DEPARTMENT OF MECHANICAL ENGINEERING CAD/ CAM LAB

INTRODUCTION:

What is CAD/CAM?

CAD/CAM (computer-aided design and computer-aided manufacturing) refers to computer

software that is used to both design and manufacture products.

CAD is the use of computer technology for design and design documentation. CAD/CAM
applications are used to both design a product and program manufacturing processes, specifically, CNC
machining. CAM software uses the models and assemblies created in CAD software to generate tool
paths that drive the machines that turn the designs into physical parts. CAD/CAM software is most often
used for machining of prototypes and finished parts.

Why CAD/CAM?

Computer Aided Design and Computer Aided Manufacture is the way things are made these days.
Without this technology we wouldn’t have the range and quality of products available or, at least, they
wouldn’t be available at a price most of us can afford. Hand-building and manual techniques still very
much have their place and Design Education needs to treasure and foster these skills so that future
generations will have the “hands-on” skills to understand the man-made world and provide the next
generation of engineers, designers and technicians.

All of these professionals will be using CAD/CAM techniques or CAD/CAM products in their
work, alongside practical hands-on skill. Design and Technology education has to reflect modern practice
so it is crucial that students have the opportunity to use real CAD/CAM tools in their designing and
making.

DESIGN PROCESS AND ROLE OF CAD

1. Recognition of need
2. Definition of problem
3. Synthesis
4. Analysis and optimization
5. Evaluation
6. Presentation

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SOLID MODELING

A solid modeling system is usually an interactive computer graphics system that is intended to
create true three-dimensional components and assemblies. Recent advances in CAD software, computers,
and graphical displays have made it possible to use solid representations of components being considered
in the design process. These solid models can be employed in numerous ways.

Advantages of Solid Modeling

A realistic visual display: By producing a shaded visible surface image of the solid, solid
modeling allows a designer to see exactly what has been created.

Easy to deal with different views: Once a part has been created, we have the ability to rotate,
shade, section, or produce almost any view required by a designer.

Single associated model database: The solid modeler provides the only database suitable for all
CAD operations. Almost all information needed for part generation is contained in the solid model. The
algorithm should be able to ensure that it represents physically possible shape that is complete and
unambiguous Applications. e.g., automatic generation of a mesh for a finite element analysis.

REQUIREMENTS FOR MODELING ASSEMBLING

1. Part modeling and analysis

The part analysis includes the material type, mass and inertial properties, functional properties of
the faces, etc.

2. Hierarchical relationships

An assemble tree and assemble sequence must be given.

3. Mating conditions

There are two methods for specifying mating conditions:

1. Specify the location and orientation of each part in the assembly, together with the representation
of the part itself, by providing a 4 x 4 homogeneous transformation matrix. (i.e., transformation
from MCS to WCS).

2. Specify the spatial relationships between its individual parts as mating conditions.

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 Computer databases are now replacing paper blueprints in defining product geometry and non-
geometry for all phases of product design, analysis, and manufacturing. It becomes increasingly
important to find effective procedures for transferring data among CAD/CAE/CAM systems.

The need to exchange modeling data is directly motivated by the need to integrate and automate
the design and manufacturing process to obtain the maximum benefits from CAD/CAE/CAM systems.

Four Types of Modeling Data to be transferred:

1. Shape
2. No shape
3. Design
4. Manufacturing
1. Shape data consists of both geometrical and topological information as well as part features. Entity
attributes such as font, color, and layer as well as annotation is considered part of the entity geometrical
information. Topological information applies only to products described via solid modeling. Features
allow high-level concept communication about parts. Examples are hole, flange, web, pocket, chamfer,
etc.
2. No shape data includes graphics data such as shaded images, and model global data as measuring units of
the database and the resolution of storing the database numerical values.
3. Design data has to do with the information that designers generate from geometric models for analysis
purposes. e.g., mass property and finite element mesh data.
4. Manufacturing data consists of information such as tooling, NC tool paths, tolerance, process planning,
tool design, and bill of materials.

Commonly Used CAD Data Exchange Format:

IGES (Initial Graphics Exchange Specification)

PDES (Product Data Exchange Using STEP)

IGES is focused on CAD-to-CAD exchange where primarily shape and non shape data were to
be transferred from one system to another.

PDES is previous called Product Data Exchange Standard. It is for the exchange of complete product
descriptions which covers the four types of modeling data (i.e., shape, non shape, design and
manufacturing).

Other data exchange interfaces include: STL, Neutral, SET, ECAD, VDA, STEP, PDGS, CATIA,
Render, CGM, VRML, PATRAN, TIFF, etc.

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 EXPERIMENT-1

Aim: To draw 2D figure using sketching commands with the help of Inventor professional

LIST OF USED COMMANDS:

Line Circular Pattern

Circle Constraints ( tangent,concentric)
Trim Dimension
Tangent Circular patrons

PROCEDURE:

Step 1.Draw the reference line by using line command

Step 2.By using line command we draw a line

Step 3.Draw the concentric lines of dia= 10, 20.

Step 4.Apply the constrains as per requirements using trim command remove the unwanted part

Step 5.By using circular pattern we create the required figure

Step 6.Provide the dimensions

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 EXPERIMENT-2
Aim: Development of part drawings of given component in the form of orthographic and
isometric With the help of Inventor professional.

LIST OF USED COMMANDS:

Rectangle Trim
Line Tangent
Circle Extrude
Dimensions Fillet

PROCEDURE:
1. First we start from TV
2. Draw the rectangle with the dimensions of 100*64
3. Draw the 2 circle in side rectangle with diameter 24, and locate as per given dimensions
then finish the sketch.
4. Extrude the sketch with 12
5. Select the face as per requirement and draw the rectangle 12*64 & extrude up to 46
6. Select the face as per requirement and draw the sketch with help of given dimensions and
extrude up to 10.
7. Using fillet (R12) commend as per requirement.
8. Provide all dimensions.
9. So we get required figure

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 EXPERIMENT: 3

Aim: Development of part drawings of given component in the form of orthographic

and isometric with the help of Inventor professional.

LIST OF USED COMMANDS:

Line Tangent
Circle Rectangular Pattern
Trim
PROCEDURE:

1. Choose the reference plane Draw the circle with diameter of 210 and finish the sketch
2. Select another reference plane i.e. perpendicular to first ref plane
3. Select arc with radius of R260 and up to 90degrees.
4. Using sweep command select cross section & path then enter.
5. Choose faces and draw the sketch square with 360*360 and extrude up to 50 .
6. Using fillet command place fillet as per requirement.
7. Select standard hole command provide holes as per the dimensions.

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 EXPERIMENT: 4

Aim: To draw 3D model figure(PULLY) using sketching commands with the help of Inventor software
along with drafting

LIST OF USED COMMANDS:

Line Revilve
Trim 3d fillet
Tangent

PROCEDURE:
Draw the axis line by line command

By using line command we draw a figure as per requirement.

Provide the dimensions

Apply the constrains as per requirements using trim command remove the unwanted part

Apply revolve and use 3d fillet

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 EXPERIMENT-5
STUFFING BOX ASSEMBLY:
Aim: To draw 3D model and assembly of Stuffing Box Assembly using sketching commands with the
help of Inventor software along with drafting

LIST OF USED COMMANDS:

Line Arc
Circle 3d hole
Extrude Assembly mates
3d fillet Using mate command in assembly
Trim
PROCEDURE:
1. Draw the rectangular base plate with given dimensions.
2. Select the surface and draw circle and extrude ,provide hole with help of extrude cut.
3. Select the surface and elliptical shape as per given dimensions R75 and extrude up to 15
4. Provide standard holes as per dimensions
5. Similarly create remaining models .then go to assemble
6. Import the part one from part template assembly
7. Choose part one and place as per requirement
8. Import 2nd part and place on assemble window then go to mate option align the axis & faces
9. Import 3rd part and place on assemble window then go to mate option align the axis & faces
10. Import 4th part and place on assemble window then go to mate option align the axis & faces

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 EXPERIMENT-6
KNUCKLE JOINT:
Aim: To draw 3D model and assembly of knuckle joint using sketching commands with the help of
Inventor software along with drafting

LIST OF USED COMMANDS:

Line Trim
Circle Arc
Extrude Assembly mates
3d fillet

PROCEDURE:

1. Take the centerlines in horizontal and vertical directions

2. Draw the circles of diameter 20& 40
3. Draw line of 26mm height at 70 distance from the axis
4. Now join the outer circle with 26 line with the help of line option
5. Select fillet option and join outer circle with horizontal line
6. Delete the extra portion with delete segment option
7. Click ok
8. Apply extrude option and give thickness as 26 and ok
9. Now select the bottom face and draw polygon as per requirement
10. Extrude it with the thickness 35
11. Select the edges and apply round with 5 on four sides of polygon
12. Again select the bottom face and draw a circle of diameter 26 and extrude it with 50
13. For fork end rod also follow the same procedure but change the dimensions as shown in figure.

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Using mate command in assembly

1. Import the part from part template assembly

2. Choose fork end rod model and place as per requirement

3. Import eye end rod and place on assemble window then go to mate option align the axis & faces

4. Import collar and place on assemble window then go to mate option align the axis & faces
 EXPERIMENT – 1
CANTILEVER BEAM

AIM: To find Maximum Deflection, Shear Force, Bending Moment and draw shear force and Bending
Moment diagrams for the given problem of Cantilever Beam.
PROCEDURE:
PRE PROCESSOR
STEP: 1 TYPE OF ELEMENT:
Pre Processor > Element Type > Add/Edit /Delete >Add >beam > 2D Elastic 3
STEP: 2 DEFLINE GEOMETRIC PROPERTIES:
Pre Processor > Real constants > Add/Edit /Delete > Add
Enter:
Cross Sectional Area = 16.3e-4m2
Moment Inertia Izz =1.309e-8m2
Beam Height h= 0.225m
STEP: 3 DEFINE MATERIAL PROPERTIES:
Pre Processor > Material Properties > Material Models > Structural > Liner > Elastic >
Isotropic
Enter:
Modulus of Elasticity E= 2e +11 N/m2
Poisson’s ratio = 0.3

10,000 N

A B

2m

STEP: 4 CREATING THE BEAM:

Pro Processor > Modeling > Create > Key Points > Inactive CS

KEY POINTS COORDINATES

X Y Z

1. 0 0 0
2. 2 0 0

Pre Processor > Modeling > Create > Lines > Straight Lines.

STEP: 5 MESHING:

Pre Processor > Meshing > Mesh tool

1
 Click On smart Size check box

Adjust the Bar to Fine size of 5

Click on Mesh

Pick the Lines to mesh

Click on OK

SOLUTION:

STEP: 6 ANALYSIS TYPE:

Solution > Analysis Type > New Analysis > Static

STEP: 7 DISPLACEMENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On Key Points.

Pick the key points to apply constraints (Key Point 1)

Fix the corresponding constraints (UX, UY, and ALL DOF)

In this Select ALL DOF.

Then click on OK.

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > numbering.

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > multi Plot

Solution> Define Loads > apply > Force/Moment

Pick the Respective point (Key Point 2) where to apply the load

Then apply the required load in the respective direction.

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve > Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:
General post Proc > Plot Result > Deformed
Shape> Click on Def + under
formed Click on Ok
Gives us the Deflection Diagram …. DMX -10.2mm.

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and Shape

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 Click on the check box of display of element (Makin it on)
General Post Proc > Plot result > contour plot > Nodal solution > Stress > vonmises Stress> Deformed
Shape Only
Gives us the stress distributed diagram.
Maximum Stress = 0.172E + 12 N/mm2
Minimum Stress = 0.625E -04 N/mm2
3. SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:
General Post Proc > Element Table> Define Table> Add
Select
By sequence sum and SMISC, 2

By sequence sum and SMISC, 6

By sequence sum and SMISC, 8

By sequence sum and SMISC, 12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot Results > Line element Res >

Select SMISC 2 & SMISC 8 to obtain shear force diagram gets a shear force diagram.

BENDING MOMENT DIAGRAM:

General Post Proc > Plot Results > 1/Line Element Res >

Select SMISC 6 & SMISC 12 to obtain Bending Moment diagram.

MANUAL CALCULATIONS:

We know that for a simply supported beam the deflection is y= -Wl 3/3EI
y = 10.2mm

SHEAR FORCE:

We know that for a cantilever beam the Bending Moment at A = -Wx.

X=2m

Bending Moment = 20000Nm

RESULT:

Maximum Deflection, shear force Bending Moment values and deflection, Shear Force, Bending Moment
diagram are obtained by using ANSYS and also calculated Manually and the results obtained in both the
cases are same.

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 10,000 N

A B

2m

Deflection δ B

δ =Y= DMX

δ =10.2mm.

A B

(-)

5000 N 5000 N
Shear Force Diagram

A B

(-)

Bending Moment diagram.

20000 Nm

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 EXPERTIMENT -2

CANTILEVER BEAM CARRYING U.D.L.

AIM: To find Maximum Deflection, shear Force, Bending Moment and to draw shear Force Bending
Moment diagram to the given problem of cantilever Beam carrying UDL for the whole span.

PROCEDURE:

PRE PROCESSOR:

STEP: 1 TYPE OF ELEMENT

Pre Processor > Element Type > Add/Edit /Delete > Add > 2D Elastic 3

STEP: 2 DEFINE GEOMETRIC PROPERATIES:

Pre Processor > Real Constants > Add/Edit/Delete > Add

Enter:

Cross Sectional Area = 16.3e-4m2

Moment Inertia Izz = 1.309e-8m2

Beam Height h = 0.225m

STEP: 3 DEFINE MATERIAL PROPERTIES:

Pre Processor > Material Properties > Material Models > Structural > Linear > Elastic > Isotropic

Enter:

Modulus of Elasticity E = 2e +11 N/m2

Poisson’s Ratio = 0.3

5,000 N/m

2m

STEP: 4 CREATING THE BEAM:

Pre Processor > Molding > Create > Key Points

KEY POINTS COORDINATE

1. X Y Z
2. 0 0 0
3. 2 0 0

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Pre Processor > Modeling > Create > Lines > Straight Lines.

STEP: 5 MESHING:

Pre Processor > Meshing g > Mesh tool

Click on smart Size Check box

Adjust the Bar to Fine size of 5

Click on Mesh

Pick the Lines to mesh

Click on OK

SOLUTION:

STEP: 6 ANALYSIS TYPE:

Solution > Analysis Type > New Analysis > Static

STEP: 7 DISPLACE MENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On Key Points.

Pick the Key points to apply constraints (Key point 1)

Fix the corresponding constraints (UX, UY, and ALL DOF).

In this Select all DOF

Then click on OK.

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot >Multi Plot

Solution > Define Loads > apply > Pressure

Pink the respective span (required line – Beam) to apply the UDL load

Then apply the required load as pressure load in the respective direction on span.

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve > Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:

General Post Proc > Plot Results > Deformed Shape >

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 Click on Def + under formed

Click on OK.

Gives us the Deflection Diagram ………….. DMX – 3.8197 mm.

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check box of display of element (Making it on)

General Post Proc > Plot results > contour plot > Nodal solution > Stress > vonmises stress >
Deformed shape only.
Gives us the stress distributed diagram.
Maximum stress = ___________________N/mm2
Minimum Stress = ____________________N/mm2
3. SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:
General Post Proc > Element Table > Define Table > Add
Select
By sequence sum and SMISC, 2
By sequence sum and SMISC, 6
By sequence sum and SMISC, 8
By sequence sum and SMISC,
12

SHEAR FORCE DIAGRAM:

General Post Proc> Plot Results > Line Element Res>

Select SMISC 2 & SMISC 8 to obtain shear force diagram

Gets a shear force diagram.

BENDING MOMENT DIAGRAM:

General Post Proc > Plot Results > 1/Line Element Res >

Select SMISC 2 & SMISC 8 to obtain shear force diagram

MANUAL CALCULATIONS:

DEFLECTION:

We know that for a simply supported beam the deflection is y = WI 4/8EI

Y = 3.8197 mm

SHEAR FORCE:

We know that shear force at A = -WL*L/and at B =0

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 i.e. at A -10000N

BENDINGMOMENT:

We know that bending moment is maximum at A and it is –Wl2/2 and at B it is Zero.

Bending Moment at A= 10000 Nm

RESULT:

Maximum deflection, shear Force, Bending Moment values and Deflection, Shear Force,
Bending Moment diagrams are obtained by using ANSYS and also calculated manually and the results
obtained in both the cases are same.

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 EXPERMENT -3
MODAL ANALYSIS

AIM: To do Modal Analysis for a given Cantilever Beam.

PROCEDURE:

PRE PROCESSOR:

STEP: 1 TYPE OF ELEMENT:

Pre Processor > Element Type > Add/Edit/Delete > Add > 2D Elastic 3
STEP: 2 DEFINE GEOMETRIC PROPERTIES:
Pre Processor > Real Constants > Add/Edit/Delete >Add
Enter:
Cross sectional Area = 0.01 X 0.01m2
Moment Inertia Izz = 8.33e-10m2
Beam Height h= 0.01m
STEP: 3 DEFINE MATEIRAL PROPERTIES:
Pre Processor > Material Properties > Material Models > Structural > Linear > Elastic > Isotropic
Enter:
Modulus of Elasticity E = 206800e+ 6 N/m2
Poisson’s Ratio = 0.3
Pre Processor > Material Properties > Material Models > Structural > Liner > Elastic
> Density.
Enter:
Density =
w

1m

STEP: 4 CREATING THE BEAM:

Pre Processor > Modeling > Create > Key Points

KEY POINTS COORDINATE

X Y Z

1. 0 0 0
2. 1 0 0

Pre Processor > Modeling > Create Lines > Straight Lines.

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STEP: 5 MESHING:

Pre Processor > Meshing > Mesh tool

Click on smart size checkbox

Adjust the Bar to Fine size of 5
Click on Mesh
Pick the Lines to mesh
Click on OK.
SOLUTION:
STEP: 6 SOLVING THE SOLUTION:
Define analysis type:
Solution > New Analysis > Modal
Set options for analysis type:
Select: Solution > Analysis Options..
A window will appears
Select the subspace method and enter 3 in the No. of modes to extract check the
box beside Expand mode shapes and enter 3 in the No of
Modes to expand
Click on OK
STEP: 7 DISPLACEMENT CONSTRAINTS:
Solution > Define Loads > Apply > structural > Displacement > on key Points.
Pick the key points to apply constraints (Key Point1)
Fix the corresponding constraints (UX, UY, All DOF)
In this Select All DOF.
Then click on OK.
STEP: 8 SOLVE THE SYSTEM:
Solution > Solve > current LS
Get Window as solution is done.
Save the Program.

STEP: 10
POST PROCESSING: VIEWING THE RESULTS:

1. Verify extracted modes against theoretical predictions

Select: General Post Proc > List Results > Results Summary….
A window will appear

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 MODE FREQUENCY Hz
1. 8.302
2. 51.94
3. 145.68
2. VIEW MODE SHAPES:
Select: General Post proc > (Read Results) First Set
This selects the results for the first mode shape
Select General Post Proc > Plot Result > Deformed shape.
Select ‘Def + un def edge’

The first mode shape will now appear in the graphics window
To view the next mode shape, select general Post Proc > (Read Results) Next
Set: As above choose General Post Proc > Plot Result > Deformed shape.
Select ‘Def + End of edge’
The other mode also viewed as similarly.
3. ANIMATE MODE SHAPES.
Select Utility Menu (Menu at the top) > Plot Ctrls > Animate > Mode shape A window will appear.
Keep the default setting and click ‘OK’

RESULT:
Modal analysis for the given Cantilever Beam is done and the Frequencies are observed for the
extracted Mode shapes and also the animated shapes of the extracted mode shapes are seen.
MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and shape

Click on the check box of display of element (Making it on)

General Post Proc > Plot result > contour Plot > Nodal solution > Stress> Vonmises stress > Deformed
shape only.

Gives us the stress distributed diagram.

Maximum Stress = ____________________ N/mm2

Minimum Stress = _____________________N/mm2

SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:

General Post Proc > Element Table > Define Table > Add

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 SELECT:

By sequence sum and SMISC, 2

By sequence sum and SMISC, 6

By sequence sum and SMISC, 8

By sequence sum and SMISC, 12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot Results > l/Line Element Res >

Select SMISC 6 & SMISC 12 to obtain Bending Moment diagram.

MANUAL CALCULATIONS:

DEFLECTION:

We know that for a simply supported beam the deflection is y = Wl3/384EI

Y=0.073 mm

SHEAR FORCE:

Shear force at A = -W*L/2 = -5000N;

Shear force at B = -W*L/2 = +5000N

BENDINGMOMENT:

Bending Moment at A = Bending Moment at B = -WL/12 = 833.33N-m

RESULT:

Maximum Deflection, shear Force, Bending Moment values and Deflection, Shear Force, Bending
Moment diagrams are obtained by using ANSYS and also calculated Manually and the results obtained
in both the cases are same.

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 EXPERIMENT – 4
SIMPLY SUPPORTED BEAM

AIM: To find Maximum Deflection, shear Force, Bending Moment and to draw shear Force and Bending
Moment diagrams of the given problem of simply supported Beam.

PORCEDURE:
STEP: 1TYPE OF ELEMENT:
Pre Processor > Element Type > add/ Edit/ Delete > Add > 2D Elastic 3

STEP: 2 DEFINE GEOMETRIC PROPERTIES:

Pre Processor > Real constants > Add /Edit/Delete > Add
Enter: Cross sectional Area = 0.000078539m2
Moment Inertia Izz = 1.309e-8m2
Beam Height h = 0.225m
STEP 3: DEFINE MATERIAL PROPERTIES:
Pre Processor > Material Properties > Material Models > Structural > Linear > Elastic > Isotropic

Enter:

Modulus of Elasticity E= 2e +11 N/m2

Poisson’s Ratio =0.3

10,000 N

A C B

2m

STEP: 4 CREATING THE BEAM:

Pres Processor > Modeling > Create > Key Points

KEY POINTS COORDINATES

X Y Z
1. 0 0 0
2. 1 0 0
3. 2 0 0

Pre Processor > Modeling > Create > Lines > Straight Lines

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STEP:5 MESHING:

Pre Processor > Meshing > Mesh tool

Click On smart size checkbox

Adjust the Bar to Fine size of 5

Click on Mesh

Pick the Lines to mesh

Click on OK

SOLUTION:

STEP: 6 ANALYSIS TYPE:

Solution > Analysis Type > New Analysis > Static

STEP: 7 DISPLACEMENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On Key Points.

Pick the key points to apply constraints (Key Points 1&3)

Fix the corresponding constraints (UX, UY, and ALL DOF).

In this Select UY

Then Click on OK.

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > Numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > multi Plot

Solution > Define Loads > Apply > Force/Moment

Pick the Respective Point (Key Point 2) Where to apply the

load Then apply the required load in the respective direction.

STEP: 10 SOLVING THE SOLUTION:

Solution > Solve > Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:
General Post Proc > Plot Results > Deformed Shape
> Click on Def + Underformed
Click on OK
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 Give us the Deflection Diagram ………DMX -0.6366mm.

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check box of display of element (Makin it
on) General Post Proc > Plot result > contour Plot > Nodal solution >
Stress > Vonmises stress > Deformed shape only
Gives us the stress distributed diagram.
Maximum Stress =0.430 E+ 11 N/mm 2
Minimum Stress = 0.156 E-04 N/ mm2
3. SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:
General Post Proc > Element Table > Define Table > Add
Select
By sequence sum and SMISC, 2
By sequence sum and SMISC, 6
By sequence sum and SMISC, 8
By sequence sum and SMISC,
12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot Results > Line Element Res >

Select

SMISC 2 & SMISC 8 to obtain shear force diagram

Gets a shear force diagram

BENDING MOMENT DIAGRAM:

General Post Proc > Plot Results > Line Element Res >

Select

SMISC6 & SMISC 12 TO obtain Bending Moment diagram.

MANUAL CALCULATIONS:

DEFLECTION:

We Know that for a simply supported beam the deflection is y = -Wl 3/48EI

Y = 0.6366 mm

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SHEAR FORCE:

We know that shear force at A = -W/2 and at B= W/2

I.e. at A -500N and at B = 5000N

BENDING MOMENT:

We know that Bending moment is maximum at mid portion of the span and it is W1/4 and at A and B it is
Zero.

Bending Moment at Mid Portion of the span = 5000 Nm

RESULT:

Maximum Deflection, Shear Force, Bending Moment values and Deflection, Shear Force, Bending Moment
diagrams are obtained by using ANSYS and also calculated Manually and the results obtained in both the
cases are same.

16
 EXPERIMENT – 5

SIMPLY SUPPORTED BEAM CARRYING U.D.L

AIM: To find Maximum Deflection, Shear Force, Bending Moment and to draw shear Force and Bending
Moment diagrams of the given problem of simply supported Beam carrying UDL for the whole span.

PROCEDURE:

STEP: 1 TYPE OF ELEMENT:

Pre processor > Element Type > Add/Edit/Delete > Add > 2D Elastic 3

STEP: 2 DEFINE GEOMETRIC PROPERATIES:

Pre Processor > Real constant > Add /Edit/ Delete > Add

Enter: Cross sectional Area = 16.3e-4m2

Moment Inertial Izz =1.309e-8m2

Beam Height h= 0.225m

STEP: 3 DEFINE MATERIAL PROPERTIES:

Pre Processor > Material Properties > Material Models > Structural > Liner > Elastic > Isotropic

Enter: Modulus of Elasticity E= 2e+11 N/m3

Poisson’s Ratio = 0.3

5,000 N/m

2m

STEP: 4 CREATING THE BEAM:

Pre Processor > Modeling > Create > Key Points

Key Points Coordinate

1. X Y Z
2. 0 0 0
3. 2 0 0

Pre Processor > Modeling > Create > Lines > Straight Lines.

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STEP: 5 MESHING:

Pre Processor > Meshing > Mesh tool

Click On smart Size Check box

Adjust the Bar to Fine size of 5

Click on Mesh

Pick the Lines to mesh

Click on OK.

SOLUTION:

STEP 6: ANALYSIS TYPE:

Solution > Analysis Type > New analysis > Static

STEP: 7 DISPLACE MENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On Key Points.

Pick the key points to apply constraints (Key points 1&3)

Fix the corresponding constraints (UX, UY, and ALL DOF)

In this select UY

Then click on OK

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > Numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > Multi Plot

Solution > Define Loads > apply > Pressure

Pick the Respective span (required line – Beam) to apply the UDL load then apply the
required load as Pressure load in the respective direction on span.

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve >Current LS

Get a Window as solutions are done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DELECTION:
General Post Proc > Plot Results > Deformed Shape>
Click on Def + Unperformed
18
 Click on OK
Gives us the Deflection Diagram ………. DMX – 0.3 mm.

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check box of display of element (Making it on)

General Post Proc > Plot results > Contour plot > Nodal solution > Stress > Vonmises stress > Deformed
shape only.

Gives us the stress distributed diagram.

Maximum Stress = N/mm2

Minimum Stress = N/mm2

3. SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:

General Post Proc > Element Table > Define Table > Add
Select:
By Sequence sum and SMISC, 2
By Sequence sum and SMISC, 6
By Sequence sum and SMISC, 8
By Sequence sum and SMISC, 12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot Results > Line Element Res >

Select SMISC 2 & SMISC 8 to obtain shear force diagram

Gets a shear force diagram

BENDIN MOMENT DIAGRAM:

General Post Proc > Plot Results > 1/Line Element Res

Select SMIC 6 & SMISC 12 to obtain Bending Moment diagram.

MANUAL CALCULATIONS:

DEFLECTION:

We know that for a simply supported beam the deflection is Y= 5 WI 4/384EI

Y= 0.3 mm

19
SHEAR FORCE

We know that shear force at A = -WL/2 and at B = WL/2>

i.e at A-5000N and at B = 5000N

BENDINGMOMENT:

We know that bending moment is maximum at mid portion of the span and it is WI 2/8 and at A and B it is
Zero.

Bending Moment at Mid portion of the span = 2500Nm

RESULT:

Maximum Deflection, Shear Force, Bending Moment values and Deflection, Shear Force, Bending
Moment diagrams are obtained by using ANSYS and also calculated Manually and the result obtained in
both the cases are same.

20
 EXPERIMENT – 6
FIXED BEAM
AIM: To find Maximum Deflection, Shear Force, Bending Moment and to draw Shear Force and
Bending Moment diagrams of the given problems of Fixed Beam carrying load at the mid span.
PROCEDURE:
PRE PROCESSOR:
STEP: 1 TYPE OF ELEMENT:
Pre Processor > Element Type > Add/Edit/Delete > Add > 2D Elastic 3
STEP: 2 DEFINE GEOMENTRIC PROPERTIES:
Pre Processor > Real constants > Add/ Edit/Delete > Add
Enter:
Cross sectional Area = 16.3e-4m2
Moment Inertia Izz = 1.309e-8m2
Beam Height h = 0.225 m
STEP: 3 DEFINE MATERIAL PROPERTIES:
Pre Processor > Material Properties > Material Models > Structural > Linear > Elastic >
Isotropic
Enter:
Modulus of Elasticity E= 2e +11 N/m2

10000 N

2m

STEP: 4 CREATING THE BEAM:

Pre processor > Modeling > create > Key Points

KEY POINTS COORDINATES

X Y Z

1. 0 0 0
2. 1 0 0
3. 2 0 0

Pre Processor > Modeling > Create > Lines > Straight lines.

21
STEP: 5 MESHING:

Pre Processor > Meshing > Mesh tool

Click on smart Size check box Adjust the Bar to fine size of 5
Click on Mesh

Pick the Lines to mesh

Click on Ok.

SOLUTION:

STEP: 6 ANALYSIS TYPE:

Solution > Analysis Type> New Analysis > Static

STEP: 7 DISPLACEMENT CONSTRAINTS:

Solution > Define Loads > Apply >Structural > Displacement > on key Points

Pick the Key points to apply constraints (Key Points 1& 3)

Fix the corresponding constraints (UX, UY, and ALL DOF).

In this select all DOF

Then click on OK.

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > Numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > Multi Plot

Solution > Define Loads > apply > Force/Moment

Pick the Respective Point (Key Point2) where to apply the

load Then apply the required load in the respective direction

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION
General Post Proc > Plot Results > Deformed Shape
> Click on Def + Underformed
Click on OK.
Gives us the deflection Diagram ………DMX -0.1591mm

22
2. MAXIMUM STRESS AND STRESS DISTRUBUTION:
Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check box of display of element (Making it
on) General Post Proc > Plot result > contour Plot > Nodal solution > Stress >
Vonmises stress > deformed shape only
Gives us the stress distributed diagram
Maximum Stress = ___________________N/mm2
Minimum Stress = ___________________N/mm2
3. SHEAR FORCE DIAGRAM &BENDING MOMENT DIAGRAM:
General Post Proc > Element table > Define table > Add
Select
By sequence sum and SMISC, 2
By sequence sum and SMISC, 6
By sequence sum and SMISC, 8
By sequence sum and SMISC,
12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot Result > Line element Res >

Select SMISC 2 & SMISC 8 to obtain Shear force diagram

Gets a shear force diagram

BENDING MOMENT DIAGRAM:

General Post Proc > Plot Results > Line Element Res >

Select SMISC 6 & SMISC 12 to obtain Bending Moment diagram.

MANUAL CALCULATIONS:

DEFLECTION:

We know that for a simply supported beam the deflection is y = -Wl 3/192EI

Y = 0.1591 mm

SHEAR FORCE

We know that shear force at A = -W/2 and at B =W/2

i.e. at A -5000N and at B = 5000N

23
BENDING MOMENT:

We know that Bending moment is maximum at mid portion of the span and it is W1/12 and at A and B it is
Zero.

Bending Moment at Mid portion of the span

RESULT:

Maximum Deflection, Shear Force, Bending Moment values and Deflection, Shear Force, Bending Moment
Diagrams are obtained by using ANSYS and also calculated manually and the results obtained in both the
cases are same.

24
 EXPERIMENT -5

FIXED BEAM CARRYING U.D.L

AIM: To find Maximum Deflection, Shear Force, Bending Moment and to draw shear Force and Bending
Moment diagrams of the given problem of Fixed Beam carrying UDL for the whole span.

PROCEDURE:

PRE PROCESSOR:

STEP: 1 TYPE OF ELEMENT:

Pre Processor > Element type > Add/Edit/Delete > Add >2D Elastic 3

STEP: 2 DEFINE GEOMENTRIC PROPERTIES:

Pre Processor > Real constants >Add/Edit/Delete > Add

Enter: Cross sectional Area = 16.3e-4m2

Moment Inertia Izz =1.309e-8m2

Beam Height h= 0.225m

STEP: 3 DEFINE MATERIAL PROPERTIES:

Pre processor > Material Properties > Material Models > Structural >Linear > Elastic >
Isotropic Enter:

Modulus of Elasticity E= 2e+11 N/m2

Poisson’s Ratio = 0.3

5,000 N/m

2m

STEP: 4 CREATING THE BEAM:

Pre Processor > Modeling > Create > Key Points

KEY POINTS COORDINATE

1. X Y Z
2. 0 0 0
3. 2 0 0

25
Pre Processor > modeling > Create > Lines > Straight Lines.

STEP: 5 MESHING:

Pre Processor > Meshing > Mesh tool

Click On smart Size checkbox

Adjust the Bar to Fine size of 5

Click on Mesh

Pick the Lines to mesh

Click on OK

SOLUTION:

STEP: 6 ANALYSIS TYPE:

Solution > Analysis type > New Analysis > Static

STEP: 7 DISPLACE MENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On Key points.

Pick the key points to apply constraints (key points 1&2)

Fix the corresponding constraints (UX, UY, All and DOF).

In this select all DOF

Then click on OK.

STEP: 8 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > Numbering

Make Key point numbering on. Make line numbering on.

Utility Bar Menu > Plot > Multi Plot

Solution > Define Loads > apply > Pressure

Pick the Respective span (required line – Beam) to apply to UDL load

Then apply the required load as Pressure load in the respective direction on span.

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve > Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 SOLVING THE SOLUTION:

1. DEFLECTION:
General Post Proc > Plot Results > Deformed
Shape> Click on Def + Unreformed
26
 Click on OK
Gives us the Deflection Diagram……..DMX – 0.073mm

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check Box of display of element (Making it on)

General Post Proc > Plot results > contour > Nodal solution > Stress >

Vonmises stress > Deformed shape only.

Gives us the stress distributed diagram.

Maximum Stress = ____________________N/mm2

Minimum Stress=_______________________N/mm2

3. SHEAR FORCE DIAGRAM & BENDING MOMENT DIAGRAM:

General Post Proc > Element Table > Define Table > Add
Select
By sequence sum and SMISC, 2
By sequence sum and SMISC, 6
By sequence sum and SMISC, 8
By sequence sum and SMISC,
12

SHEAR FORCE DIAGRAM:

General Post Proc > Plot result > Line Element Res>

Select SMISC 2 & SMISC 8 to obtain Shear force diagram

Gets a shear force diagram.

BENDING MOMENT DIAGRAM:

General Post Proc > Plot Result > 1/Line Element Res >

Select SMISC 6 & SMISC 12 to obtain Bending Moment diagram.

MANUAL CALCULATIONS:

DEFLECTION:

We know that for a simply supported beam the deflection is y = Wl 3/384EI

Y=0.073mm

27
SHEAR FORCE

Shear Force at A = -W*L/2 = -5000N;

Shear Force at B= +W* L/2 = + 5000N

BENDING MOMENT:

Bending Moment at A= Bending Moment at = -WL/12 = 833.33N-m

RESULT:

Maximum Deflection, Shear Force, Bending Moment values and Deflection, Shear Force, Bending
Moment diagrams are obtained by using ANSYS and also calculated Manually and the results obtained in
both the cases are same.

28
 EXPERIMENT -6

TRUSSES

AIM: To determine the nodal deflection reaction force and stress of the indeterminate truss system when
subjected to a load of 2000N.

Given data: E= 2e5 A= 3250mm2 Poissions ration=0.3

Step 1: From the main menu select preferences

Select structural and press ok

Step2: From the main menu select pre- Processor

Element type- Add/ edit /delete- add- link-2d spar8- apply-close

Real constants – add g properties –area=3250

Material properties – material models- structural- linear- elastic- isotropic

Ex=2e5 PRXY=0.3

Step3: form the main menu select pre- processor –Modeling

Create the key points in the workspace

Pre processor – modeling – create – nodes – in active cs

x Y Z
0 0 0
5 0 0
10 0 0
15 0 0
2.5 2.5 0
7.5 2.5 0
12.5 2.5 0
Click apply to all the points and for the lost point click ok

Crate lines using the elements

Preprocessor -modeling- create elements - auto numbered -through nodes –select node 1&2 – apply-2&3
–apply-3&4 – apply -1& 5 apply – 5&2- apply-2&6- apply-6&3 – apply-3&7-apply -7&4-apply-
5&6-apply-6&7 – apply-ok- close

Solution phase: Assigning loads and solving

Step4: from the ANSYS main menu open solution

Solution – Snalysis type-new analysis_ Static

Step5: Defining loads at the key points

Solution –define loads-apply-structural-displacement-on nodes –select nodes 1&4-ok-select all DOF-

ok

Left and-all DOF arrested

Solution-Define loads- apply- Structural- force/moment- on nodes

Select node 2&3 – ok FY direction-give force value as 2000n –ok - close

29
 Step6: solving the system

Solution-solve-current LS

Post processing: Viewing the results

1. Deformation
From the main menu select general post processing
General post processing- plot results-deforms shape
Select ‘Def + undef edge’ and click ‘ok’ to view both the deformed and the undeformed object.

Nodal solution
From the utility menu select plot
Plot-results- contour plot- Nodal solution- DOF solution-Y component of displacement-ok

Result:

DMX=

SMN=

SMX=

30
 EXPERIMENT – 7
PLATE WITH SECTOR HOLE

AIM: To find Maximum Deflection and Stresses of a Plate having a sector hole.

2m

1m

1000N

R -0.5m

PROCEDURE:

PRE PROCESSOR:

STEP: 1 TYPE OF ELEMENT:

Pre Processor > Element Type > Add/Edit/Delete > Add > Solid > Quad 4 node 42 > Options – Plane stress

STEP: 2 DEFINE MATERIAL PROPERTIES:

Pre Processor > Material Properties > Material Models > Structural > Liner > Elastic>

Isotropic Enter:

Modulus of Elasticity E= 2e +5 N/m2

Poisson’s Ratio = 0.3

STEP: 3 CREATING THE PLANE:

Pre Processor> Modeling > Create > Key Points

Key Points Coordinates

X Y

1. 0 0
2. 2 0
3. 2 1
4. 0 1

31
Pre Processor > Create > Areas > Arbitrary > through KP’s

Pre Processor > Create > areas > circle > solid circle

X 0

Y 0

Radius0.5

Pre Processor > Operate > Booleans > Subtract > Areas

Select the Area from which to be subtracted

Click OK.

Select the Area to be subtracted

Click On OK

STEP: 4 MESHING:

Pre Processor > Meshing > Size Ctrl > Areas > Picked Areas
Element edge length = 0.5

Pre Processor > Meshing > Mesh < Areas > Free

SOLUTION:

STEP: 5 DISPLACE MENT CONSTRAINTS:

Utility Bar Menu > Plot Ctrls > numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > multi Plot

Solution > Define Loads > Apply > structural > Displacement > on lines.

Pick required line & fix in ALL DOF

STEP: 6 APPLY LOADS:

Solution > Define Loads > apply > Structural > Pressure > on

lines Pick the required lines & Apply Pressure – 1000 N STEP:9

SOLVING THE SOLUTION:

Solution > Solve > Current LS

32
Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:
General Post Proc > Plot Results > Deformed Shape
> Click on Def + Unreformed
Click on OK

Gives us the Deflection Diagram ……… DMX = …………mm.

2. MAXIMUM STRESS AND STRESS DISTRIBUTION:

Utility menu > Plot Ctrls > Style > Size and Shape

Click on the check box of display of element (Marking it on)

General Post Proc > Plot results > contour plot > Nodal solution > Stress >
Vonmises stress > deformed shape only
Give s us the stress distributed diagram.
Maximum stress = _____________________ N/mm 2
Minimum Stress = ______________________N/mm2

RESULT:
Maximum Deflection, Maximum stress and Minimum Stress are obtained for the given problem
by using ANSYS.

33
 EXPERIMENT – 8
RECTANGULAR PLATE
AIM: To find Maximum Deflection and Stress for the given problem of a Plate.
PROCEDURE:
PREPROCESSOR:
STEP: 1 TYPE OF ELEMENT:
Pre Processor > Element Type > Add/Edit/Delete > Add > Solid Quad 4 node 42 >
Options – Plane stress
STEP 2: DEFINE MATERIAL PROPERTIES:
Pre Processor > Material Properties > Material Models > Structural >Linear > Elastic >
Isotropic Enter:

Modulus of Elasticity E = 2e +5 N/m2

Poisson’s Ratio = 0.3 1000 N

(-2, 1) (2, 1)

(-2,-1) (2,-1)

STEP: 4 CREATING THE PLACE:

Pre Processor> Modeling > Create> Key points

KEY POINTS COORDINATES

X Y

1. -2 -1
2. 2 -1
3. 2 1
4. -2 1

Pre Processor > Create > Areas > Arbitrary > through KP’s

STEP: 4 MESHING:

Pre Processor > Meshing > Size cntrl > Manual Site > Area > Picked Areas

Element edge length= 0.5

34
Pre processor > Meshing > Mesh > Areas > Free

SOLUTION:

STEP: 5 DISPLACEMENT CONSTRAINTS:

Solution > Define Loads > Apply > Structural > Displacement > On lines.

Pick lines L1 & fix in all DOF

STEP: 6 APPLY LOADS:

Utility Bar Menu > Plot Ctrls > Numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot > Multi Plot

Solution > Define Loads > apply > Structural > Pressure> on line

Pick Line L3 & Apply Pressure 1000 N

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve > Current LS

Get a Window as solution is done.

Save the Program.

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:
General Post Proc > Plot Result > Deformed Shape
> Click on Def + under formed
Click on OK.
Gives us the Deflection Diagram ….DMX =…………………mm.
2. MAXIMUM STRESS AND STRESS DISTRUBUTION:
Utility Menu > Plot Ctrls > Style > Size and Shape
Click on the check box of display of element (Making it on)
General Post Proc > Plot result > contour Plot > Nodal solution > Stress >
Vonmises stress > deformed shape only
Gives us the stress distributed diagram.
Maximum Stress= ………………………..N/mm2
Minimum Stress=………………………….N/mm2
RESULT:
Maximum Deflection, Maximum stress and Minimum Stress are obtained by using ANSYS.

35
 EXPERIMENT -9

TRAPEZOID PLATE

AIM: To find Maximum Deflection and Stress of a Trapezoid plate

2m 1m

2m

4m

PROCEDURE:

PRE PROCESSOR:

STEP: 1 TYPE OF ELEMENT:

Pre Processor > Element Type > Add/Edit/Delete > Add > Solid > Quad 4 node 42 > Options – Plane Stress

STEP: 2 DEFINE MATERIAL PROPERTIES:

Pre processor > Material Properties > Material Models > Structural > Liner > Elastic > Isotropic

Enter: Modulus of Elasticity E= 2e+5 N/m2

Poisson’s Ratio =0.3

STEP: 3 CREATING THE PLANE:

Pre Processor > Modeling g > Create > Key Points

KEY POINTS COORDINATE

X Y

1. 0 0
2. 4 0
3. 3 2
4. 1 2

36
STEP: 4 MESHING:

Pre Processor > Meshing > size Ctrl > Areas > Picked Areas

Element edge length = 0.5

Pre Processor > Meshing > Mesh > Areas > Free

SOLUTION:

STEP: 5 DISPLACEMENT CONSTRAINTS:

Utility Bar Menu > Plot Ctrls > Numbering

Make key point numbering on.

Make line numbering on.

Utility Bar Menu > Plot Multi Plot

Solution > Define Loads > Apply > Structural > Displacement > On Lines.

Pick Require lines & fix in ALL DOF

STEP: 6 APPLY LOADS:

Solution > Define Loads > apply > Structural > Pressure > on

Lines Pick the required line & apply Pressure -1000N

STEP: 9 SOLVING THE SOLUTION:

Solution > Solve > current LS

Get Window as solution is done.

Save the Program

STEP: 10 VIEWING THE RESULTS:

1. DEFLECTION:
General Post Proc > Plot Result > Deformed Shape >
Click on Def + Underformed
Click on OK.
Gives us the Deflection Diagram ……….. DMX = ……………..mm.

37
2. MAXIMUM STRESS AND STRESS DISTRIBUTION:
Utility Menu > Plot Ctrls > Style > Size and shape
Click on the check box of display of element (Making it on)
General Post Proc > Plot result > Contour Plot > Nodal solution > Stress >
Vonmises stress > Deformed shape only
Gives us the stress distributed diagram.
Maximum Stress = _______________ N/mm 2
Minimum Stress = ________________N/mm2

RESULT:

Maximum Deflection, Maximum stress and Minimum stress are obtained for the given problem by using
ANSYS.

38
 COMPUTER-AIDED MANUFACTURING

Computer-aided manufacturing (CAM) is the use of computer-based software tools that assist
engineers and machinists in manufacturing or prototyping product components. Its primary purpose is to
create a faster production process and components with more precise dimensions and material
consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste),
while simultaneously reducing energy consumption. CAM is a programming tool that makes it possible to
manufacture physical models using computer-aided design (CAD) programs. CAM creates real life
versions of components designed within a software package

CNC Technology
Numerical Control (NC) is a software-based machine tool control technique developed at Massachusetts
Institute of Technology (MIT) in early 1960s. It has now evolved into a mature technology known as
Computer Numerical Control (CNC). Although major applications of CNC even today continue to be in
machining, it finds applications in other processes such as sheet metal working, non-traditional machining
and inspection. Robots and Rapid Prototyping machines are also CNC controlled. In fact, any process that
can be visualized as a sequence of motions and switching functions can be controlled by CNC. These
motions and switching functions are input in the form of alphanumeric instructions. CNC is the basis of
flexible automation which helps industries cut down time-to-market and enables launch of even low
volume products. Unlimited muscle power, unmanned operation, independent axes coordinated through
software, simplified generic tooling even for the most complex jobs and accurate construction are some of
the salient features of CNC.
CNC Machining
Automats and Special Purpose Machines (SPMs) require special cams/ templates and clutch settings for
each part. Manufacture of these cams/ templates is costly and slow. Furthermore, changing over from one
part to the other on these machines also consumes considerable time. The high cost and long time of these
hard automated machines to produce parts can be justified only in mass production. With the advent of
fast, rigid and accurate CNC machines and sophisticated CAM packages, generation of NC programs and
change over from one product to the other are easy and fast as it does not require any mechanical change.
These in conjunction with advanced cutting tools have made High Speed Cutting (HSC) of hard materials
a reality. Therefore, CNC machining has become a standard means to produce dies and molds; tool
makers today require EDM only for producing inaccessible regions, sharp corners, tiny features and
desired surface quality. Intricate aerospace parts are realized through 5 axis CNC machining. Internet
technology in a global village enables designing in one place, NC programming and verification in
another place and actual machining in yet another place.

Advantages of CNC

Flexibility

Accuracy

Speed

Simplified fixturing and generic cutting tools

Storage of machining skill in NC programs

Less skilled operators will do

Less fatigue to the operators
G-codes

1
G-Code, or preparatory code or function, are functions in the Numerical control programming language.
The G-codes are the codes that position the tool and do the actual work, as opposed to M-codes, that
manages the machine; T for tool-related codes. S and F are tool-Speed and tool-Feed, and finally D-codes
for tool compensation. The programming language of Numerical Control (NC) is sometimes informally
called Gcode. But in actuality, G-codes are only a part of the NC-programming language that controls NC
and CNC machine tools.
A basic list of `G' operation codes is given below. This direct motion of the tool.
1. G00 - Rapid move (not cutting)
2. G01 - Linear move
3. G02 - Clockwise circular motion
4. G03 - Counterclockwise circular motion
5. G04 - Dwell
6. G05 - Pause (for operator intervention)
7. G08 - Acceleration
8. G09 - Deceleration
9. G17 - x-y plane for circular interpolation
10. G18 - z-x plane for circular interpolation
11. G19 - y-z plane for circular interpolation
12. G20 - turning cycle or inch data specification
13. G21 - thread cutting cycle or metric data specification
14. G24 - face turning cycle
15. G25 - wait for input #1 to go low (Prolight Mill)
16. G26 - wait for input #1 to go high (Prolight Mill)
17. G28 - return to reference point
18. G29 - return from reference point
19. G31 - Stop on input (INROB1 is high) (Prolight Mill)
20. G33-35 - thread cutting functions (Emco Lathe)
21. G35 - wait for input #2 to go low (Prolight Mill)
22. G36 - wait for input #2 to go high (Prolight Mill)
23. G40 - cutter compensation cancel
24. G41 - cutter compensation to the left
25. G42 - cutter compensation to the right
26. G43 - tool length compensation, positive
27. G44 - tool length compensation, negative
28. G50 - Preset position
29. G70 - set inch based units or finishing cycle
30. G71 - set metric units or stock removal
31. G72 - indicate finishing cycle (EMCO Lathe)
32. G72 - 3D circular interpolation clockwise (Prolight Mill)
33. G73 - turning cycle contour (EMCO Lathe)
34. G73 - 3D circular interpolation counter clockwise (Prolight Mill)
35. G74 - facing cycle contour (Emco Lathe)
36. G74.1 - disable 360 deg arcs (Prolight Mill)
37. G75 - pattern repeating (Emco Lathe)
38. G75.1 - enable 360 degree arcs (Prolight Mill)
39. G76 - deep hole drilling, cut cycle in z-axis

2
40. G77 - cut-in cycle in x-axis
41. G78 - multiple threading cycle
42. G80 - fixed cycle cancel
43. G81-89 - fixed cycles specified by machine tool manufacturers
44. G81 - drilling cycle (Prolight Mill)

45. G82 - straight drilling cycle with dwell (Prolight Mill)

46. G83 - drilling cycle (EMCO Lathe)
47. G83 - peck drilling cycle (Prolight Mill)
48. G84 - taping cycle (EMCO Lathe)
49. G85 - reaming cycle (EMCO Lathe)
50. G85 - boring cycle (Prolight mill)
51. G86 - boring with spindle off and dwell cycle (Prolight Mill)
52. G89 - boring cycle with dwell (Prolight Mill)
53. G90 - absolute dimension program
54. G91 - incremental dimensions
55. G92 - Spindle speed limit
56. G93 - Coordinate system setting
57. G94 - Feed rate in ipm (EMCO Lathe)
58. G95 - Feed rate in ipr (EMCO Lathe)
59. G96 - Surface cutting speed (EMCO Lathe)
60. G97 - Rotational speed rpm (EMCO Lathe)
61. G98 - withdraw the tool to the starting point or feed per minute
62. G99 - withdraw the tool to a safe plane or feed per revolution
63. G101 - Spline interpolation (Prolight Mill)

M-Codes
M-Codes control machine functions and these include,
1. M00 - program stop
2. M01 - optional stop using stop button
3. M02 - end of program
4. M03 - spindle on CW
5. M04 - spindle on CCW
6. M05 - spindle off
7. M06 - tool change
8. M07 - flood with coolant
9. M08 - mist with coolant
10. M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill)
11. M09 - coolant off
12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)
13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill)
14. M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change
15. M17 - subroutine end
16. M20 - tailstock back (EMCO Lathe)
17. M20 - Chain to next program (Prolight Mill)
18. M21 - tailstock forward (EMCO Lathe)

3
19. M22 - Write current position to data file (Prolight Mill)
20. M25 - open chuck (EMCO Lathe)
21. M25 - set output #1 off (Prolight Mill)
22. M26 - close chuck (EMCO Lathe)

23. M26 - set output #1 on (Prolight Mill)

24. M30 - end of tape (rewind)
25. M35 - set output #2 off (Prolight Mill)
26. M36 - set output #2 on (Prolight Mill)
27. M38 - put stepper motors on low power standby (Prolight Mill)
28. M47 - restart a program continuously, or a fixed number of
times (Prolight Mill)
29. M71 - puff blowing on (EMCO Lathe)
30. M72 - puff blowing off (EMCO Lathe)
31. M96 - compensate for rounded external curves
32. M97 - compensate for sharp external curves
33. M98 - subprogram call
34. M99 - return from subprogram, jump instruction
35. M101 - move x-axis home (Prolight Mill)
36. M102 - move y-axis home (Prolight Mill)
37. M103 - move z-axis home (Prolight Mill)

CNC PROGRAMMING
· The coordinates are almost exclusively Cartesian and the origin is on the work piece. · For a lathe, the in
feed/radial axis is the x-axis, the carriage/length axis is the z-axis. There is no need for a y-axis because
the tool moves in a plane through the rotational center of the work. Coordinates on the work piece shown
below are relative to the work.
CNC lathes are rapidly replacing the older production lathes (multi spindle, etc) due to their ease of
setting and operation. They are designed to use modern carbide tooling and fully utilize modern
processes. The part may be designed and the tool paths programmed by the CAD/CAM process, and the
resulting file uploaded to the machine, and once set and trailed the machine will continue to turn out parts
under the occasional supervision of an operator.The machine is controlled electronically via a computer
menu style interface; the program may be modified and displayed at the machine, along with a simulated
view of the process. The setter/operator needs a high level of skill to perform the process, however the
knowledge base is broader compared to the older production machines where intimate knowledge of each
machine was considered essential. These machines are often set and operated by the same person, where
the operator will supervise a small number of machines (cell).

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 1. PLAIN TURNING AND FACING OPERATION

AIM: To write the part program for component shown in Fig. 01. Assuming the work piece is
Aluminum and the speed is 1200 rpm, feed 20 mm/min and maximum depth of cut is 1 mm.
a. With Canned cycle
b. Without Canned cycle.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
PART DRAWING:

FIGURE: 01
PART PROGRAM:
(A) WITH CANNED CYCLE
N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 < EOB>
N 02 G 00 X 30 Z 0 <EOB>
N 03 G 71 Z -3 X 0 I 1 F 20 <EOB>
N 04 G 00 X 30 Z 0 <EOB>
N 05 G 72 X 24 Z -50 I 1 F 20 <EOB>
N 06 G 00 X 50 Z 10 <EOB>
N 07 M 30 <EOB>

(B) WITHOUT CANNED CYCLE

N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 00 X 30 Z 1 <EOB>
N 03 G 01 Z –1 F 20 <EOB>
N 04 G 01 X 00 F 20 <EOB>
N 05 G 00 X 30 Z 00 <EOB>
N 06 G 01 Z –2 F 20 <EOB>
N 07 G 01 X 00 F 20 <EOB>
N 08 G 00 X 30 Z 00 <EOB>
N 09 G 01 Z –3 F 20 <EOB>
N 10 G 01 X 00 F 20 <EOB>
N 11 G 00 X 30 Z 00 <EOB>
N 12 G 01 Z -50 F 20 <EOB>

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N 13 G 01 X 28 F 20 <EOB>
N 14 G 00 X 30 Z 00 <EOB
N 15 G 01 Z -50 F 20 <EOB>
N 16 G 01 X 26 F 20 <EOB>
N 17 G 00 X 30 Z 00 <EOB
N 18 G 01 Z -50 F 20 <EOB>
N 19 G 01 X 24 F 20 <EOB>
N 20 G 00 X 50 Z 10 <EOB
N 21 M 30 <EOB>
RESULT:
The program is written and simulated and stored in System No…and file name as…

6
 2. STEP TURNING OPERATION
AIM: To write the part program for the component shown in fig 2. assuming work piece as AL the speed
is 1200rpm, feed given is 20mm/min.
(a) Without canned cycle
(b) With canned cycle.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
PART DRAWING:

PART PROGRAM: (A) WITHOUT CANNED CYCLE

N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 04 X 02 <EOB>
N 03 G 00 X 30 Z 00 <EOB>
N 04 G 01 Z -50 F 20 <EOB>
N 05 G 00 X 30 Z 00 <EOB>
N 06 G 01 X 26 F 20 <EOB>
N 07 G 01 Z -50 F 20 <EOB>
N 08 G 00 X 30 Z 00 <EOB>
N 09 G 01 X 24 F 20 <EOB>
N 10 G 01 Z -50 F 20 <EOB>
N 11 G 00 X 30 Z 00 <EOB>
N 12 G 01 X 22 F 20 <EOB>

N 13 G 01 Z -22 F 20 <EOB>
N 14 G 00 X 30 Z 00 <EOB>
N 15 G 01 X 20 F 20 <EOB>
N 16 G 01 Z -22 F 20 <EOB>
N 17 G 00 X 30 Z 00 <EOB>
N 19 G 00 X 50 Z 10 <EOB>
N 20 M 30 <EOB>

( B) WITH CANNED CYCLE:

N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 04 X 03 <EOB>
N O3 G 00 X 30 Z 00 <EOB>

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N 04 G 72 X 24 Z -50 I 01 F 20 <EOB>
N 05 G 72 X 20 Z -22 I 01 F20 <EOB>
N 06 G 00 X 30 Z 00 <EOB>
N 08 X 50 Z 10 <EOB>
N 09 M 30 <EOB>
RESULT:
The program is written and simulated and stored in System No…and file name as…

8
 3. PATTERN REPEATED CYCLE
AIM: To write the part program for the component shown in Fig. 3. Assuming work
piece is Aluminum and the speed is 1200 rpm, feed given is 20 mm/min,using pattern
repeated cycle.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
PART DRAWING:

FIGURE. 3.
PART PROGRAM:
N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 04 X 04 <EOB>
N 03 G 00 X 30 Z 00 <EOB>
N 04 G 73 P 05 Q 09 I 01 <EOB>
N 05 G 01 X 18 F 20 <EOB>
N 06 G 01 X 24 Z -22 F 20 <EOB>
N 07 G 01 Z -50 F 20 <EOB>
N 08 G 00 X 30 <EOB>
N 09 G 00 Z 00 <EOB>
N 10 G 00 X 50 Z 05 <EOB>
N 11 M 30 <EOB>
RESULT: The program is written and simulated and stored in System No…and file
name as…

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 4. THREAD CUTTING
AIM: To write the part programming for the component shown in Fig 4. Assuming
work piece as Aluminum and the turning speed is 1200 rpm and feed is 20 mm / min
and the depth of cut is 1 mm. For thread cutting reduce the speed to half of the
turning speed and pitch is 0.1mm.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
PART DRAWING:

FIGURE.4.

PART PROGRAME:

N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 00 X 30 Z 00 <EOB>
N 03 G 01 Z -01 F 20 <EOB>
N 04 G 01 X 00 F 20 <EOB>
N 05 G 00 X 30 Z 00 <EOB>
N 06 G 72 X 20 Z -40 I 01 F 20 <EOB>
N 07 G 00 X 30 Z 05 <EOB>
N 08 M 05 <EOB>
N 09 T 0202 <EOB>
N 09 M 03 S 600 <EOB>

N 10 G 04 X 02 <EOB>
N 11 G 01 X 20 Z 00 F 20 <EOB>
N 12 G 93 (or) 92 X 20 Z -35 I 0.1 F 01 <EOB>
N 13 G 00 X 30 Z 01 <EOB>
N 14 M 30 <EOB>
RESULT: The program is written and simulated and stored in System No…and file name as…

10
 5. CIRCULAR INTER POLATION
AIM: To write the part programming for the figure shown in Fig.5. speed is 1200 rpm,
feed is 20 mm / min. Assuming work piece as Aluminum.
MATERIAL REQUIRED: Aluminum Rod of 30 mm diameter and 80 mm length.
THEORY:
Circular interpolation is used to simplify the programming of arcs and circles.
It required of four bits of information those are.
• The direction of cutter travel (GOZ for cw and G03 is for CCW)
• Start point for arc (xs zs) for lathe and (xs, ys) for milling
• Center of arc (xl,zl) for lathe and (xl,yl) for milling machine
• The final point of the arc except for (xf,zf) for lathe and (xf,yf) for milling.
PART DRAWING:

FIGURE.5.
PART PROGRAM:
N 00 G 21 G 90 <EOB>
N 01 M 03 S 1200 <EOB>
N 02 G 04 X 04 <EOB>
N 03 G 00 X 30 Z 00 <EOB>
N 04 G 72 X 20 Z -55 I 01 F 20 <EOB>
N 05 G 00 X 30 Z 00 <EOB>
N 06 G 00 X 20 Z 00 <EOB>
N 07 G 01 X 18 F 20 <EOB>

N 08 G 02 X 20 Z -01 K -1 I 0 F 20 <EOB>
N 09 G 00 Z 00 <EOB>
N 10 G 01 X 16 F 20 <EOB>
N 11 G 02 X 20 Z -02 K -2 I 0 F 20 <EOB>
N 12 G 00 Z 00 <EOB>
N 13 G 01 X 14 F 20 <EOB>
N 14 G 02 X 20 Z -03 K -3 I 0 F 20 <EOB>
N 15 G 00 Z 00 <EOB>
N 16 G 01 X 12 F 20 <EOB>

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N 17 G 02 X 20 Z -04 K -4 I 0 F 20 <EOB>
N 18 G 00 Z 00 <EOB>
N 19 G 01 X 10 F 20 <EOB>
N 20 G 02 X 20 Z -5 K -5 I 0 F 20 <EOB>
N 21 G 00 Z 00 <EOB>
N 22 G 01 X 8 F 20 <EOB>
N 23 G02 X20 Z-6 K-6 I0 F20 <EOB>
N 24 G00 Z 00 <EOB>
N 25 G 01 X 6 F 20 <EOB>
N 26 G 02 X 20 Z -7 K -7 I 0 F 20 <EOB>
N 27 G 00 Z 00 <EOB>
N 28 G 01 X 4 F 20 <EOB>
N 29 G 02 X 30 Z -8 K-8 I 0 F 20 <EOB>
N 30 G 00 Z 00 <EOB>
N 31 G 01 X 2 F 20 <EOB>
N 32 G 02 X 20 Z -9 K -9 I 0 F 20 <EOB>
N 33 G 00 Z 00 <EOB>
N 34 G 01 X 0 F 20 <EOB>
N 35 G 02 X 20 Z -10 K -10 I 0 F 20 <EOB>
N 36 G 01 Z -31 F 20 <EOB>
N 37 G 01 X 28 F 20 <EOB>

N 38 G 03 X 30 Z -32 K 0 I 2 F 20 <EOB>
N 39 G 00 Z -31 <EOB>
N 40 G 01 X 26 F 20 <EOB>
N 41 G 03 X 30 Z-33 K 0 I 4 F 20 <EOB>
N 42 G 00 Z -31 <EOB>
N 43 G 01 X 24 F 20 <EOB>
N 44 G 03 X 30 Z -34 K 0 I 6 F 20 <EOB>
N 45 G 00 Z –31 <EOB>
N 46 G 01 X 22 F 20 <EOB>
N 47 G 03 X 30 Z -35 K 0 I 8 F 20 <EOB>
N 48 G 00 Z –31 <EOB>
N 49 G 01 X 20 F 20 <EOB>
N 50 G 03 X 30 Z -36 K 0 I 10 F 20 <EOB>
N 51 G 00 X 35 Z 10 <EOB>
N 52 M 30 <EOB>
RESULT: The program is written and simulated and stored in System No…and file name as…

12