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CAM Lab
Manual
JSS ACADEMY OF TECHNICAL EDUCATION
BENGALURU - 560060
DEPARTMENT OF MECHANICAL ENGINEERING
VII Semester
Computer Aided Manufacturing
Laboratory Manual
18MEL76
In-charge Faculty Member of the Laboratory:
Dr./Mr./Ms.
Technical Staff:
Mr./Ms. _
Department Of Mechanical Engineering 1

CAM Lab
Manual
Department of Mechanical Engineering, JSSATE, Bangalore 560 060
Vision
Be amongst the top Mechanical Engineering Department in the region by sculpting competent
engineers through education and research.
Mission
M1: Build strong foundation in Mechanical Engineering domain complemented with
interdisciplinary skills.
M2: Develop state-of-the-art facilities with emphasis on industry interaction, consultancy,
research, and innovation.
M3: Enable to seek professional employment, pursue higher studies and promote
entrepreneurship.
Program Educational Objectives (PEO)

PEO1: Graduates shall have sound knowledge in Mechanical Engineering domain.
PEO2: Graduates shall have necessary skills for addressing industry and societal needs.
PEO3: Graduates shall show professionalism in engineering practices for life - long learning
with positive attitude.
Program Specific Outcomes (PSOs)
PSO1: Apply the acquired knowledge in design, thermal, manufacturing and interdisciplinary
areas for solving industry related problems.
PSO2: Solve complex Mechanical Engineering problems using appropriate software tools.

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Manual
Program Outcomes (PO)
Our graduates will be able to:
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural
sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and
design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of
the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex engineering activities
with an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant
to the professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need
for sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and

CAM Lab
Manual
write effective reports and design documentation, make effective presentations, and give and
receive clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the
engineering and management principles and apply these to one’s own work, as a member
and leader in a team, to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage
in independent and life-long learning in the broadest context of technological change.
Course Outcomes
CO1. Demonstrate the knowledge of CNC part programming with suitable prerequisites such as
knowledge of cutting tools, machine tools, materials, etc., leading to tool path verification
using appropriate part programming software tool.
CO2. Use appropriate CAM software tool for simulating turning, drilling and milling operations
thereby generating the NC program, cycle time sheet, tool list, tool layout,etc. and
estimating the power required.
CO3. Illustrate the working of an automated storage and retrieval system in an FMS.
CO4. Demonstrate the knowledge of robot programming for simple robot operations, and the
working principles of hydraulics and pneumatics.
COs/POs/ PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
PSOs
CO1 3 2 … 2 3 … … … 2 … … 2 1 2
CO2 3 2 … 2 3 … … … 2 … … 2 1 2
CO3 2 2 … 2 2 … … … 1 … … 2 1 2
CO4 2 2 … 2 3 … … … 1 … … 2 1 2
Average 2.5 2 … 2 2.75 … … … 1.5 … … 2 1 2

CAM Lab
Manual
Computer Integrated Manufacturing Lab
Subject Code : 15MEL77 IA Marks : 20

No. of Practical Hrs./ Week : 03 Exam Hours : 03
Total No. of Practical Hrs. : 42 Exam Marks : 80
PART - A
Manual CNC Part Programming for 2 turning and 2 milling parts. Selection and assignment of
tools, correction of syntax and logical errors, and verification of tool path.
CNC Part Programming using CAM packages. Simulation of Turning, Drilling, Milling
operations. 3 typical simulations to be carried out using simulation packages like: CADEM, CAM
Lab-Pro, MasterCAM, etc.
Program generation using software. Optimize spindle power, torque utilization, and cycle time.
Generation and printing of shop documents like process and cycle time sheets, tool list, and tool
layouts. Cut the part in single block and auto mode and measure the virtual part on screen.
Post processing of CNC programs for standard CNC control systems like FANUC, SINUMERIC
and MISTUBISHI.
PART - B
(Only for Demo/Viva voce)
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.
PART - C
(Only for Demo/Viva voce)
Robot programming: Using Teach Pendent & Offline programming to perform pick and place,
stacking of objects, 2 programs.
Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these

topics to be conducted.
Scheme of Examinations
Two questions from Part A – 60 Marks (30+30)

Viva Voce – 20 Marks
Total – 80 Marks

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Dos and Don’ts
Do:
1. Leave the footwear outside the lab in the designated place.

2. Enter login details in the register.
3. Work only on the allotted system throughout the semester.
4. Wait patiently at your designated place for instructions.
5. Bring the Lab manual, Observation book and Lab record regularly.
6. Complete the record book with previous experiments updated.
7. Maintain strict discipline inside the lab.
8. Keep your lab clean and free of disorder.
Don’t:
1. Bring Pen drives / Mobile / CDs inside the lab. In case they are found, they will be
confiscated.
2. Change any setting on the computer.
3. Leave the lab without the permission of the staff concerned / instructor.
4. Start the computer system / machine until you are asked to do so.

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Manual
PART - A
CNC PROGRAMMING
Computer Numerical Control programming is a procedure of preparing a detailed list of

instructions that need to be executed by the machine control unit (MCU) to achieve the final
component shape. CNC programming can be done by two different ways.
1. Manual Part programming

2. Computer Assisted Part Programming
MANUAL PART PROGRAMMING: MPP involves writing programs with a set of alphabets,
numbers and symbols. The commonly used part programming formats are:
1. Fixed sequential format
2. Tab sequential format
3. Word address format
Word address format is the most commonly used one.
NC BLOCK: NC block is a collection of NC words. An NC word is a collection of address letters

& a sequence number. It gives information about the movement of the tool in X,Y & Z co
ordinates, the tool to be used, spindle speed, feed etc.
A generalized NC block is given below:
N_ G_ X_ Y_ Z_ R_ F_ S_ T_ M_
N is the Sequence number. Each block or line starts with a sequence number which
identifies the block. It gives an identifying number for each block of information. It is generally
good practice to increment each block number by 5 or 10 to allow additional blocks to beinserted
if future changes are required.
G is the Preparatory function by which the MCU instructs the machine tool as to what to
next. In other words, various machine tool movements such as linear movement, circular
movement, rapid traverse of the tool, etc. are controlled by G words. Preparatory functions prepare
the controller to carry the instructions that are to follow after the G letter.

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X, Y & Z are used to specify the co ordinates along X, Y & Z axes. R is the arc radius to
be used in circular interpolations. F is the Feed Rate in mm/min or mm/rev. S is the spindle speed
in RPM. T is the tool function which specifies the type of the tool & its offset number in automatic
tool changer.
M is the miscellaneous function used to perform auxiliary functions which do not relate
to the dimensional movements of the machine tool or the cutting tool. These functions include tool
change, spindle ON/OFF, coolant ON/OFF, program START/STOP, etc.
seeNC TURN
seeNC turn is special purpose CNC part program verification software used for the turning
center programs. Turning centers typically use only X and Z axis as shown in the fig below. The
X-axis denotes the axis perpendicular to the spindle and controls the diameter of the part. The Z-
axis denotes the movement of the tool parallel to the spindle axis and controls the length of the
part.

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Manual
Axes convention:
The main screen of the See NC turn consists of three screens namely
1. Program editor screen: Wherein the program enters the part programs.
2. Syntax error message screen: Where in the errors in the part program are displayed.
3. Tool path simulation screen: Where in the specified path of the tool can be observed.
PROCEDURE
1. Double click on the See NC turn icon

2. Start a new file. Enter the part program in the program editor screen.
3. Define the shape of the blank.
4. Select the machine
5. Check the program for any syntax errors and correct the errors.
6. Assigning a tool for the different operation.
7. Tool path simulation
PREPARATORY CODES: (G Codes)

G-code Function
G00 Rapid traverse positioning
G01 Linear interpolation (with feed)
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G20 Inch unit
G21 Metric unit
G28 Automatic zero return (home position)
G32 / G33 Thread cutting (single motion)
G40 Tool nose radius compensation cancel

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Manual
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G70 Finishing cycle
G71 Stock removal in turning
G72 Stock removal in facing
G73 Pattern repeating
G74 Peck drilling on Z axis / Face grooving
G75 Grooving cycle
G76 Multiple threading cycle
G94 / G98 Feed per minute
G95 / G99 Feed per revolution
G00 POSITIONING IN RAPID

N_ G00 X_ Z_
The G00 command is a rapid tool move. A rapid tool move is used to move the tool linearly from
position to position without cutting any material. When the tool being positioned at a point
preparatory to a cutting motion, to save time it is moved along a straight line at Rapid traverse, at
a fixed traverse rate which is pre-programmed into the machine's control system. Typical rapid
traverse rates are 10 to 25 m /min., but can be as high as 80 m/min.
G01 LINEAR INTERPOLATION

N_ G01 X_ Z_ F_
The G01 command is mainly used for the linear removal of material from a work piece. Any
combination of the X or Z axes can be used. The machine tool will follow a linear trajectory from
the current position to the target position. The tool moves along a straight line in one or two axis
simultaneously at a programmed linear speed, the feed rate.

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G02 CIRCULAR INTERPOLATION (CLOCKWISE):

N_ G02 X_ Z_ R_ F_ (R specifies the radius)
Circular Interpolation is defined by the G02 command. It executes all circular or radial cuts in a
clockwise motion. The G02 command requires an endpoint for the move, the radius, and a feedrate.
G03 CIRCULAR INTERPOLATION (COUNTER-CLOCKWISE)

N_ G03 X_ Z_ R_ F_ (R specifies the radius)
The G03 command executes all radial cuts in a counterclockwise motion. It requires an endpoint
for the move, then the radius, the distance from the start point to the center point, and a feedrate.

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G04 DWELL
N_ G04 P_
The G04 command is a nonmodal dwell command that halts all axis movement for a specified
time while the spindle continues revolving at the specified rpm. A dwell is sometimes used to
allow for the clearance of chips.
G20 INCH UNITS

N_ G20
The G20 command defaults the system to inch units. When a program is being run and the G20
command is encountered, all coordinates are stated as inch units. This command is usually found
at the beginning of a program. However, it can be used to switch between inch and metric units
while the middle of a program.
G21 METRIC OR SI UNITS

N_ G21
The G21 command defaults the system to metric units. When a program is being run and the G21
command is encountered, all coordinates are stated as millimeter units. This command is usually
found at the beginning of a program. However, it can be used to switch between metric and inch
units in the middle of a program.

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G28 AUTOMATIC RETURN TO REFERENCE POINT
N_ G28 X_ Z_
The G28 command is commonly used prior to an automatic tool change. It allows the existing tool
to be positioned to the predefined reference point automatically via an intermediate position. This
ensures that when the tool turret is engaged, it is properly aligned and clears the work piece.
G33 THREAD CUTTING MOTION
Thread cutting is done by moving the tool along the thread repeatedly at different depths till the
final thread profile is formed. Each cut must start at the same angular position on the part. The
spindle has an encoder, which generates a pulse at exactly the same angular position in every
revolution. When a threading motion is programmed, the linear motion of the tool starts when
this pulse is detected. This ensures that every cut starts at the same angular position. Thread cutting
must be done at constant spindle speed.
Block format
N G33 X Z F
X, Z are the end point of the thread and F is the pitch of the thread.
The controller calculates feed rate through the following relationship

Feed rate = Pitch x Spindle speed
Each threading cut involves 4 motions: 1 threading motion and 3 rapid traverse motions. Since a
thread normally requires multiple cuts, G32 results in a long program and is not normally used.
The G76 canned cycle is normally used for threading.

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G40 TOOL NOSE RADIUS (TNR) COMPENSATION CANCEL
N_ G40
The G40 command cancels any cutter compensation that was applied to the tool during aprogram.
It also acts as a safeguard to cancel any cutter compensation applied to a previous program or G-
codes.
G41 TOOL NOSE RADIUS (TNR) COMPENSATION LEFT

N_ G41
The G41 command applies cutter compensation to the left hand side of the programmed tool
path. This amount is equal to the current tool's nose radius value, which is stored in the Tool Offset
Register table of the controller. This register number is referenced by the last two digits in the tool
change command. For example, a tool change command with T0202 will reference the tool nose
radius value in register #2.
G42 TOOL NOSE RADIUS COMPENSATION RIGHT

N_ G42
The G42 command applies cutter compensation to the right hand side of the programmed tool
path. This amount is equal to the current tool's nose radius value, which is stored in the Tool Offset
Register table of the controller.
CANNED CYCLES:
A canned cycle simplifies a program by using a few blocks containing G-codes functions to specify
the machining operations usually specified in several blocks.
G70 FINISHING CYCLE

N_ G70 P_ Q_
The G70 command is used immediately after a roughing cycle, such as a G71 Rough Turning, or
G72 Rough Facing cycle command. The remaining material is machined as specified by the P
and Q block number values, which point to the start and finish blocks of the desired part profile
contour.

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G71 ROUGH TURNING CYCLE
G71 U (d) R (e)
G71 P (n) Q(n) U(u) W(w) F(f)
N (n) _ _ _ _
_______
_______
N (n)_ _ _ _
U = Reference point
R = Retraction of the tool
P = Starting block number
Q = Ending block number
d = Depth of cut
e = Retract amount
n = Number of the first block of the shape
n = Number of the last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate
The G71 command automatically generates roughing passes to turn a work piece to a specified
profile leaving an allowance for finishing. It reads a program segment specified by the P and Q
letter addresses and determines the number of passes, the depth of cut for each pass, and the number
of repeat passes for the cycle.
G72 ROUGH FACING CYCLE

G71 U(d) R (e)
G71 P (n) Q(n) U(u) W(w) F(f)
N (n) _ _ _ _
_______
_______
N (n) _ _ _ _
d = Depth of cut
e = Retract amount

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n = Number of the first block of the shape
n = Number of the last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate
The G72 command automatically faces off a part to a predefined profile, with preset offsets and
federates leaving an allowance for finishing. It reads a program segment specified by the P and Q
letter addresses and determines the number of passes, the depth of cut for each pass, and the
number of repeat passes for the cycle.
G74 Peck Drilling Cycle

N_ G74 X0 Z_ K_ F_
The G74 command involves individual peck moves in each drilling operation. When this command
is invoked, the tool positions itself as in a standard G81 drill cycle. The K value specifies the peck
depth.
G75 GROOVING CYCLE

N_ G75 R(e)
N_ G75 X_ Z_ P_ Q_ F_
The G75 command invokes an outside diameter groove cycle. This cycle involves plunges into the
work piece from the outside of the work piece parallel to the X axis. The X value is the final
diameter. The Z value represents the final Z position. The R value specifies the retract after every
plunge. The P and Q values specify the incremental movements in the X and Z axes, respectively.
G76 THREADING CYCLE

N_ G76 X_ Z_ D_ K_ A_ F_
The G76 command automatically performs all cutting operations required to achieve a thread. The
G76 cycle code is used for the CNC lathe single point threading applications. This code allows the
CNC programmer to enter the data required for a specified thread size & the controller will
determine the number of thread passes & automatically position the tool. The G76 code reduces
the number of programming blocks required for a threading operation.

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Format:
G76 P Q R
G76 X Z P Q F
Ex: G76 P031560 Q150 R0.015
P 03 indicates Number of passes for finishing operations.

15 indicate a Pull out angle (150 to 220) .
60 indicate Thread Angle.
Q150 is the depth of cut for each pass in microns.
R 0.015 is the finishing allowance.
G76 X9.854 Z-20 P1073 Q300 F1.75
X 9.854 is the Minor Diameter in mm for M12 X 1.75mm pitch.
Z-20 is the length of the thread
P1073 is the height of the thread in microns.
Q300 is the Depth of cut for first pass in microns.
F1.75 is the pitch of the thread.
G90 ABSOLUTE POSITIONING

N_ G90
The G90 command defaults the system to accept all coordinates as absolute coordinates. These
coordinates are measured from a fixed origin (X0, Y0, Z0) and expressed in terms of X, Y, and Z
distances.
G91 INCREMENTAL POSITIONING

N_ G91
The G91 command defaults the system to accept all coordinates as incremental, or relative,
coordinates. This command is found at the beginning of some programs to default the system to
incremental coordinates. It is possible to switch between incremental and absolute coordinates at
any time within a program (see the G90 command).
G98 LINEAR FEEDRATE PER TIME
N_ G98
The G98 command sets the linear feed rate to units (inch or millimeter) per time (minutes). The
setting depends on which type of unit is currently active.

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G99 FEEDRATE PER REVOLUTION

N_ G99
The G99 command sets the feed rate to units (inch or millimeter) per revolution. The setting
depends on which type of unit is currently active.
MISELLANEOUS CODES: (M codes)

M codes vary from machine to machine depending on the functions available on it and the
manufacturer of the machine decides them. The M codes listed below are the common ones.
M-codes Function
M00 Optional program stop automatic
M01 Optional program stop request
M02 Program end
M03 Spindle ON clock wise (CW)
M04 Spindle ON counter clock wise (CCW)
M05 Spindle stop
M06 Tool change
M07 Mist coolant ON (coolant 1 ON)
M08 Flood coolant ON (coolant 2 ON)
M09 Coolant OFF
M30 End of program, Reset to start
M98 Sub program call
M99 Sub program end

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SAMPLE PROGRAMS FOR TOOL PATH VERIFICATION - TURNING
PROBLEM 1:
BILLET DIA 75 LENGTH 103 START Z 3
N01 G21 G99 N23 G00 Z5

N02 G28 U0 W0 N24 G01 X41
N03 M06 T0101 N25 G01 Z-49 F0.2
N04 M03 S1000 M08 N26 G01 X42 F2
N05 G00 X76 Z2 N27 G00 Z5
N06 G01 X-1 F0.2 N28 M09 M05
N07 G00 Z5 N29 G28 U0 W0
N08 G00 X73 N30 T0202 M06
N09 G01 X73 Z-100 F0.2 N31 M03 S500 M08
N10 G01 X74 F2 N32 G00 X71 Z0
N11 G00 Z5 N33 G01 X-1
N12 G01 X71 F2 N34 G01 Z2
N13 G01 X71 Z-100 F0.2 N35 G00 X40
N14 G01 X72 F2 N36 G01 Z-50 F0.05
N15 G00 Z5 N37 G01 X70 F0.05
N16 G01 X61 N38 G01 Z-100 F0.05
N17 G01 Z-49 F0.2 N39 G01 X72 F2
N18 G01 X62 F2 N40 G00 Z0
N19 G00 Z5 N41 G28 U0 W0
N20 G01 X51 N42 M09 M05
N21 G01 Z-49 F0.2 N43 M30
N22 G01 X52 F2

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PROBLEM 2:
O 02
BILLET DIA 42 LENGTH 60 START Z 0
N01 G21 G98

N02 G28 U0 W0
N03 M06 T0101
N04 M03 S1200
N05 G00 X42 Z1
N06 G71 U0.5 R1
N07 G71 P08 Q17 U0.1 W0.1 F35
N08 G01 X5 Z0
N09 X10 Z-10
N10 Z-15
N11 G02 X25 Z-25 R10 F25
N12 G01 Z-30 F30
N13 G03 X35 Z-35 R5F25
N14 G01 Z-42
N15 X40 Z-47
N16 G01 Z-52
N17 G28 U0 W0
N18 M06 T0202
N19 M03 S1500
N20 G00 X10 Z1
N21 G70 P08 Q17 F25
N22 G28 U0 W0
N23 M05 M09
N24 M30

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PROBLEM 3:
BILLET DIA 55 LENGTH 113
N05 G21 G99 N85 G28 U0 W0

N10 G28 U0 W0 N90 M09 M05
N15 M06 T0101 N95 M06 T0202
N20 M03 S1000 M08 N100 M03 S500 M08
N25 G00 X55 Z1 N105 G70 P40 Q70 F0.05
N30 G71 U0.5 R0.5 N110 G28 U0 W0
N35 G71 P40 Q70 U0.1 W0.1 F0.2 N115 M09 M05
N40 G01 X10 Z0 N120 M06 T0303
N45 G03 X20 Z-5 R5 F0.15 N125 M03 S500 M08
N50 G01 X20 Z-25 F0.2 N130 G00 X0 Z1
N55 G02 X40 Z-35 R10 F0.15 N135 G01 Z-10 F0.01
N60 G01 X40 Z-55 F0.2 N140 G01 Z30 F0.2
N65 G01 X50 Z-70 N145 M09 M05
N70 G01 X50 Z-110 N150 G28 U0 W0
N75 G00 X55 N155 M30
N80 M09 M05

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PROBLEM 4:
BILLET X32 Z70
N05 G21 G98

N10 G28 U0 W0
N15 M06 T0101
N20 M03 S1500
N25 G00 X33 Z1
N30 G71 U0.5 R1
N35 G71 P40 Q65 U0.1 W0.1 F40
N40 G01 X0 Z0
N45 G03 X10 Z-5 R6
N50 G01 X10 Z-20
N55 G01 X20 Z-30
N60 G01 X20 Z-40
N65 G02 X30 Z-45 R5
N70 M05 M09
N75 G28 U0 W0
N80 M06 T0202
N85 M03 S1000
N90 G70 P40 Q65 S2000 F25
N95 G28 U0 W0
N100 M05
N105M30

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PROBLEM 5:
BILLET X32 Z70
N05 G21 G98

N10 G28 U0 W0
N15 M06 T0101
N20 M03 S1500
N25 G00 X33 Z1
N30 G72 W0.5 R1
N35 G72 P40 Q65 U0.1 W0.1 F40
N40 G01 X32 Z-50
N45 G01 X24 Z-50
N50 G01 X24 Z-40
N55 G01 X16 Z-34
N60 G01 X12 Z-34
N65 G01 X12 Z0
N70 M06 T0202
N75 G00 X12 Z-32
N80 G75 R1
N85 G75 X8 Z-34 P100 Q200 F15
N90 G28 U0 W0
N95 M05
N100 M30

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PROBLEM 6:
BILLET 42 DIA 100 LENGTH START Z 2
N01 G21 G98 N20G00 X12 Z-32

N02 G28 U0 W0 N21G01 X8 F10
N03 M06 T0101 N22G75 R500
N04 M03 S1500 M08 N23G75 X8 Z-40 P2500 Q1000 R0.00
N05 G00 X42 Z1 F15
N06 G71 U0.5 R1 N24G00X20Z0
N07 G71 P08 Q15 U0.1 W0.1 F40 N25G28U0W0
N08 G01 X12 Z0 N26M05 M09
N09 G01 X12 Z-46 N27 M06 T0404
N10 G01 X20 Z-51 N28 M03 S300 M08
N11 G01 X20 Z-61 N29G00 X12 Z5
N12 G03 X36 Z-69 R8 F35 N30G76 P031560 Q50 R0.015
N13 G01 X36 Z-79 F40 N31G76 X9.854 Z-30 P1073 Q100
N14 G01 X40 Z-84 F1.75
N15 G01 X40 Z-94 N32G28U0W0
N16 M05 M09 N34M05
N17 G28 U0 W0 N35M30
N18M06 T0505
N19M03 S350

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PROBLEM 7:
BILLET DIA 42 L 85
N05 G21 G98 N110 G75 R1

N10 G28 U0 W0 N115 G75 X16 Z-38 P100 Q1000 F15
N15 M06 T0101 N116 M05 M09
N20 M03 S1500 M08 N117 G28 U0 W0
N25 G00 X42 Z1 N118 M06 T0303
N30 G71 U0.5 R1 N119 M03 S500 M08
N35 G71 P40 Q60 U0.1 W0.1 F40 N120 G00 X40 Z-69
N40 G01 X18 Z0 N125 G75 R1
N45 G01 X20 Z-2 N130 G75 X36 Z-77 P100 Q1000 F15
N50 G01 X20 Z-42 N135 M05 M09
N55 G01 X40 Z-62 N140 G28 U0 W0
N60 G01 Z-82 N145 M06 T0404
N65 M05 M09 N150 M03 S500 M08
N70 G28 U0 W0 N155 G00 X20 Z-2
N75 M06 T0202 N160 G76 P031560 Q50 R0.015
N80 M03 S2000 M08 N165 G76 X18.161 Z-32 P919.5 Q100
N85 G70 P40 Q60 F20 F1.5
N90 G28 U0 W0 N170 M05 M09
N95 M06 T0303 N175 G28 U0 W0
N100 M03 S500 M08 N180 M30
N105 G00 X20 Z-34

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PROBLEM 8:
BILLET DIA 22 L 75
N01 G21 G98 N32 G76 X10.4675 Z-30 P766.25 Q100

N02 G28 U0 W0 N33 F1.25
N03 M06 T0101 N34 M05 M09
N04 M03 S1500 M08 N35 G28 U0 W0
N05 G00 X22 Z1 N36 G28 U0 W0
N06 G71 U0.5 R1 N37 M30
N07 G71 P10 Q20 U0.1 W0.1 F35 M30
N08 N10 G01 X12 Z0
N09 G01 Z-34
N10 G02 X16 Z-44 R15
N11 G01 Z-54
N12 G03 X20 Z-64 R15
N13 N20 G01 Z-74
N14 M05 M09
N15 G28 U0 W0
N21 M06 T0505
N22 M03 S400 M08
N23 G00 X12 Z-32
N24 G75 R1
N25 G75 X8 Z-34 P100 Q1000 F20
N26 M05 M09
N27 G28 U0 W0
N28 M06 T0606
N29 M03 S400 M08
N30 G00 X12 Z1
N31 G76 P031560 Q50 R0.015

CAM Lab
PROBLEM 9:
[INTERNAL MULTIPLE TURNING]

[BILLET X80 Z100]
G21 G98
G28 U0 W0
M06 T0101
G50 S2500
G96 S250
M03 S800
G00 X0 Z1
G74 R1
G74 X0 Z-5 Q500 F30
G28 U0 W0
M06 T0202
M03 S600
G00 X0 Z1
G74 R1
G74 X0 Z-75 Q500 F30
G28 U0 W0
M06 T0303
M03 S1500
G00 X0 Z1
G74 R1
G74 X0 Z-75 Q500 I20
G28 U0 W0
M06 T0404
M03 S1500
G00 X12 Z1
G71 U0.5 R1
G71 P01 Q10 U0.1 W0.1 F50
N01 G01 X50
N02 G01 Z0
N03 GO1 X50 Z-15
N04 G01 X47 Z-30
N05 G02 X42 Z-35 R5
N06 G03 X38 Z-39 R4
N07 G01 X35 Z-45
N08 G01 X35
N09 G01 Z-60
N10 GO1 X12
G28 U0 W0

CAM Lab
[THREADING CYCLE]
M06 T0606
M03 S600
G00 X49 Z1
G76 P020060 Q10 R50
G76 X51.836 Z-8 P940 Q363 F1.5
GO1 X 48 F 30
GO0 Z2
G28 U0 W0
M05
M30

CAM Lab
seeNC MILL
seeNC mill is special purpose CNC part program verification software used for the machining
center programs. Milling machines uses all the three axes as shown in the figure below. In the
vertical milling machine, the Z-axis denotes the movement parallel to the spindle axis i.e., the up
and down movement of the spindle. The X-axis moves to the operators left and right. The Y axis
moves towards and away from the operator.
Axis convention
The tool can be moved to any position in a 3 dimensional cartesian co-ordinate system.
The Z axis is along the spindle axis. The X and Y axes are perpendicular to Z.
VMC (Vertical Machining Center)

CAM Lab
LIST OF G-CODES
G-code Function
G00 Positioning rapid traverse
G01 Linear interpolation (feed)
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G20 Inch unit
G21 Metric unit
G28 Automatic zero return
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G43 Tool length compensation
G80 Canned cycle cancel
G81 Drilling cycle
G82 Drilling cycle with dwell
G83 Peck drilling cycle / deep drill
G84 Tapping cycle
G85 Boring / Reaming cycle
G86 Boring cycle
G90 Absolute command
G91 Incremental command
G94 Feed per minute
G95 Feed per revolution
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle
CUTTER RADIUS COMPENSATION (CRC)
G40 Tool nose radius compensation Cancel

G41 Tool nose radius compensation Left
G42 Tool nose radius compensation Right
G40 CUTTER COMPENSATION CANCEL

N_ G40
The G40 cancels any cutter compensation that was applied to the tool during a program and acts
as a safeguard to cancel any cutter compensation applied to a previous program or G-codes.

CAM Lab
G41 CUTTER COMPENSATION LEFT

N_ G41 X_ Y_ Z_ F_
The G41 compensates the cutter a specified distance to the left-hand side of the programmed tool
path. It is used to compensate for excessive tool wear or substitute a tool to profile a part.
G42 CUTTER COMPENSATION RIGHT

N_ G42 X_ Y_ Z_ F_
The G42 compensates the cutter a specified distance to the right-hand side of the programmed
tool path. It is used to compensate for excessive tool wear or substitute a tool to profile a part.
N G01 G41/42 X Y D F
Necessity of using CRC
• Difficult to calculate cutter center co-ordinates

• If cutter center co-ordinates are used same diameter of cutter is required to be used
Cutter wear cannot compensated

CAM Lab
G43 TOOL LENGTH COMPENSATION

N_ G43 H_
The G43 command compensates for tool length in a positive direction. Different tools of different
lengths are used in machining any part. The lengths of the tools are not considered inthe part
program. They are entered in the machine’s memory, and are considered automatically for each
motion in the program depending on the tool that is being used. The tool lengths in the Z direction
are called the Tool length offsets.
CANNED CYCLES
Canned or fixed cycles are programming aids that simplify programming. Canned cycles combine
many programming operations and are designed to shorten the program length, minimize
mathematical calculations, and use minimal tool motions.
Examples: Drilling, peck drilling, tapping, boring, back spot facing.
G81 Drilling cycle
G82 Drilling cycle with dwell (Counter bore cycle)
G83 Peck drilling cycle / deep drill
G84 Tapping cycle
G85 Reaming cycle
G86 Boring cycle
G81 DRILLING CYCLE
The G81 invokes a drill cycle at specified locations.

CAM Lab
G82 DRILLING CYCLE WITH DWELL OR COUNTER BORING CYCLE

N_ G82 X_ Y_ Z_ R_ P_ F_
The G82 cycle follows the same operating procedures as the G81 drilling cycle, with the addition
of a dwell.
G83 DEEP HOLE DRILLING CYCLE / PECKDRILL CYCLE
N_ G83 X_ Y_ Z_ R_ Q_ F_
The G83 involves individual peck moves in each drilling operation. When this command is
invoked, the tool positions itself as in a standard G81 drill cycle.

CAM Lab
Manual

CAM Lab
Manual

CAM Lab
Manual

CAM Lab
Manual
SAMPLE PROGRAMS FOR TOOL PATH VERIFICATION – MILLING & DRILLING
PROBLEM NO. 1:
O01
BILLET 120 X 120 X 30 MM
N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 T0101
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G01 X25 Y35 F35
N07 G01 Z-10 F40
N08 G01 Y55
N09 G01 X35 Y65
N10 G01 Y75
N11 G03 X45 Y85 R10 F35
N12 G02 X55 Y95 R10 F35
N13 G01 X85 F40
N14 G02 X95 Y85 R10 F35
N15 G01 Y35 F40
N16 G02 X85 Y25 R10 F35
N17 G01 X35
N18 G02 X25 Y35 R10 F35
N19 G00 Z5
N20 M05
N21 G28 X0 Y0 Z0
N22 M30

CAM Lab
Manual
PROBLEM NO 2:
O02
N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 M06 T01
G43 H01
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G00 X25 Y25 Z5
N07 G01 Z-10 F40
N08 G01 X25 Y100
N09 G02 X85 Y100 R30 F30
N10 G01 X105 Y50 F40
N11 G01 X125 Y40
N12 G01 Y25
N13 G01 X25 Y25
N14 G00 Z5
N15 M05 M09
N16 G28 X0 Y0 Z0
N17 M30

CAM Lab
Manual
PROBLEM NO 3:
O03
N01 G21 G94 G90 G40 N16 G01 Y25

N02 G28 X0 Y0 Z0 N17 G01 X25 Y25
N03 T01 N18 G00 Z5
G43 H01 N19 M05
N04 M03 S1500 M08 N20 G28 X0 Y0 Z0
N05 G00 X0 Y0 Z5 N21 T02
N06 G00 X25 Y25 G43 H02
N07 G01 Z-15 F40 N22 G00 X55 Y50 Z3

N08 X25 Y75 N23 G01 Z-10
N09 G01 X67 Y75 N24 G00 Z3
N10 G03 X75 Y83 R8 F30 N25 G00 X145 Y50
N11 G01 Y125 F40 N26 G01 Z-10
N12 G01 X125 N27 G00 Z3
N13 G01 X125 Y83 N28 M05 M09
N14 G03 X133 Y75 R8 F30 N29 G28 X0 Y0 Z0

N15 G01 X175 N30 M30
CAM Lab
Manual
PROBLEM NO 4:
O04
CANNED CYCLES USED: G81 & G85
N01 G21 G94 G90 N18 G99 G85 Z-10 R3 F75

N02 G28 X0 Y0 Z0 N19 Y75
N03 M06 T0101 N20 X75
G43 H01 N21 Y25
N04 M03 S1500 M08 N22 X50 Y50
N05 G00 X0 Y0 Z5 N23 G80 M09 M05

N06 G00 X25 Y25 N24 G28 X0 Y0 Z0
N07 G99 G81 Z-10 R5 F100 N25 M06 T03
N08 Y75 N26 M30
N09 X75
N10 Y25
N11 X50 Y50
N12 G80 M09 M05
N13 G28 X0 Y0 Z0
N14 M06 T02
N15 G43 H02
N16 M03 S750 M08
N17 G00 X25 Y25
CAM Lab
Manual
PROBLEM NO 5:
O05
CANNED CYCLES USED: G83
N01 G21 G94 G90 N14 M03 S1500 M08

N02 G28 X0 Y0 Z0 N15 G00 X0 Y0 Z5
N03 M06 T01 N16 G00 X30 Y65
G43 H1 N17 G99 G83 Z-40 Q5 F100
N04 M03 S1500 M08 N18 X60 Y95
N05 G00 X0 Y0 Z5 N19 X90 Y65
N06 G00 X25 Y25 N20 X60 Y35
N07 G99 G83 Z-40 Q5 R5 F100 N21 G80 M09 M05
N08 Y105 N22 G28 X0 Y0 Z0
N09 X105 N23 M30.
N10 Y25
N11 G80 M09 M05
N12 G28 X0 Y0 Z0
N13 M06 T02
G43 H2

CAM Lab
Manual
PROBLEM NO 6:
O06
CANNED CYCLES USED: G81 & G86
N01 G21 G94 G90 N20 G00 X225 Y50 Z5

N02 G28 X0 Y0 Z0 N21 G99 G81 Z-10 R5 F100
N03 M06 T01 N22 G00 X275 Y100
N04 G43 H01 N23 X225 Y137.5
N05 M03 S1500 M08 N24 G80 M09 M05
N06 G00 X0 Y0 Z10 N25 G28 X0 Y0 Z5
N07 G01 X25 Y75 F100 N26 M06 T03
N08 G01 Z-10 G43 H03
N09 G01 Y125 N27 M03 S500 M08
N10 X100 Y175 N28 G00 X225 Y50 Z5
N11 X225 N29 G99 G86 R5 Z-10 F75
N12 G02 X225 Y25 R75 F70 N30 G00 X275 Y100
N13 G01 X100 N31 X225 Y137.5
N14 G01 X25 Y75 N32 G80 M09 M05
N15 G01 Z5 N33 G28 X0 Y0 Z5
N16 M05 M09 N34 M30
N17 G28 X0 Y0 Z5 N35 M30
N18 M06 T02
G43 H02
N19 M03 S1000 M08

CAM Lab
Manual
PROBLEM NO 7:
O1234
G90 G21
M06 T01
G90 G00 X10.0 Y40. S1000
M03Z1
M98 P10055
M70
M98 P10055
M80
M71
M98 P10055
M81
M70
M71
M98 P10055
M05
Z100
G00 G91 G28 Y0.0
M30
O55
G00 X10 Y40
G01 Z-5.0 F100
X40 Y10
X10. Y10.0
X10 Y40
G00 Z5
M99
PROBLEM NO 8:
[RECTANGULAR POCKETING]
G91 G28 X0 Y0 Z0
M06 T1
M03 S1500
G90 G00 X0 Y0
G01 X20 Y20 Z-5 F30
G01 X20 Y40
G01 X40 Y40
G01 X40 Y20
G01 X20 Y20
G01 X0 Y0 Z5000
G91 G28 X0 Y0 Z0
M05
M30

CAM Lab
Manual
SIMULATION OF MACHINING OPERATIONS USING A CAM

SOFTWARE TOOL (CAPSturn and CAPSmill)
CAPS turn and CAPS mill are the CADEM’S application software tools available to
simulate turning & milling related operations by creating complex designs and models. It can also
be utilized as a tool to generate a part and in turn to generate the NC part program for the part
generated. Writing a manual part program requires the knowledge of the part (drawing) to be
produced, the syntax of the program, the knowledge of preparatory and miscellaneous codes for
various control models, etc. But, by using CAPSturn & CAPSmill, the part program will generate
by itself for the part drawn by the operator. It is also possible to interface this software directly to
a CNC machine where in the part designed can be machined.
The programming process of CAPSturn & CAPSmill includes the following 8 steps
Steps Operation Menu option
1 Start a new program File
2 Define a work setup
3 Draw the part Geometry
4 Define Blank Geometry
5 Perform Machining Machining
6 Select Machine Machines
7 View tool path Tool path
8 Generate NC program NC program

CAM Lab
Manual

CAM Lab
Manual
Cycle time calculation

Extremely accurate cycle time – less than 1 % error.
Try out many process options, decide on the one with least cycle time.
Generates printable cycle time sheet.
Reduce cycle time
Reduce
documentation
time Reduce skill
level of
programmer

CAM Lab
Manual
Spindle power graph
Check if you are using the available spindle power to the maximum. Check if
you are over-using the spindle.
Reduce cycle time

Reduce damage to machine

CAM Lab
Manual
TO GENERATE THE PROGRAM

Steps in CAPSTURN/CAPSMILL NC programming
1. Start new program

2. Define work setup
Generate:
3. Draw the part
4. Draw the blank
Machining:
5. Perform machining
6. Select machine
Simulation:
7. View tool path
Tool Path & NC Program Generation:

8. Generate NC program
1. Start new program
Double click on the CAPSTURN icon
Or
Select start- program –CADEM –CAPSTURN
2. Define work setup
Setup data is required for machining, and documentation is related to the details of the
program. The work setup data is divided into
Setup data 1,
Setup data 2 and
Documentation.

CAM Lab
Manual
Entering the setup data mandatory, while documentation is optional.
3. Draw the part
Draw-use the drawing tools to construct the geometry of the part
Draw-define part – create part shape
4. Draw the blank
Draw –define blank
5. Perform machining
Switch to the machining menu clicking on the machining tab
Select appropriate machining operation and define tool details used for that operation
6. Select machine
Select suitable machine from the available list
7. View tool path.
Switch to tool path mode by clicking on tool path tab
Select tool path-start
8. Generate NC program
Click on NC PROGRAM ON THE menu bar
9. Documents
Power
Tool list
Time Study Sheet

CAM Lab
Manual
Steps to Simulate CAPSTURN
External Machining:
R
2,
R
2,
30
8
6
6
BLANK
1.Facing
2.contour turn
3.Grooving
4. Threading
OK>Create a new part>Ok

Jaw positon absolute Z=80
Clearance OD=35
Clearance Z=2
OK

CAM Lab
Manual
Geometry:
Draw>Multiline>0,0>6,0>8,-2,>8,-12> done
Draw>Groove>Base width=5>depth=2>external>OK>8,-12
Draw Multiline>8,-17>8,-22>12,-27
Draw Arc>Start-End-Radius>12,-27>17,-32>5>Ok
Draw Arc>Start-End-Radius>22,-37>17,-32>5>Ok
Draw Multiline>22,-37>30,-37>30,-50>done
Drawn>Define Part>Select the drawn Object>Yes
Drawn>Multiline>0,2>35,2>35,-80>done
Drawn>Defind Blank>Length=80, dia=35, Start Z=2>Ok
Machining:
Turning Operation
Plain Face>New tool>Select tool>Ok>Select 35,2> 35,0>Depth of Cut=0.5
Contour Turn>New Tool>Select Suitalbe Tool>OK>0,0>30,-50>Depth of Cut=0.5
Groove>Radial>New tool>Select suitable tool>Select the groove>OK
Thread>New tool>Suitable tool>Select line of thread>No of cutting pass=4>Thread
Pitch=1>Thread Depth=0.613 >OK
Tool Path:
Simulation Starts
NC Program:
Edit your name and USN Number
Save in Suitable folder
OK
Documents
Power
Tool list
Time Study Sheet

CAM Lab
Manual
CAPSTURN
Internal Machining:
20
24
60
12
Operations
1.Facing
2.Centre Drill
3.Peck Drill
4.Drill
5.Boring
6.Tapping
OK>Create a new part>OK

Jaw positon absolute Z=100
Clearance =0
Outer Diameter =30
OK

CAM Lab
Manual
Geometry:
Draw>Multiline>24,0>24,-30>20,-30>20,-50>12.5,-50>12.5,-70>0,-70> done
Draw>Define Part>Select the Object>Yes
Drawn Multiline>0,0>30,0>30,-90>Done
Draw>Define Blank>Select the blank>Yes
Machining:
Hole Operation
Centre Drill>New tool> Select Suitable tool>OK
Tool Tip depth=1>OK
Peck Drilling>New tool>Select Suitable Tool>OK
Hole Depth=70>Peck Depth=5>OK
Drilling>New Tool>Drill >Twist Drill>Select 12.5 drill>OK
Hole depth=70>OK
Finish Boring
New tool>Select Suitable boring tool>OK
Hole depth=50>Bore diameter=20>OK
Finish boring
New>Select suitable boring tool>Ok
Hope depth=50>Bore Diamter=20>Ok
Finish Boring>New tool>Select suitable boring tool>OK
Finish Boring>Hole Depth=30>Bore Diameter 24>OK
Tapping>New Tool>Tap Metric>Select suitable tapping tool=M24X3 tap>Ok
Hole depth=20>OK
Tool Path:
Simulate
NC Program:
OK

CAM Lab
Manual
Documents
Power
Tool list
Time Study Sheet
CAPSMILL
5 5
O
50
15
R
100
O
62,5
62,5
37,5
5 5

CAM Lab
Manual
Operations
1. Face mill
2. Side mill
3. Slot mill
4. T – Slot mill
5. Track , Slot mill
6. Rectangular Pocketing
7. Circular pocketing
8. Hole operations
OK>Create a new part>OK

OK
Geometry:
Draw>Shapes>Rectangle (opposite corner)>0, 0>100,100>done

Draw>Shapes>Slot>Length=100, Breadth=5>OK>50, 92.5>OK
Draw>Shapes>Slot>Length=100, Breadth=5>OK>50, 7.5>OK
Draw>Point pattern>Points random>25, 37.5>done>50, 37.5
Draw>Shapes>Rectangle (Corner length width)>Length=15, Breadth=15>Ok>15, 62.5>done
Draw>Shapes>Rectangle (Corner length width)>Length=15, Breadth=15>Radius=7.5>Ok>75,
62.5>done
Drawn>Shapes>Track>Length=4, Arc radius=10>Ok>-2, 50
Drawn>Shapes>Track>Length=4, Arc radius=10>Ok>102, 50
Draw>Define blank>Maximum X=105, Y=105>Minimum X=-5, Y=-5>Blank Thickness=15>
Z coordinate at the bottom = -8>ok
Machining:
Milling Operation:
Face milling>New tool>Select suitable tool;>Ok>Select a contour>Material
thickness=3>OK>Select machine starting point suitably
Side mill>New tool>Select suitable tool>Ok>Select a contour>Select starting point of
machining>Mill the whole contour=Yes>Select the side of milling outside>Material width=5,
Material depth=12>OK

CAM Lab
Manual
Slot mill>New tool>Select suitable tool>Ok>Select the slot>Depth=4>OK
Rectangular Pocketing:
New tool>Select suitable tool>OK>Select rectangular contour>Pocket depth=12>OK
Circular Pocketing:
New tool>Select suitable tool>OK>Select circular contour>Pocket depth=12>OK
Hole Operation:
Centre drill>Select new tool> Select suitable tool>OK> Select 25, 37.5>done>Select 50,
37.5>done>No.
Drilling:
Drill> Select new tool>tool dia 5 >depth 12> OK> Select 25, 37.5>done>Select 50,
37.5>done>OK
Counter Boring:
Select new tool> tool dia 7.5 > Ok> Select 25, 37.5>done>Select 50, 37.5>done>No>hole
depth=5>Ok
Tapping:
Select new tool>M5.0*0.80 tap metric>Ok> Select 25, 37.5>done>Select 50, 37.5>done>hole
depth=12>Ok
Tool Path:
Simulate
NC Program:
OK
Documents
Power
Tool list
Time Study Sheet

CAM Lab
Manual
PART - B
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.
FLEXIBLE MANUFACTURING SYSTEM (FMS)

The need for a more flexible response to rapidly changing market demands has caused a rather
dramatic change in the philosophy on the design and the layout of production systems, as well as
on production organizations and even product development (Zijm, W. H. M., 1987).
Philosophically, FMS incorporates a system view of manufacturing. The buzzword for today’s
manufacturer is “agility”. An agile manufacturer is one who is the fastest to the market, operates
with the lowest total cost and has the greatest ability to “delight” his/her customers. FMS is simply
a way that the manufacturers are able to achieve this agility. Physically, a flexible manufacturing
system (FMS) is a highly automated Group Technology (GT) machine cell, consisting of a group
of processing stations (usually CNC machine tools), interconnected by an automated material
handling and storage system, and controlled by an integrated computersystem. An FMS is capable
of processing a variety of different part styles simultaneously under NC program control at the
different workstations.
Schematically, an FMS can be shown as below:

CAM Lab
Manual
Types of FMS
Flexible manufacturing systems can be distinguished according to:

• The kinds of operations they perform: processing operations or assembly operations.
• Number of machines and level of flexibility.
Based on number of processing machines, FMSs can be

• Single-machine cell
• Flexible manufacturing cell
• Flexible manufacturing system.
A single-machine cell consists of one CNC machining center combined with a parts-storage
system for unattended operation (fig. next slide)
A flexible manufacturing cell (FMC) consists of two or three processing workstations (typically
CNC machining centers or turning centers) plus a parts-handling system. The parts- handling
system is connected to a load/unload station.
A flexible manufacturing system (FMS) has four or more processing stations connected
mechanically by a common parts-handling system and electronically by a distributed computer
system.
Based on Level of Flexibility, flexible manufacturing systems are classified as

(1) Dedicated FMSs, and (2) Random-order FMSs
A dedicated FMS is designed to produce a limited variety of part styles.
A random-order FMS is more appropriate for the following circumstances:

(1) the part family is large, (2) there are substantial variations in part configurations, (3) new part
designs are introduced into the system and engineering changes will be made to parts currently
produced, and (4) the production schedule is subject to change from day-to-day.
It is equipped with general-purpose machines to deal with the product variations and is capable
of processing parts in various sequences (random order).

CAM Lab
Manual
Components of FMS
The three basic components of a flexible manufacturing system are: (1) processing workstations,
(2) material handling and storage system, and (3) computer control system.
In addition, even though an FMS is highly automated, people are required to manage and operate
the system.
Functions typically performed by humans include:

• loading raw work parts into the system and unloading finished parts (or assemblies) from
the system
• changing and setting tools
• performing equipment maintenance and repair
• performing NC part programming
• programming and operating the computer system
• managing the system.
FMS Applications and Benefits

FMS technology is most widely applied in machining operations. Other applications include
sheet metal press working, forging, and assembly.
The principal benefits of FMS are:
1. Increased machine utilization.
2. Fewer machines required.
3. Reduction in factory floor space required.
4. Greater responsiveness to change.
5. Reduced inventory requirements.
6. Lower manufacturing lead times.
7. Reduced direct labor requirements and higher labor productivity.
8. Opportunity for unattended production.

CAM Lab
Manual
Automated Storage and Retrieval System (AS/RS)
An automated/storage and retrieval system (AS/RS) can be defined as a storage system that
performs storage and retrieval operations with speed and accuracy under a defined degree of
automation.
The operations are totally automated, computer controlled, and fully integrated with factory and/or
warehouse operations, and human workers control the equipment and perform the storage/retrieval
transactions. AS/RSARE custom designed for each application, although the designs are based on
standard modular components available from each respective AS/RS supplier.
An AS/RS consists of one or more storage aisles that are each serviced by a storage/retrieval (S/R)
machine. The aisles have storage racks for holding the stored materials. The S/R machines are
used to deliver materials to the storage racks and to retrieve materials from the racks.
Components of an AS/RS:
Virtually all of the automated storage/retrieval systems consist of the following components: (1)
storage structure, (2) S/R machine, (3) storage modules (e.g., pallets for unit loads), and (4) one or
more pickup-and-deposit stations. In addition, a control system is required to operate the AS/RS.
Basic components in a (i) fixed aisle AS/RS, (ii) carousel type AS/RS

CAM Lab
Manual
AS/RS Types and Applications
Unit load AS/RS
Deep-lane AS/RS
Mini load AS/RS
Man-on-board AS/RS
Automated item retrieval system
Vertical lift storage modules (VLSM)
Many applications of AS/RS technology have been associated with warehousing and distribution
operations. An AS/RS can also be used to store raw materials and work-in-process in
manufacturing. Three application areas can be distinguished for automated storage/retrieval
systems: (1) unit load storage and handling, (2) order picking, and (3) work-in-process storage
systems.
Automated storage/retrieval systems are also used in high-production operations. Examples are
found in the automobile industry, where some final assembly plants use large capacity AS/R
systems to temporarily store car and small truck bodies between major assembly steps. The AS/RS
can be used for staging and sequencing the work units according to the most efficient production
schedule.

CAM Lab
Manual
ROBOT PROGRAMMING [1]
Industrial Robot
An industrial robot is a general-purpose, programmable machine possessing certain

anthropomorphic characteristics. The most obvious anthropomorphic characteristic of an industrial
robot is its mechanical arm that is used to perform various industrial tasks. Other human-like
characteristics arc the robot's capability to respond to sensory inputs, communicate with other
machines, and make decisions. These capabilities permit robots to perform a varietyof useful
tasks.
Common Robot Configurations

A robot manipulator can he divided into two sections: a body-and-arm assembly and a wrist
assembly. There are usually three degrees-of-freedom associated with the body-and-arm, and
either two or three degrees-of-freedom associated with the wrist. At the end of the manipulator's
wrist is a device related to the task that must be accomplished by the robot. The device, called an
end effector, is usually either (1) a gripper for holding a workpart or (2) a tool for performing some
process. The body-and-arm of the robot is used to position the end effector and the robot's wrist is
used to orient the end effector.
Robot Programming
To do useful work, a robot must be programmed to perform its motion cycle. A robot program can
be defined as a path in space to be followed by the manipulator, combined with peripheral actions
that support the work cycle. Examples of the peripheral actions include opening and closing the
gripper, performing logical decision making, and communicating with other pieces of equipment
in the robot cell. A robot is programmed by entering the programming commands into its controller
memory. Different robots use
different methods of entering the commands.
Today, nearly all industrial robots have digital
computers as their controllers, together with
compatible storage devices as their memory units.
For such robots, the following programming
methods are in use:

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● Lead through method
● Computer-like programming languages
● Offline programming.
The lead through method makes use of a teach pendant to power drive the robot through its motion
sequence. The teach pendant is usually a small hand held device with switches and dials to control
the robots physical movements. Each motion is recorded into memory for future playback during
work cycle. The lead through method is very popular among robot programming methods because
of its ease and convenience.
Computer-like (robot) programming languages
The use of textual programming languages became an appropriate programming method as digital
computers took over the control function in robotics. Their use has been stimulated by the
increasing complexity of the tasks that robots are called on to perform, with the concomitant need
to imbed logical decisions into the robot work cycle. These computer-like programming languages
are really on-line/off-fine methods of programming, because the robot must still be taught its
locations using the lead-through method.
The VAL Language

• The VAL language was developed for PUMA robot
• VAL stands for Victors Assembly Language
VAL is basically off-line language in which program defining the motion sequence is can be
developed off-line but various point location used in the work cycle are defined by lead through.
VAL statements are divided into two categories:
a) Monitoring command b) Programming instructions.
Monitor command are set of administrative instructions that direct the operation of the robot
system. Some of the functions of Monitor commands are:
● Preparing the system for the user to write programs for PUMA
● Defining points in space
● Commanding the PUMA to execute a program
● Listing program on the CRT
Examples for monitor commands are: EDIT, EXECUTE, SPEED, HERE etc.

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Program instructions are a set of statements used to write robot programs. One statement usually
corresponds to one movement of the robots arm or wrist.
Example for program instructions are Move to point, move to a point in a straight line motion, open
gripper, close gripper. (MOVE, MOVES, APPRO, APPROS, DEPART,
OPENI, CLOSEI, AND EXIT)
The MCL Language

● MCL stands for Machine Control Language developed by Douglas.
● The language is based on the APT and NC language. Designed control complete
manufacturing cell.
● MCL is enhancement of APT which possesses additional options and features needed to
do off-line programming of robotic work cell.
● Additional vocabulary words were developed to provide the supplementary capabilities
intended to be covered by the MCL. These capabilities include Vision, Inspection and
Control of signals.
● MCL also permits the user to define MACROS like statement that would be convenient
to use for specialized applications.
● MCL program is needed to compile to produce CLFILE.
● Some commands of MCL programming languages are DEVICE, SEND, RECEIV,
WORKPT, ABORT, TASK, REGION, LOCATE etc.
Off- line programming:

This method involves the preparation of the robot program off-line, in a manner similar to NC part
programming. Off-line robot programming is typically accomplished on a computer terminal.
After the program has been prepared, it is entered in to the robot memory for use during the work
cycle. The advantaged of off-line robot programming is that the production time of the robot is not
lost to delay in teaching the robot a new task. Programming off-line can be done while the robot
is still in production on the preceding job. This means higher utilization of the robot and the
equipment with which it operates.
Another benefit associated with off-line programming is the prospect of integrating the robot into
the factory CAD/CAM data base and information system.

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Sample Robot Programs for Simple Operations (pick, place and stack)
<program type="icon">
MOVETO A
GRIPOPEN
MOVETO B
GRIPCLOSE
MOVETO C
MOVETO D
MOVETO E
GRIPOPEN
MOVETO F
HOME
END
User Inter phase of robot sim software

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Motions

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The following sub-sections describe the task commands available in Robo CIM 5150.
1. Channel
2. Delay
3. Do
4. Else
5. End
6. End if
7. Go sub
8. Grip
9. Grip close
10. Grip open
11. Home
12. Input
13. Message
14. Move to
15. Output
16. R channel
17. Relay
18. Repeat

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PNEUMATICS AND HYDRAULICS, ELECTRO-PNEUMATICS
In industries, three methods are used for transmitting power from one point to another. Mechanical
transmission is through shafts, gears, chains, belts, etc. Electrical transmission is through wires,
transformers, etc. Fluid power is through liquids or gas in a confined space.
The terms Pneumatics (pneuma meaning air in Greek) and Hydraulics (hydra meaning water in
Greek) are used to signify the applications of fluid power. Pneumatics uses an easily compressible
gas such as air or a suitable pure gas - while hydraulics uses relatively incompressible liquid media
such as oil (petroleum and synthetic oils). Fluid power is the use of fluids under pressure to
generate, control, and transmit power.
Fluid power systems perform work by a pressurized fluid bearing directly on a piston in a cylinder
or in a fluid motor. A fluid cylinder produces a force resulting in linear motion, whereas a fluid
motor produces torque resulting in rotary motion. Within a fluid power system, cylinders and
motors (also called actuators) do the desired work. Control components such as valves regulate
the system.
Basic Components of a Hydraulic System:

Figure below shows a simple circuit of a hydraulic system with basic components:

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 The hydraulic actuator is a device used to convert the fluid power into mechanical power
to do useful work. The actuator may be of the linear type (e.g., hydraulic cylinder) or rotary
type (e.g., hydraulic motor) to provide linear or rotary motion, respectively.
 The hydraulic pump is used to force the fluid from the reservoir to rest of the hydraulic
circuit by converting mechanical energy into hydraulic energy.
 Valves are used to control the direction, pressure and flow rate of a fluid flowing through
the circuit.
 External power supply (motor) is required to drive the pump.
 Reservoir is used to hold the hydraulic liquid, usually hydraulic oil.
 Piping system carries the hydraulic oil from one place to another.
 Filters are used to remove any foreign particles so as keep the fluid system clean and
efficient, as well as avoid damage to the actuator and valves.
 Pressure regulator regulates (i.e., maintains) the required level of pressure in the
hydraulic fluid.
Basic Components of a Pneumatic System:

Figure below shows a simple circuit of a pneumatic system with basic components:

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The functions of various components shown in Fig. above are as follows:
 The pneumatic actuator converts the fluid power into mechanical power to perform useful
work.
 The compressor is used to compress the fresh air drawn from the atmosphere.
 The storage reservoir is used to store a given volume of compressed air.
 The valves are used to control the direction, flow rate and pressure of compressed air.
 External power supply (motor) is used to drive the compressor.
 The piping system carries the pressurized air from one location to another.
Fluid power applications can be classified into two major segments:

Stationary hydraulics: Stationary hydraulic systems remain firmly fixed in one position. The
characteristic feature of stationary hydraulics is that valves are mainly solenoid operated.
The applications of stationary hydraulics are as follows:

 Production and assembly of vehicles of all types.
 Machine tools and transfer lines.
 Lifting and conveying devices.
 Metal-forming presses.
 Plastic machinery such as injection-molding machines.
 Rolling machines.
 Lifts.
 Food processing machinery.
 Automatic handling equipment and robots.
Mobile hydraulics: Mobile hydraulic systems move on wheels or tracks such as a tower crane
or excavator truck to operate in many different locations or while moving. A characteristic
feature of mobile hydraulics is that the valves are frequently manually operated. The applications
of mobile hydraulics are as follows:
 Automobiles, tractors, aeroplanes, missile, boats, etc.

 Construction machinery.

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 Tippers, excavators and elevating platforms.
 Lifting and conveying devices.
 Agricultural machinery.
Pneumatic systems are used in automation equipment such as transfer lines, robots, etc.; in
brake system of automobiles, railway coaches, etc.; material handling equipment, medical
equipment, power hammers and nut runners, etc.
ELECTRO PNEUMATICS [5]

An electro-pneumatic system consists of electrical control systems operating pneumatic power
systems. The interface between the electrical and pneumatic systems is mainly accomplished
through solenoid valves. Devices like limit switches and proximity sensors are used as feedback
elements.
In Electro-pneumatics, an electrical signal either from AC or DC source is used. Operating
voltages range from around 12 V to 220 Volts. The final control valve is activated by solenoid
actuation.
Control of Electr-pneumatic system is carried out either using combination of Relays and
Contactors or with the help of Programmable Logic Controllers (PLCs). A Relay is often is used
to convert signal input from sensors and switches to number of output signals (either normally
closed or normally open).
In Electro-pneumatic control, three important steps involved are:
Input Signal Generation by switches and contactors, and various types of contact and proximity
sensors.
Signal Processing by a combination of Contactors and Relays or using Programmable Logic
Controllers.
Input Signal Generation and end use: These signals activate solenoids, indicators or alarms.
Simple exercises on pneumatics and hydraulics circuits.

(a simulation using open source tools may be demonstrated)

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References:
[1]. Groover, Mikell P. Automation, Production Systems and Computer-Integrated
Manufacturing, 4th Edition, Pearson Higher Education, NJ, 2015.
[2]. Groover, Mikell P. Fundamentals of Modern Manufacturing: Materials, Processes and

Systems, 4th ed., John Wiley & Sons, Inc., 2010.
[3]. Shivanand, H.K., Benal, M.M. and Koti, V. Flexible Manufacturing Systems, New Age
International (P) Ltd., 2006
[4]. https://nptel.ac.in/courses/112106175/Module%201/Lecture%201.pdf
[5]. https://nptel.ac.in/courses/112106175/Module%204/Lecture%2041.pdf

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EXERCISE PROBLEMS

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VIVA VOCE QUESTIONS
01. What is CAM?

02. What are the advantages, limitation of CAM?
03. Differentiate between conventional and computer controlled machines?
04. What are NC, CNC and DNC machines?
05. What are different types of motion controllers in CNC machines?
06. Differentiate between absolute and incremental programming?
07. Explain the various types of programming format
08. Explain NC procedure
09. Explain sequence no, preparatory code and misc. code.
10. What is the meaning of canned cycle?
11. Why cutter compensation is required in turning and milling?
12. What is machine zero, home zero and work zero?
13. What is ATC and explain its advantages?
14. What are different types of ATC?
15. Explain single gripper and double gripper arm in case of machining center.
16. What is APC?
17. What are the advantages of APC?
18. Differentiate between rapid and linear movement.
19. What are the limitations of NC machines over CNC machines?
20. Differentiate between turning and machining center.
21. How do you differentiate VMC and HMC?
22. What are the axis conventions in turning center?
23. What are the axis conventions in machining center?
24. Explain 4th and 5th axis in case of machining center.
25. How do you test the NC program?
26. What is sub-programming and Macros? Why it is required?
27. Name standard CAM packages.
28. Differentiate G02 and G03 preparatory function.
29. Differentiate G00 and G01 preparatory function.

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30. What is G80 preparatory code?
31. What is the meaning of reference shift?
32. How do you set the reference on the work-piece in turning center?
33. How do you set the reference on the work-piece in machining center?
34. What are the safety measures required while operating turning/machining center?
35. List various standard controllers.
36. Define robot.
37. Why robot is required?
38. What are the various configuration of robot?
39. Explain pitch, yoke and wrist in robot?
40. Explain different robot programming methods.
41. Explain application area of robot.
42. How do you explain intelligence robot?
43. How do you explain off-line programming method?
44. Define fluid power?
45. What is hydraulics and pneumatic system?
46. Define Pascal’s law?
47. List the components of a hydraulic and pneumatic system?
48. List the advantage and disadvantages of hydraulic and pneumatic system?
49. How are pumps classified? Give examples
50. What is the function control component in the hydraulic system? List them &give
example each
51. What are the major censes of a hydraulic system breakdown?
52. List properties of hydraulic fluids?
53. What is a hydraulic power pack?

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CAM Lab

Computer Aided Manufacturing

Department Of Mechanical Engineering 1

Department of Mechanical Engineering, JSSATE, Bangalore 560 060

Program Educational Objectives (PEO)

Program Specific Outcomes (PSOs)

Department Of Mechanical Engineering 2

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

Department Of Mechanical Engineering 3

Department Of Mechanical Engineering 4

Subject Code : 15MEL77 IA Marks : 20

FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval

Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these

Two questions from Part A – 60 Marks (30+30)

Department Of Mechanical Engineering 5

1. Leave the footwear outside the lab in the designated place.

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Computer Numerical Control programming is a procedure of preparing a detailed list of

1. Manual Part programming

NC BLOCK: NC block is a collection of NC words. An NC word is a collection of address letters

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Department Of Mechanical Engineering 8

1. Double click on the See NC turn icon

PREPARATORY CODES: (G Codes)

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G00 POSITIONING IN RAPID

G01 LINEAR INTERPOLATION

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G02 CIRCULAR INTERPOLATION (CLOCKWISE):

G03 CIRCULAR INTERPOLATION (COUNTER-CLOCKWISE)

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G20 INCH UNITS

G21 METRIC OR SI UNITS

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G33 THREAD CUTTING MOTION

The controller calculates feed rate through the following relationship

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G41 TOOL NOSE RADIUS (TNR) COMPENSATION LEFT

G42 TOOL NOSE RADIUS COMPENSATION RIGHT

G70 FINISHING CYCLE

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G72 ROUGH FACING CYCLE

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G74 Peck Drilling Cycle

G75 GROOVING CYCLE

G76 THREADING CYCLE

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P 03 indicates Number of passes for finishing operations.

G90 ABSOLUTE POSITIONING

G91 INCREMENTAL POSITIONING

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G99 FEEDRATE PER REVOLUTION

MISELLANEOUS CODES: (M codes)

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BILLET DIA 75 LENGTH 103 START Z 3

N01 G21 G99 N23 G00 Z5

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N01 G21 G98

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BILLET DIA 55 LENGTH 113

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