Institute of Space Technology, Islamabad
Manufacturing Project report
processes
Zohaib Ahmad (160501018) Manufacturing
Tauqeer Yousaf (160501005)
Taimur Sultan (160501036)
of cooling
Arslan arshad (160501015) casing on CNC
Haseeb Altaf (160501025)
machine
Abstract:
A 3 D part based to learn turning operation was manufactured using CNC lathe . A 3D
CAD model was generated in creo for the required part according to the required drawing and
GM code was generated for the model from CAM using CREO parametric. The GM code were
then apply into the CNC lathe machine by which the required 3D part is obtained.
Objective:
Following are the objective of this project
To understand the procedure to manufacture parts on CNC machine and to
learn the clamping of the stock material.
To understand and analyze the working of CNC machine by generating the
CAD/CAM profiles
Introduction:
In this project different a two stroke engine was to manufactured by the class and
different parts of the engine were divided into different group which can be assembled later to
manufactured the complete engine. The part which we were assigned to be manufactured was
‘COOLING CASING’ which is manufactured on CNC machine using the both machines (milling
and lathe). From the CAD model, GM codes were generated for the machine through CAM
profile using CREO parametric.
Theory:
Cooling casing
A cooling casing is used as a heat exchanger in two stroke engines. When the piston
slides with the cylinder excessive heat is being produce which must be removed in order to
proper functioning of the engine. The heat removal is due to increase in contact area by using
fins structure which largely increase the heat transfer.
CAD/CAM
CAD/CAM stands for computer-aided design & computer-aided manufacturing.
CAD/CAM software is used to design and manufacture prototypes, finished products, and
production runs. This software provides different tools for the generation of required models
and to specify different machining operations for manufacturing these parts. They show the
manufacturing of the parts in the form of a simulation by the step and commands which we
specify to form that specific part.
GM codes:
GM code means Geometric codes and Machine codes. These are the different specified
numbers in the form of some alphabet and numerical numbers which are the set of instruction
for the machine (CNC machine) to manufacture the part. These codes are generated by the CAD
model of part designed and the specified processes and steps that we define in the software to
manufacture that part.
Stock Material:
Stock of Aluminum metal of the size 65X240mm
Procedure:
Generate CAD and then CAM profile of required part, in which all the
requirements like feed rate, spindle speed, tolerance and coolant requirement
are given. Now generate GM code from CAM profile . In case of CNC lathe,
profile is manually input into the machine and machine shows a simulation of
the input profile. In case of CNC miller GM code is feed into the machine. Clamp
stock into the machine and set it w.r.t. the zero reference of the machine.
One side of the cooling casting is made up on the cnc lathe and other on cnc
milling machine
On CNC lathe the profile was loaded manually by selecting the points manually
by the operator on the machine without using any GM code.
Firstly the roughing cut is taken by machine for required geometry. After that
finishing cut is used on CNC lathe
Now circular chuck is fixed on the CNC miller and round side of cooling casing
raw part is clamped w.r.t. zero reference. Now the GM code file is installed on
the CNC according to which milling operation is performed by the machine
Result:
By following the above procedure the cooling casing is manufactured successfully and
rough ends/ sides were smoothen and polished using emiry papers and files. All the dimensions
are according to the drawing and lies with in the tolerance limit. Cooling casing that is
manufactured has the tolerance and finishing better than the parts that are manufactured on
manual lathe and milling. The contours on the part are perfectly cut which are very difficult to
cut through the feed given manually on milling.
Conclusion:
The cooling casing is an essential component of the engine as it act as the heat exchanger and
remove the excessive heat from the engine which ensure the perfect working and avoid
overheating of the engine. CNC lathe and milling machines are used to manufacture the cooling
casing which was successfully completed under dimensional tolerances and accuracy.
