PROJECT TOPIC

Xyz moving drill machine

PERSONAL TRANSPORTER

SHRI RAM COLLEGE OF ENGINEERING AND MANAGEMENT

(AFFILIATED TO MAHARSHI DAYANAND UNIVERSITY, ROHTAK) NH2, AURANGABAD (PALWAL), HARYANA.

CANDIDATE DECLARATION
We the students of Bachelor Of Technology in Mechanical discipline, Session: 2008 12, Faculty of Engineering and Technology(SRCEM); hereby declare that the work presented in this dissertation entitled Segway- a Personal Transporter is the outcome of our work, is bonafide and correct to the best of our knowledge and this work has been carried out taking care of engineering ethics. The work presented does not infringe any patented work and has not been submitted to any other university or anywhere else for the award of any degree or any professional diploma.

Chirag Gupta Mohit Chaudhary Pawan Malik Sachin Sharma Vinod Chauhan

(83009) (83026) (83033) (83041) (83053)

CERTIFICATE

This is to certify that Mr. Vinod Chauhan student of B.Tech (Mechanical) from SHRI RAM COLLEGE OF ENGINEERING AND MANAGEMENT, Maharishi Dayanand University, Rohtak, have completed his project as per partial fulfillment of the requirement for the award of the Degree of Bachelor Of Engineering (ME) of M.D. University in a record of bonafied work carried out under the guidance of Mr. Surender Kumar. The project work entitled SEGWAY- A PERSONAL TRANSPORTER embodies the original work done by him during his final year. He have successfully completed the project work up to our full satisfaction. We wish him success in his future life.

Mr. Surender Kumar

Dr. D.S. Sharma

Professor & Head of Department Mech. Department

(Dean, Mech.)

ACKNOWLEDGMENT

I would like to express my gratitude to Mr. Surender Kumar (Professor & HOD), Department Mechanical who was instrumental in the formulation of the project. I am very grateful to him for his encouragement and dedication in making this project a successful one.

I express my sincere regards to other staff of the college for their constant support and suggestions during the making of this project and for all the facilities provided.

I extend my thanks to all my friends and well wishers for their instant and efficient co-operation whose efforts resulted in the timely development of the project. I also thank the technical staff of the computer labs who provided the facilities required during development.

Finally I am indebted to my parents who have constantly provided us the opportunity and support to rise to higher levels in life.

Vinod Chauhan

(83053)

Semester VIII B.Tech. (Mechanical) SRCEM,AURANGABAD(PALWAL)

Introduction

Congratulations! Your XYZ Bed Mill with the ProtoTRAK SMX CNC is an excellent tool room machine. It features an easy-to-use interface and dozens of features that maximize machinists productivity for any kind of toolroom job. Manual machining is always available and made easier with features like power feed, rapid positioning, tool offsets and all the best features of sophisticated DROs. Two-axis machining is available at the touch of a button for prototyping and moderately complex, low volume work. Three-axis machining is programmed and run with unprecedented flexibility. Programs may be entered at the control or imported from CAD/CAM files. Advanced color graphics show program features. The ProtoTRAK SMX CNC allows you to chose the CNC configuration that is right for you. The base system is a powerful CNC for toolroom work. You may add options for additional features and capabilities. This manual will describe the operation of all basic and optional features in the appropriate context. Where optional features are discussed, a note will explain in which option the particular feature is found. 1.1 Manual Organization Section 2 of this manual provides important safety information. It is highly recommended that all operators of this product review this safety information. Section 3 provides a description of the XYZ Bed Mill and the ProtoTRAK SMX CNC. Machine Control Options are described in this section. Section 4 describes the operation of the milling machine and some basic operations of the ProtoTRAK SMX CNC. Section 5 defines some terms and concepts useful in learning to program and operate

the ProtoTRAK SMX CNC. The ProtoTRAK SMX CNC is organized into six Modes of operation that are described in the following sections. Section 6 DRO: Digital Readout, jog, and powerfeed operations. Section 7 Programming, Part 1: covers some general programming information and instructions on starting new programs. Section 8 Programming, Part 2: Program Events - instructions for the canned cycles, or events, used to program the ProtoTRAK SMX CNC. Section 9 Programming, Part 3: the A.G.E., or Auto Geometry Engine, so powerful it gets its own section. Section 10 Edit: for routines to make large-scale changes to programs in current memory, including the powerful Spreadsheet Editing Section 11 Set-Up: Tool information, part graphics and special codes. Section 12 Run: Instructions on running a program to machine your part. Section 13 and 14 Program In/Out: Storing and managing your programs. Section 15: Sample programs for practice. EVENT 1 Bolt Hole NOTES center drill DRILL O R BORE # OF HOLES X CENTER Y CENTER Z RAPID Z END RADIUS ANGLE # OF PECKS FOR DRILL

Z FEEDRATE TOOL # 1 5 ABS SET 0 ABS SET 0 ABS SET 3 ABS SET -3 ABS SET 33 SET 45 SET 1 SET 125 SET 1 SET Drill Function Known print value Use the center as the reference Sets the rapid to 3mm above the part Sets the drill depth to -1 The radius of the bolt hole circle Angle of first hole from zero (0) degrees Sets 1 peck Sets Z plunge rate to 125 mmpm Selects Tool # 1 as the Center drill 145 XYZ Machine Tools Ltd. XYZ Bed Mills and ProtoTRAK SMX CNC Safety, Programming, Operating & Care Manual

EVENT 2 Bolt Hole NOTES drill to final size DRILL OR BORE # OF HOLES X CENTER Y CENTER Z RAPID Z END RADIUS ANGLE # OF PECKS FOR DRILL Z FEEDRATE TOOL # 1 SET 5 ABS SET 0 ABS SET 0 ABS SET 3 ABS SET -9 ABS SET 33 SET 45 SET 3 SET 125 SET 2 SET Drill Function Known print value Use the center as the reference Sets the rapid to 3mm above the part

Sets the drill depth to 9 (through) The radius of the bolt hole circle Angle of first hole from zero (0) degrees Sets 3 peck Sets Z plunge rate to 125 mmpm Selects Tool # 2 as the M7 drill EVENT 3 CIRC PCKT NOTES X CENTER Y CENTER Z RAPID Z END RADIUS DIRECTION # OF PASSES ENTRY MODE FIN CUT Z FEEDRATE XYZ FEEDRATE FIN FEEDRATE TOOL # 0 ABS SET 0 ABS SET 3 ABS SET -5 ABS SET 19 SET 2 SET 2 SET

1 SET .25 SET 100 SET 250 SET 200 S ET 3 SET Sets the pocket center to X zero Sets the pocket center to Y zero Sets the Rapid Sets the pocket depth Sets radius of pocket Makes the cut direction CCW Cuts the pocket using two (2) depths Selects tool ramp into the material Sets finish cut for the wall of the pocket Sets the ramp feedrate in mmpm Sets the pocket cutting feedrate Sets the finish pocket feedrate. Sets mill tool # EVENT 4 RECTANGULAR PROFILE NOTES select PROFILE and then IRREG PROFILE X1 Y1 X3 Y3

Z RAPID Z END CONRAD DIRECTION TOOL OFFSET # PASSES FIN CUT Z FEEDRATE XYZ FEEDRATE FIN FEEDRATE TOOL # -50 ABS SET -50 ABS SET 50 ABS SET 50 ABS SET 3 ABS SET -7.5 ABS SET 0 SET 1 SET 2 SET 2 SET .25 SET 100 SET 250 SET INC SET 3 SET Start at lower left corner

Through the p late Sets tool offset LEFT Machined at 2 depths No change of federate

Intro to CNC Machining CNC stands for computer numeric controlled. It refers to any machine tool (i.e. mill, lathe, drill press, etc.) which uses a computer to electronically control the motion of one or more axes on the machine.

The development of NC machine tools started from a task supported by the US Air Force in the early 1950s, involving MIT and several machine-tool manufacturing companies. The need was recognized for machines to be able to manufacture complex jet aircraft parts.

As computer technology evolved, computers replaced the more inflexible controllers found on the NC machines; hence the dawn of the CNC era.

CNC machine tools use software programs to provide the instructions necessary to control the axis motions, spindle speeds, tool changes and so on.

CNC machine tools allow multiple axes of motion simultaneously, resulting in 2D and 3D contouring ability.

CNC technology also increases productivity and quality control by allowing multiple parts to be produced using the same program and tooling.

Basics of CNC Programming There are two ways to program modern CNC machine tools. 1. Conversational Programming. This is the simpler of the two methods. In effect, this is a macro programming language used to instruct the machine to perform pre-programmed cycles (i.e. facing, drilling holes in arrays, etc.). When writing a conversational program, you simply enter the appropriate parameters associated with each machining cycle. This is analogous to using the polar array function in SolidWorks or Pro/E; you dont have to do the layout o r trig to find the location of the features; you just specify the essential parameters and the software does the rest for you.

1. CAM Programming. This is the more powerful of the two methods. Using this method, you import your part model into a CAM (computer aided manufacturing) program and define the parameters associated with each and every machined feature on the part. These parameters include tool diameter and length, depth of cut, tool path geometry, etc.

Conversational CNC Programming The following cycles are typical of the machining operations available when programming a 3-axis CNC milling machine. Position. Used to move the XYZ coordinates at rapid feedrate. Drill_one. Used to position the tool at a specific XYZ coordinate position in order to automatically drill a hole. The automatic drill cycles allow for simple drilling, peck drilling, spot-facing and bore cycles. Drill_pattern. Used to define polar or rectangular hole arrays for automatic drilling. Line. Used to cut straight lines along an axis or a diagonal at the desired feedrate. Arc. Used to cut a circle or partial circle that is part of a series of cuts that usually includes lines as well. Face. Used to define a rectangular zig-zag pattern used to clean off a part surface. Pocket. Used to clear the material out of a rectangle, circle or polygon. Frame. Used to cut the inside or outside outline of a rectangle, circle or polygon. Tool. Used to enter tool parameters, machine function parameters and program pause/stop codes. Scale/mirror. Used to scale and/or mirror other part features. Rotate. Used to repeat other part features around a specific center of rotation.

Conversational CNC Programming Example #1 Drill Pattern Bolt Circle Variables (G121): X = X center Y = Y center R = Radius A = Start angle (absolute) N = # of holes H = # of holes to drill

Conversational CNC Programming Example #2 Arcs and Lines (dashed line is tool path for 1/8 diameter endmill)

Conversational CNC Programming Example #2 (cont)

Below is the actual tool path code for the previous example. After the user enters the basic parameters, this is the program that is generated by the conversational interface to run on the CNC. An analogy to software programming is that conversational programming is similar to programming using a compiler (ie C, Fortran, VB, etc.) and the actual tool path code generated is equivalent to the final compiled machine code or instructions. G90 G0 X0 Y-0.75 Z1 F5 [G90=absolute; G0=rapid; F=XY feed] Z0 M3 [M3=spindle on, CW] G1 Z-0.1 E2 [G1=linear motion; E=Z feedrate] Y-0.5625 G2 J0.5625 X0 Y0.5625 [G2=CW circular motion] G1 X0.6507 [G1=linear motion] X1.5625 Y0.03608 Y-0.3 G2 I-0.2625 X1.3 Y-0.5625 [G2=CW circular motion] G1 X0 [G1=linear motion] G0 Y-0.75 Z1 [G0=rapid] M30 [M30=end of program/rewind]

CNC CAM Programming Once the part has been designed using conventional mechanical design methods (structural analysis, FEA, fatigue study, etc.), the part is manufactured using the following method. 1. Create a solid 3D model of the part to be produced. Any standard CAD format is acceptable.

1. Import the solid model into the CAM (computer aided manufacturing) software. (this demonstration uses MasterCAM) 1. Input the raw material stock size and set the parts coordinate origin.

1. Input the necessary information for each tool used in machining the part features. Typically, a tool library will exist, which is simply a database of tools and their related parameters.

1. For each part feature, select the appropriate tool from the library and set the parameters necessary for machining that feature. Typical parameters include spindle speed, depth of cut, feedrate, number of passes, tool path pattern, etc. 1. Verify the programmed tool path(s) by running the CAM softwares virtual machining cycle.

Final Facts about CNC Machining CNC manufacturing offers advantages on two types of parts: (1) simple parts that are mass produced and/or (2) complex parts with features requiring multiple axes of simultaneous motion. For simple parts in low quantity, it is often quicker to produce the parts on manual machines (as in lab).

CNC does not inherently imply increased part accuracy. An old CNC with a lot of hours of use will produce less accurate features than a new quality manual machine and vise-versa; so dont automatically associate higher accuracy with CNC machines. (Accuracy has more to do with machine design, component selection and mechanical wear.)

Modern CNC machines offer increased productivity due to stiffer machine and spindle designs, more powerful motors, high pressure coolant (up to 1000 psi) that floods the cutting zone, automatic tool changers, digital workpiece and tool probing, and/or horizontally mounted spindles.

Downsides to CNC machines are higher initial cost, larger space and electrical requirements, increased maintenance cost, required programming skillset and their inherent complexity means theres a higher probably of component failure during the useful lifespan.