.
Machine use :

Figure 1: Makino KE55 milling machine.

3.2 The processing time of each process.
Simulation processing time:
a. Roughing process: 1 h 51 min
b. Sweeping process:
i. Major : 2 h 07 min
ii. Minor : 36 sec
c. Pocketing process:
i. 2 min 05 sec
ii. Outside : 15 min 25 sec
d. Facing process: 35 sec
e. Drilling process:
i. Spot drill: 1 min
ii. Drilling: 3 min

Total machining time: 4 h 20 min 6 sec

3.3 The stock size, the cost, & the volume.

Size: 100mm X 100mm X 50mm
Material cost: RM 20
Volume:
Volume = length x width x height
= 110 x 110 x 50
= 605000 mm^3
 3.4 List of tool cutters needed.
No
Tool Quantity Diameter
.
1. Flat end mill 3 10mm, 6mm, & 4mm
2. Ball end mill 2 4mm, & 6mm

3.5 The specification of the CNC machine tool.

Figure 1: Lists of tool

No
Tool Diameter Tooth Specification
.
D10 x 30FL x
1. 10 mm 2
75L
2. Flat end mill 6 mm 2 D6 x 18FL x 60L
3. 4 mm 2 D4 x 15FL x 50L
4. 6 mm 2 D6 x 18FL x 60L
5. Ball end mill 4 mm 2 D4 x 15FL x 50L
-
Flat
end mill the cutter generally rotates on an axis vertical to the workpiece. Cutting teeth
are located on both the end face of the cutter and the periphery of the cutter body.
-A ball nose end mill, also known as a spherical end mill or ball end mill, has a
semisphere at the tool end. Ball nose end mills are used on workpieces with complex
surfaces.
 3.6 Calculate the total manufacturing cost of the part.
-Total manufacturing cost is the aggregate amount of cost incurred by a
business to produce goods in a reporting period.
Calculation of total manufacturing cost is as follows:
Direct Materials-Add the total cost of materials purchases in the period to
the cost of beginning inventory, and subtract the cost of ending inventory.
The result is the cost of direct materials incurred during the period.
Direct Labor (Process time cost)- Compile the cost of all direct
manufacturing labor incurred during the period, including the cost of
related payroll taxes. The result is the cost of direct labor
Overhead-Aggregate the cost of all factory overhead incurred during the
period. This includes such costs as production salaries, facility rent,
repairs and maintenance, and equipment depreciation.
-Add together the totals derived from the first three steps to arrive at total
manufacturing cost.
No. Cost Price (RM)
1. Material cost 30.00
Direct Labor(Processing time cost)
2. -

3. Overhead -

-Materials Cost included workpieces and process tools for our project.
-Direct Labor and Overhead cost are excluded because of we are using university
provided machine(no facility rental fee required) and also proceed project by our
own (no salaries required).
 4. RESULTS AND DISCUSSION
Comparison between simulated machining and actual machining.

Tool Simulation Experiment Error

Volume Volume Volume
Time (sec) Time (sec) Time (sec)
(mm3) (mm3) (mm3)
Flat end
mill
Ball end
mill

Through this project, we had learned a lot of new thing especially on how to produce a 3D
product through the CATIA software. Firstly, we learned to know the coding. Then, we learned how
to design and simulate its machining operations using the CATIA software. From the CATIA
software, we also are able to demonstrate the generate NC coding and transfer it to the computer of
the milling machine.

Before we proceed with this design, our first design was rejected by the lecturer because do
not full fill the project requirement. So, after propose a new design to the lecturer, finally it is
accepted.

During the manufacturing process, there are a few challenges that we faced. Such as, the
technical problems to transfers the generate NC coding to the milling machine because all of us do not
have any experience to send the code. So, we tried to fix the coding until it works correctly. Besides
that, we also faced a problem with the smaller number of milling machines. The milling machine
were in use by others students. Other than that, the machine also read the code wrongly. Moreover, in
the middle of the milling process, there are no air pressure from the machine which enable us to
change the tool.

For machining time, there are a bit different between total simulation machining time compare
to total actual machining time due to different override and feed rate setting on the milling machine
itself. We set it at low override and it causes longer total machining time. Moreover, the roughing
and sweeping process took longer time because the setting for number of levels is 3 rather than other
groups who set for number of levels is 1 only. We prefer 3 for number of levels to produce smoother
and good surface finish.
 Figure 3: CATIA design

Figure 4: Result of the products simulation.

 5. CONCLUSION

As a conclusion, throughout this project we had improved our knowledge on CAD/CAM and
also Catia software. We learnt to design our own product on CATIA and simulate the operations that
involved to create the product through varieties of process such as roughing, sweeping, milling,
drilling and facing. We design a product using Catia and execute the code from it. We also able to
demonstrate the application of CAM in manufacturing by creating a product using a real milling
machine. We learned the process needed to generate the NC code and transfer it into the computer of
the milling machine to be automatically operated. Overall, this project can be summaries as a
successful one.