SHRI VAISHNAV VIDYAPEETH VISHWAVIDYALAYA · LAB MANUAL Subject: CAD/CAM/CIM BTME 505 Semester-V LIST OF EXPERIMENTS 1. Basic concepts of CAD/CAM 2. Study and development of 2 D model

SHRI VAISHNAV VIDYAPEETH

VISHWAVIDYALAYA

SHRI VAISHNAV INSTITUTE OF TECHNOLOGY AND SCIENCE, INDORE

MECHANICAL ENGINEERING DEPARTMENT

LAB MANUAL

CAD/CAM/CIM BTME 505

Prepared By: Submitted By:

Asst. Prof. Sunil Pipleya

Mechanical Deptt.

SVITS, Indore

BTME 505 CAD/CAM/CIM Prepared By: Sunil Pipleya Asst. Prof. Mechanical Deptt.

MECHANICAL ENGINEERING DEPARTMENT LAB MANUAL

Subject: CAD/CAM/CIM BTME 505 Semester-V

LIST OF EXPERIMENTS

1. Basic concepts of CAD/CAM

2. Study and development of 2 D model on CAD software.

3. Study and development of 3 D model on CAD software.

4. Study of Part Programming fundamentals and G & M codes.

5. Study of Group technology and part families.

6. Study of Computer Aided Process Planning.

7. Study of Flexible Manufacturing System


Experiment No. 1

1.0 TITLE : - Basic concepts of CAD/CAM

2.0 PRIOR CONCEPT:-

I. Era of CAD/CAM

II. Importance of CAD/CAM

III. Basic of CAD/CAM

NEW CONCEPT:

Figure 1.1 : Elements of CAD System

SHRI VAISHNAV INSTITUTE OF TECHNOLOGY AND SCIENCE ,

INDORE

DEPARTMENT OF MECHANICAL ENGINEERING Page No :

CAD/CAM/CIM (BTME 505) Enroll No :

Session : July-Nov. 2018 Section : Batch No :


3.0 INTRODUCTION:

Computer Aided Design (CAD) tools allow designers to spend their intellectual energyon innovation

instead of focusing their attention on the mechanics of designing. As idea sere developed, designers

must document and further develop them into fully market able concepts. The more fluid the

innovation process, the more readily innovative designs can be achieved. CAD tools have relieved

the burden of documenting a design idea, and have gone further to provide automated calculations

and analysis to allow the designer to focus their attention on their designs. The ideal design tool must

embed significant industry knowledge and become a natural part of the innovation process, enabling

product advancements that were previously unachievable. In essence, what would have taken a small

army of assistants to retrieve information, perform calculations and analyze designs should now be

automated at the designer’s fingertips.

3.1 COMPUTER AIDED DESIGN (CAD)

CAD can be defined as the use of computer systems to assist in the creation, modification, analysis,

and optimization of a design.

3.2 COMPUTER AIDED MANUFACTURING (CAM)

CAM can be define as the use of computer systems to plan, manage and control the operation of a

manufacturing plant through either direct or indirect computer interface with the plant’s production

resources

3.3 DEFINITION OF CAD/CAM: -

4.0 DESIGNS STEPS & REASONS OF IMPLEMENTING CAD SYSTEM

The process of designing something is characterized by SHIGLEY as an interactive procedure which

consist of six identifiable steps or phases:

(1) Recognition of need: - It involves the realization by someone that a problem exists for

which some corrective action should be taken. This might be the identification of some defect

in a current machine design by an engineer or the perception of a new product marketing

opportunity by a sales person.


(2) Definition of the problem:-It involves a thorough specification of the item to be designed.

This specification includes physical & functional characteristics, cost, quality & operating

performance

(3) Synthesis:-Synthesis & analysis are closely related & highly iterative in the design process.

(4) Analysis & Optimization:-A certain component or sub system of the overall system is

conceptualized by the designer, subjected to analysis, improved through this analysis

procedure, & redesigned.

(5) Evaluation:- It is concern with measuring the design against the specifications established in

the problem definition phase. This evaluation often requires the fabrication & testing of a

prototype model to assess operating performance, quality, reliability, & other criteria.

(6) Presentation: - The final phase in the design process is the presentation of the design .This

includes documentation of the design process by means of drawings, material specifications,

assembly lists, & so on.

5.0 BENEFITS OF CAD/CAM

a. Improved engineering productivity

b. Shorter lead times

c. Reduced engineering personnel requirements

d. Customer modifications are easier to make

e. Faster response to requests for quotations

f. Avoidance of subcontracting to meet schedules

g. Minimized transcription errors

h. Improved accuracy of design

i. In analysis, easier recognition of component interactions

j. Provides better functional analysis to reduce prototype testing

k. Assistant in preparation of documentation

l. Designs have more standardization

m. Better designs provided

n. Improved productivity in tool design

o. Better knowledge of costs provided

5.1 FUNCTIONAL AREA OF CAD

a. Geometric modeling

b. Engineering analysis

c. Design review and evaluation


d. Automatic drafting

e. Part coding and classification

6.0 Answer the following questions on separate A4 size (Un ruled) paper

1. What is CAD and what are its applications and benefits? 2. What are the hardware requirements of a Design workstation? Explain.

3. Discuss different types of Manufacturing units based on quantity

4. Described the needof CAD/CAM and the various issues raised by Computer Integrated Manufacturing.

5. What are various activities of a manufacturing plant which can be carried out through computer control

6. Differentiate between physical integration , application integration and business integration

7. Discuss the stages in product development cycle and importance of each stage

8. What are the important output devices used in CAD

9. How CAD data can be imported to Cam software?

10. List out the names of CAD/CAM/CAE software

------------xxxxxxxxxx-----------



INDORE




Experiment No. 2

1.0 TITLE : Study and development of 2 D model on CAD software.

2.0LEARNING:-

I. Introduce to various CAD packages available

II. AutoCAD/Creo/Solid Edge/Catia Software Sketching Commands

III. Drawing different views of a Component/Part

3.0 NEW CONCEPTS:

4.0 PROPOSITION: DESIGN PROCESS AND ROLE OF CAD

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

Benefits of Using CAD: (1) Increasing productivity (2) Improving quality of design (3) Improving communications (4) Creating data-base for manufacturing


Concept structure:

Fig. 1.1 – Role of computers in design process Geometric Modeling

The term geometric modeling (or representation) means a method of describing commonly used

curves and surfaces in terms of values of a few parameters. Three Types of Geometric Models Wireframe Model : connect 3D vertex points, sometimes ambiguous. Surface Model : define surface to form an object. Solid Model : various representation schemes are used to describe a solid object

5.0 Answer the following questions on separate A4 size (Un ruled) paper



INDORE


CAD/CAM/CIM (BTME 505) Enroll No : 0838 ME


Experiment No. 3

1.0 Title: - Study and development of 3 D model on CAD software.

2.0 Learning:-

I. Introduce to CATIA/Creo/Solidworks/Solid Edge Software Modeling Commands

II. Various 3D Commands

III. Part Modeling of given part

3.0 INTRODUCTION

Following are the important features of 3D modeling

Protrusion ( PAD ) Feature

Hole Feature

Round Feature

Chamfer Feature

Rib Feature

Shell Feature

Pipe Feature

3.1 PROTRUSION (EXTRUDE) FEATURE

Protrusion is the method of adding a solid material.It can add material in a void or on An

existing solid. Pro/engineer provides the following basic method of adding material to a

model.

Extrude – creates a solid feature by extruding a section normal to the section plane.


Revolve - creates a solid feature by revolving a section about an axis.

Sweep - creates a solid feature by sweeping a section about a trajectory.

Blend - creates a solid feature by blending various cross sections at various level.

3.2 HOLE FEATURE

Insert > Hole

Feature > Create > Solid > Hole

When you invoke this command Software displays the hole dialog box.

3.2.1 TYPES OF HOLES:

Straight Hole: Straight Hole is An Extruded Cut with a Circular Section. The Diameter Of the

hole is Constant. It Begins At the Placement Surface and Extends To The Specified End

Surface Or User Defined Depth.

Sketched Hole: A Sketched Hole is created by sketching a section for revolution in sketcher

mode and placing it into the part. Sketched holes are always blind and one-sided. A tapered

Hole could be created as a sketched hole.

Standard Hole: Standard Hole is the combination of the sketched and extruded feature. It is

based on industries standard fastener tables. You can calculate either the tapered or the

clearance diameter appropriate to the selected faster. You can use system-supplied standard

lookup tables for these diameters or create your own.

3.3 ROUND FEATURE

Insert > Round

Feature > Create > Solid > Round

In Solid Edge Round option is used to create a filleting between surfaces or in place of a middle

surface. Surfaces can be Pro/Engineer Zero thickness quilts, surfaces and surfaces of solid

Models.

Simple & Advance Rounds you can create two different types of round simple and advanced. the

type of round you create depend on the complexity of the reference geometry and on your need

to customize the default round geometry supplied by the system.Generally, after you specify the

placement references and radius of the round, the system generates the default round geometry


by using some default attributes. The System Normally terminates the round geometry whenever

it encounters non-tangents Edges.

3.4 CHAMFER FEATURE

Insert > Chamfer

Feature > Create > Solid > Chamfer

In Solid Edge chamfer command is used to create a beveled surface. There are two types of

chamfer.

1. Edge

2. Corner

Edge: An Edge Chamfer removes a flat section of material from a selected edge to create a

beveled surface between the two original surfaces common to that edge. One can select multiple

edges to create an edge chamfer.

45 x d: this option is used to create a chamfer that is at angle of 45 degrees to both surfaces &

distance d from the edge along each surface. The dimension appears as "45 x d", but you can

modify the distance, D only. You can create 45 x d chamfers only on an edge formed by the inter

section of two perpendicular surfaces.

d x d: creates a chamfer that is at a distance d from the edge along each surface. If you modify

the chamfer, the system displays the distance as the only dimension.

d1 x d2: Creates a chamfer at a distance d1 from the selected edge along one surface and a

distance d2 from the selected edge along the other surface. the system displays both distances

their respective surfaces when you modify the chamfer.

Ang x d: Creates a chamfer at a distance d from the selected edge along one adjacent surface at a

specified angle to that surface. The system displays both values as dimensions when you modify

the chamfer. you can use this option between two planer surfaces only.

Corner: A corner chamfer removes material from the corner or a part. In the next step is you

have to select the corner and the edges. Pro/ENGINEER Displays the pick/Enter

Menu, which allows you to specify the location of the chamfer vertex on the highlighted edge.


3.5 SHELL FEATURE:

Insert > Shell

Feature > Create > Solid > Shell

The Shell option Removes a surface or surfaces from the solid then hollows out the inside,

leaving a shell of a specified wall thickness.

When Pro/Engineer Makes the shall all the features that ware added to the solid before you chose

shell are hollowed out. Therefore, the order of feature creation is very important when you use

shell.After involving this command Pro/Engineer Displays the feature creation dialog box. if

desired, select the optional element spec thick to specify thickness individually.

4.0 Draw the 3D Models in the CAD Software to understand the commands

Fig. 3.1 Fig. 3.2

Fig. 3.3 Fig. 3.4



INDORE




Experiment No. 4

1.0 TITLE: Study of Part Programming fundamentals and G & M codes

2.0 LEARNING:-

I. Introduce NC & CNC

II. Designation of different motion

III. Knowing of G & M codes

3.0NC SYSTEM

Flexible automation is implemented in machine tools in the form of digital control. The programs are in

binary, in numerical form; strictly speaking alphanumeric. This instructions when read by the system,

regulate the various slides of the machine tool to enable the tool/tools to shape the objects to required

profiles by positional and/or continues control. Such systems are known as numerical control (NC)

system.


3.1 CLASSIFICATION OF NC MACHINE

3.2 COORDINATE SYSTEM

The guiding coordinate system for designating the axes is the conventional mathematical right-

hand coordinate system. Some possible dispositions of these coordinates are shown in Figure

below. One could use his right hand to get to these alternative relative positions of the same

right-hand coordinate system.

Figure: Finding positive direction for rotary motion

N C Machine

Rotating

spindle / tool

and stationary

work piece

Rotating work

piece and

stationary /

rotating tool

Both Tool and

work piece

not rotating

Example: Vertical

knee mill, drilling

machines, vertical

boring mill, tapping

machines, etc.

Example: Lathes,

Grinding machines

etc. surface

generating

machines

Example:

Shaper,

Planner

etc.

Machines

other than

machine tools

Example:

drafting

machine

etc.

Horizontal

spindle

Vertical

spindle


3.2.1 Z-MOTION

Location: Z-axis motion is either along the spindle axis or parallel to the spindle axis. It is also

recognized as the one perpendicular to the work holding surface which may or may not be

passing through the controlled point (i.e. cutting tool tip or drafting machine pen tip).

3.2.2 X – MOTION

The X-Motion is principal motion in the positioning plane of the cutting tool or the work piece.

Location: It is perpendicular to the axis and should be horizontal and parallel to the work

holding surface wherever possible.

Direction: For normal machines, when looking from the principal tool spindle to the column the

positive (+) X is to the RIGHT.

For Gantry profiler when looking from the principal spindle to the left hand gantry support the

positive (+) X is to the Right.

For Horizontal boring machine when looking from the principal tool spindle towards the work

piece the positive (+) X is to the RIGHT.

For Turret Lathe it is radial and parallel to the cross slide, X is positive (+) when the tool recedes

from the axis of rotation of the work pieces.

For Shaper and Drafting Machine the x-axis is parallel to the positive (+) in the principle

direction of movement (or cutting) of the guided point (or the cutting tool).

3.2.3 Y – MOTION

It is designation is derived from the already recognized Z and X axes. It is perpendicular to both

X and Z axes and + Y is in the direction which completes with +X and +Z motions a right hand

Cartesian coordinate system. In Figs this has been demonstrated in the columns under coordinate

system Y. The first two columns under Z and X show the designation of Z and X axes as per the

principles mentioned earlier. The column under coordinate system shows the relevant right hand

coordinate system. From the third column the Y axis designation is derived and is mentioned in

column under Y.

3.2.4 ROTARY MOTIONS


Location: These motions are located about the axis parallel to X, Y and Z respectively. If, in

addition to the above mentioned primary rotary motions, there exist secondary rotary motions,

whether parallel or not to A, B and C those should be designated as D and E.

Direction: Positive (+) A,B and C are in the directions which advance right and screws in the

positive (+) X, Y and Z directions respectively.

3.3 OBJECTVIES OF AXIS DESIGNATION:

The conventional mathematical right hand coordinate system is in general known and well

understood. The machine movements designated as above permit the part programmer to assume

safely that the tool moves relative to the right hand coordinate system of a stationery work piece.

The programmer can thus imagine to be sitting on a tool and describe all the machining

operations without having to know whether the tool approaches the work piece or the work piece

approaches the tool. He thus uses only the unprimed letters for the intended motions. For

example in Fig. on a Vertical Milling Machine, For a moving a tool (say a drill) from position P

to Position Q, the part programmer specifies the movement from coordinates (5,7,6) to (8,6,5).

The actual motions which take place on the machine tool are:

Movement of Quill (Z): 5-6 : -1 i.e. the tool tip comes down one unit.

Movement of table (X’): 8-5 : +3 i.e. Table moves left by 3 units, and

(Y’): 6-7 : -1 i.e. Table moves towards the column by 1 unit.

3.4 STRUCTURE OF CNC PART PROGRAMMING

There are many codes specifying the particular area of instruction required to control the

machine tool. The tool path of C.N.C machine is then described in machines codes, which

usually take the structure of –

N –G –X –Y –Z –I –J –K –F –S –T –M - EOB

Where,

N = sequence number.

G = preparatory function – ISO codes.

XYZ = dimension words – in mm or inch.

IJK = dimensions words for arc and circle – in mm or inch.

F = feed rate.

S = spindle speed – revolution/min.


T = tool selection.

M = miscellaneous function – ISO codes.

EOB = End of block.

1.”N”: The sequence number is designated by the address character “N” and three numeric

digits. The word indicates the start of specific sequences of operation. It is the first word for the

programming sequence in the block.

2. “G”: The preparatory function is designated by the character “G” and two numeric digits. This

word immediately follows the sequence number word. The “G” word prepare numeric control

unit for specific mode of operation.

3. “XYZ”: These addresses signify axis motion in accordance with the designated axis motion of

machine tools. These address could be supplement by “W, A, B, etc” if the machines have extra

axis of motion. XYZ are three axes. C.N.C can have up to six axes.

4.”IJK”: These addresses are used when employing circular interpolation to specify the center of

the program arc, I, J, and K which are equivalent to X, Y, and Z but with reference to the start

point.

5. “F”: The feed rate for slide displacement is expressed in mm/min and is a three digit number

is prefixed by the letter “F”.

6.”S”: The spindle speed is expressed in rev/min and is a four digit number prefixed to the letter

“S”.

7. “T”: The tool function is designated by the letter “T” and maximum of five numeric digits.

This word immediately follows the spindle speed word. Tool function code to identify the tool to

be used or loaded if at a tool change.

8. “M”: The miscellaneous function is designated by the letter “M” and two numeric digits.

These functions are a family of instruction that cause the starting stopping or setting of a variety

of machines function. Some M- functions have been standardized by popular usage and others

have special significance for individual machines.


3.4.4 LIST OF G – CODES

SR.NO. CODE FUNCTION

1. G00 RAPID POSITIONING

2. G01 LINEAR INTERPOLATION

3. G02 CLOCKWISE CIRCULAR INTERPOLATION

4. G03 COUNTER CLOCKWISE CIRCULAR INTERPOLATION

5. G04 DWELL IN SECONDS

6. G20 INCH PROGRAMMING

7. G21 METRIC PROGRAMMING

8. G28 AUTO. RETURN TO REF. POINT

9 G32 THREAD CUTTING CYCLE

10. G70 FINISHING CYCLE

11. G71 STOCK REMOVAL IN TURNING

12. G72 STOCK REMOVAL IN FACING

13. G73 PATTERN REPEATING CYCLE

14. G74 PECK DRILLING CANNED CYCLE

15. G90 DIAMETER CUTTING CYCLE

16. G92 THREADING CANNED CYCLE

17. G96 CONSTANT SURFACE SPEED ON

18. G97 CONSTANT SURFACE SPEED OFF

3.4.2 LIST OF M - CODES

Sr. No. CODE FUNCTION

1. M01 OPTIONAL PROGRAM STOP

2. M02 PROGRAM END


3. M03 SPINDLE START CLOCKWISE

4. M04 SPINDLE START ANTICLOCKWISE

5. M05 SPINDLE STOP

6. M07 COOLANT NO. 1 ON

7. M08 COOLANT NO. 2 ON

8. M09 COOLANTS OFF

9. M13 SPINDLE CLOCKWISE & COOLANT ON

10 M14 SPINDLE ANTI-CLOCKWISE & COOLANT ON

9. M30 PROGRAM END & REWIND

10. M98 START OF SUBROUTINE

11. M99 END OF SUBROUTINE

Also write 3 CNC Mill and 3 CNC Lathe Prgramme



INDORE




Experiment No. 5

1.0 TITLE : - Study of Group technology and part families

2.0 LEARNING :

I. Part Classification &Coding

II. Part Family Concept

III. Types of Coding System

3.0 THEORY :

Group Technology is anapproach to manufacturing in which similar parts are identified and

grouped together in order to take advantage of their similarities in design and production Similarities

among parts permit them to be classified into certain groups and in each group processing steps are

similar The improvement is typically achieved by organizing the production facilities into

manufacturing cells that specialize in production of certain part family

3.1 PART FAMILY

A group of parts that possess similarities in geometric shape and size, or in the processing steps

used in their manufacture

Part families are a central feature of group technology

There are always differences among parts in a family

But the similarities are close enough that the parts can be grouped into the same family


Figure 8.1 A Family of Similar Parts

Here Ten parts that are different in size and shape, but quite similar in terms of manufacturing. Here

similarity is that all parts are machined from cylindrical stock by turning; some parts require drilling

and/ormilling

3.2 METHODS OF CLASSIFICATION.

1. VisualInspection (VI)- using best judgment to group parts into appropriate families, based on the

parts or photos of the parts

2. ProductionFlow Analysis (PFA) - using information contained on route sheets to classify parts

3. PartsClassification and Coding- identifying similarities and differences among parts and relating

them by means of a coding scheme

3.3 PARTS CLASSIFICATION AND CODING

Most classification and coding systems are one of the following:

Systems based on part design attributes

Systems based on part manufacturing attributes

Systems based on both design and manufacturing attributes


3.3.1 PART DESIGN ATTRIBUTES

Major dimensions

Basic external shape

Basic internal shape

Length/diameter ratio

Material type

Part function

Tolerances

Surface finish

3.3.2 PART MANUFACTURING ATTRIBUTES

Major process

Operation sequence

Batch size

Annual production

Machine tools

Cutting tools

Material type

3.3.3 THREE STRUCTURES USED IN CLASSIFICATION AND CODING SCHEMES

I. Hierarchical structure, known as a mono-code, in which the interpretation of each

successivesymbol depends on the value of the preceding symbols

II. Chain-type structure, known as a polycode, in which the interpretation of each symbol in

thesequence is always the same; it does not depend on the value of preceding symbols

III. Mixed-mode structure, which is a hybrid of the two previous codes

3.4 SOME OF THE IMPORTANT PART CLASSIFICATION SYSTEMS

OPITZ classification system –the University of Aachen in Germany, nonproprietary, Chain

type.Brisch System –(Brisch-Birn Inc.)

CODE (Manufacturing Data System, Inc.)

CUTPLAN (Metcut Associates)

DCLASS (Brigham Young University)


Multiclass (OIR: Organization for Industrial Research), hierarchical or decision-tree coding

structure

Part Analog System (Lovelace, Lawrence & Co., Inc.)

BASIC STRUCTURE OF THE OPITZ PARTS CLASSIFICATION AND CODING


Form code (digits 1-5) for rotational parts in the Opitz coding system

Example 1: A part coded 20801

2 - Parts has L/D ratio >= 3

0 - No shape element (external shape elements)

8 - Operating thread

0 - No surface machining

1 - Part is axial

MultiClass–developed by the Organization for Industrial Research (OIR)

First 18 digits of the Multiclass Classification and Coding System


Benefits of aWell-Designed Classification and Coding System

Facilitates formation of part families

Permits quick retrieval of part design drawings

Reduces design duplication

Promotes design standardization

Improves cost estimating and cost accounting

Facilitates NC part programming by allowing new parts to use the same part program as

Existing parts in the same family

Computer-aided process planning (CAPP) becomes feasible

Composite Part Concept

Acomposite part for a given family is a hypothetical part that includes all of the design

and manufacturing attributes of the family

In general, an individual part in the family will have some of the features of the family,

but not all of them

A production cell for the part family would consist of those machines required to make

the composite part

Such a cell would be able to produce any family member, by omitting operations


corresponding to features not possessed by that part

Composite Part Features and Corresponding Manufacturing Operations

Design feature Corresponding operation

1.External cylinder Turning

2.Face of cylinder Facing

3.Cylindrical step Turning

4.Smooth surface External cylindrical grinding

5.Axial hole Drilling

6.CounterboreCounterboring

7.Internal threads Tapping

Benefits of Group Technology

Standardization of tooling, fixtures, and setups is encouraged

Material handling is reduced

Parts are moved within a machine cell rather than entire factory

Process planning and production scheduling are simplified

Work-in-process and manufacturing lead time are reduced

Improved worker satisfaction in a GT cell

Higher quality work

Problems in Group Technology

Identifying the part families (the biggest problem)


If the plant makes 10,000 different parts, reviewing all of the part drawings and grouping

the parts into families is a substantial task

Rearranging production machines in the plant into the appropriate machine cells

It takes time to plan and accomplish this rearrangement, and the machines are not

Producing during the changeover

1. Conclusion



INDORE




Experiment No. 6

1.0 Title Study of Computer Aided Process Planning.

Theory – 1) Introduction. 2) Types of Computer aided process planning. i) Retrieval process planning. ii) Generative process planning. 3) Advantages of computer aided process planning.

Conclusion.



INDORE




Experiment No. 7

1.0 Title Study of Flexible Manufacturing System

2.0 LEARNING

I. What is a Flexible Manufacturing System?

II. FMS Components

III. FMS Applications and Benefits

IV. FMS Planning and Implementation Issues

V. Quantitative Analysis of Flexible Manufacturing Systems

3.1 THEORY

To qualify as being flexible, a manufacturing system should satisfy the following criteria (“yes” answer

for each question):

1. Can it process different part styles in a non-batch mode?

2. Can it accept changes in production schedule?

3. Can it respond gracefully to equipment malfunctions and breakdowns?

4. Can it accommodate introduction of new part designs?


Automated manufacturing cell with two machine tools and robot. Is it a flexible cell?

1. Part variety test

Can it machine different part configurations in a mix rather than in batches?

2. Schedule change test

Can production schedule and part mix be changed?

3. Error recovery test

Can it operate if one machine breaks down?

Example: while repairs are being made on the broken machine, can its work be

temporarily reassigned to the other machine?

4. New part test

As new part designs are developed, can NC part programs be written off-line and then

downloaded to the system for execution?

Types of FMS

Kinds of operations


Processing vs. assembly

Type of processing

If machining, rotational vs. non-rotational

Number of machines (workstations):

Single machine cell (n = 1)

Flexible manufacturing cell (n = 2 or 3)

Flexible manufacturing system (n = 4 or more)


Features of three Catagories

1. Dedicated FMS

Designed to produce a limited variety of part styles

The complete universe of parts to be made on the system is known in advance

Part family likely based on product commonality rather than geometric similarity

2. Random-order FMS

Appropriate for large part families

New part designs will be introduced

Production schedule is subject to daily changes


FMS Components

1. Workstations

2. Material handling and storage system

3. Computer control system

4. Human labor

Workstations

Load and unload station(s)

Factory interface with FMS

Manual or automated

Includes communication interface with worker to specify parts to load, fixtures needed,

etc.

CNC machine tools in a machining type system

CNC machining centers

Milling machine modules

Turning modules

Assembly machines

Material Handling and Storage

Functions:

Random, independent movement of parts between stations

Capability to handle a variety of part styles

Standard pallet fixture base

Workholding fixture can be adapted

Temporary storage

Convenient access for loading and unloading

Compatibility with computer control


FMS In-Line Layout

Straight line flow, well-defined processing sequence similar for all work units

Work flow is from left to right through the same workstations

No secondary handling system

FMS Loop Layout

One direction flow, but variations in processing sequence possible for different part types

Secondary handling system at each workstation

FMS Rectangular Layout


Rectangular layout allows recirculation of pallets back to the first station in the sequence after

unloading at the final station

FMS Benefits

Increased machine utilization

Reasons:

24 hour operation likely to justify investment

Automatic tool changing

Automatic pallet changing at stations

Queues of parts at stations to maximize utilization

Dynamic scheduling of production to account for changes in demand

Fewer machines required

Reduction in factory floor space required

Greater responsiveness to change

Reduced inventory requirements

Different parts produced continuously rather than in batches

Lower manufacturing lead times

Reduced labor requirements

Higher productivity

Opportunity for unattended production

Machines run overnight ("lights out operation"

Documents

SHRI VAISHNAV VIDYAPEETH VISHWAVIDYALAYA · LAB MANUAL Subject: CAD/CAM/CIM BTME 505 Semester-V LIST OF EXPERIMENTS 1. Basic concepts of CAD/CAM 2. Study and development of 2 D model