Report of Cam Cep

COMPLEX ENGINEERING PROBLEM
GROUP MEMBERS:
1. AAIRA SHAHID IM-001
2. AREESHA AHSAN IM-004
3. ZAKIA GHANI IM-007
4. TEHNIYAT ZEHRA IM-032
COURSE:
COMPUTER AIDED MANUFACTURING
SUBMITTED TO:
SIR MAQSOOD
DATED:
TABLE OF CONTENTS
1. INTRODUCTION:
This Complex Engineering Problem deals with the Modelling, Process planning, Optimization of
Machining Processes and Tool Path Planning through CAD/CAM software CATIA.
Objective:
In this evolving world of manufacturing, the efficiency of machining processes plays a vital role. The
objective of this report is the optimization of machining operations using a comprehensive approach,
beginning with the selection and modeling of using CATIA software. Through the chosen model we
explore tool path planning, machining parameter selection, simulation, and a subsequent comparative
analysis.
Scope:
 The initial phase involves the creation of a detailed 3D model of the chosen component using
CATIA, a widely acclaimed computer-aided design (CAD) tool. Following this, our investigation
shifts to tool path planning, a crucial step in ensuring optimal material removal and minimizing
production time. The selection of appropriate machining parameters is critical to this process,
influencing the quality and efficiency of the final product.
 The subsequent stage entails the simulation of the machining process, providing a virtual
preview of the manufacturing sequence. Through this simulation, we aim to identify potential
challenges, refine the tool paths, and enhance overall process efficiency. The report further
encompasses a comparative analysis, evaluating the effectiveness of various tool path strategies
and their impact on the final product.
 A key focus of our study is the optimization of machining time, achieved through a strategic
alteration of tool diameters and the selection of the most efficient tool path strategy. By
exploring these parameters, we aim to not only enhance productivity but also improve the
overall cost-effectiveness of the machining process. This report emphasis on optimizing
machining processes of the model.
Deliverables:
 Part model using CATIA part design workbench.
 Drawing of design part
 Machining features required for the generation of tool path.
 Process plan describing the detailed manufacturing process.
 Tool path generation using CATIA machining workbench.
 Cutting simulation through CATIA software.
 Difficulties faced during the project.
 New things you learnt during the project.
 Reference of learning materials.
About the software:

Software used for this Complex Engineering Problem is CATIA . CATIA (Computer Aided Three-
Dimensional Interactive Application), is much more than a CAD (Computer Aided Design) software
package.
CATIA is a versatile software suite developed by Dassault Systems for CAD, CAE, and CAM. Known for its
parametric modeling, CATIA supports the entire product development process, offering tools for
generative shape design, assembly design, digital mock-ups, and sheet metal design. It integrates with
PLM solutions, facilitating collaboration and data management. CATIA finds extensive use in aerospace,
automotive, and other industries, providing a comprehensive platform for complex product
development. Its capabilities include CAM for CNC machining, making it a preferred choice for precision
engineering and design tasks.
It's a full software suite which incorporates CAD, CAE (Computer-Aided Engineering) and CAM
(Computer-Aided Manufacture).
2. Machining features:
1. Part Description:
 Material used is Aluminum
2. Machine used:
3- axis milling machine
3. Machining Operations:
a) Pocketing 1:
Tool used: flat end mill
Diameter: 10mm
Depth of cut: 2mm
b) Pocketing 2:
Tool used: drill
Diameter: 40mm
Depth of cut: 20mm
3. Process plan:
Process plan
Part name:
Part material: Aluminum
Tool material: HSS
Date: 4/1/2024
Operation no. Operation name: Machine used Tool used Machining

Time (minutes)
1. Pocketing 1 3 axis milling machine Flat end mill 4 min 57 sec
2. Pocketing 2 3 axis milling machine Flat end mill
3. Facing 3 axis milling machine Flat end mill
4. PART TO BE DESIGNED
5. Modelling of the design part in CATIA:
3.1. Choosing the plane:
x-y plane is chosen for the part to be machined on milling machine.
3.2. Sketching a rectangle:
Using the centered rectangle tool, a 100x80 rectangle is drawn on the x-y plane.
3.3. Padding the sketch:
Exiting the sketch and using the pad command ,sketch is padded 44mm towards the z-axis.
3.4. Defining a hole:
A hole of 40mm diameter is created in the centre of the rectangle

3.5. Sketching lines to create a pocket:
Using the line tool, lines are created with the given dimension on the x-y plane of the part body.
3.6. Pocket defenition:
An open pocket of 20mm of depth is created, removing the skeched part on the part body.
3.6. Modelling stock:

A second body ‘body2’ is inserted over the part body as a stock material with the dimension of 100x80.
Transparency is added to show the machined model.
3. Generation of tool path and its

verification through simulation.
Selecting the reference point:
Selecting the reference point in CAM is crucial for accurate toolpath generation, as it influences
machining precision. It ensures proper alignment with the workpiece, minimizing errors and enhancing
overall machining efficiency. The chosen reference point directly impacts the reliability and quality of
the CNC machining process.
In this model, reference point is selected to be the left corner at the height of 20mm of the part. This is a
feasible point because this reference point makes the tool path easy and straight forward and it will save
machining time.
Selecting the area for pocketing:
Selecting the tool:

Selecting the appropriate tool in CAM is important for precision and efficiency in machining processes.
The chosen tool directly influences factors such as cutting speed, feed rate, and surface finish, impacting
the overall quality and speed of the manufacturing operation. Proper tool selection is essential for
optimizing tool life, minimizing production costs, and achieving desired machining outcomes.
For the process of pocketing, the tool chosen is Flat end mill cutter with a diameter of 10mm. Smaller
diameter is chosen for precision and for a finer surface finish.
4.3 Tool path generation:
Making a hole through pocketing OPERATION:
4.4 Cutting simulation:
Comparative analysis:
6. Difficulties faced during the project:
7. New things learnt:
8. References of learning:

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COMPLEX ENGINEERING PROBLEM

 Drawing of design part

 Machining features required for the generation of tool path.

 Process plan describing the detailed manufacturing process.

 Tool path generation using CATIA machining workbench.

 Cutting simulation through CATIA software.

 Difficulties faced during the project.

 New things you learnt during the project.

 Reference of learning materials.

About the software:

Depth of cut: 20mm

Part material: Aluminum

Tool material: HSS

Operation no. Operation name: Machine used Tool used Machining

1. Pocketing 1 3 axis milling machine Flat end mill 4 min 57 sec

2. Pocketing 2 3 axis milling machine Flat end mill

3. Facing 3 axis milling machine Flat end mill

3.2. Sketching a rectangle:

3.3. Padding the sketch:

A hole of 40mm diameter is created in the centre of the rectangle

3.6. Pocket defenition:

3.6. Modelling stock:

3. Generation of tool path and its

Selecting the tool:

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