# A project report of map of india made by the CNC SIMULATOR PRO software Mechanical Engineering

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### A project report of map of india made by the CNC SIMULATOR PRO software Mechanical Engineering

1. 1 | P a g e A Project Report On Making map of india using By Cnc simulator pro software Submitted In Partial Fulfillment for the Award of the Degree of Bachelor of Technology In Mechanical Engineering Submitted By-: Submitted To-: Jayant Tailor (19ME84D) Mr. Tarun Kumar Aseri Kalpana Meena (18ME33) Asst. Prof. Mechanical Engg. Irfan Khan (18ME32) Engg. College Ajmer Kamana (18ME34) Barliya Circle,NH-8,Ajmer Inder Bawal(18ME31)
2. 2 | P a g e TABLE OF CONTENTS S. No. DESCRIPTION 1.INTRODUCTION 1.1 INTRODUCTION OF CNC MACHINE 1.2 CLASSIFICATION OF CNC MACHINE 1.3 COORDINATE SYSTEM 2. CNC SIMULATOR PRO 3. CNC PROGRAMMING 3.1 TYPES OF CNC PROGRAMMING 3.2 CNC PROGRAMING ELEMENT 4. MAP OF INDIA 4.1 2D DESIGN 4.2 STEPS INCLUDING IN CNC SIMULATOR 4.3 CNC MACHINE SELECTION 4.4 PROGRAMMING OF DESIGN 4.5 SNAPSHOTS OF DESIGN 5. COST OF MATERIAL 6. RESULT&CONCLUSIONS 7. REFERENCES
3. 3 | P a g e 1.1 INTRODUCTION TO COMPUTER NUMERICALLY CONTROLLED (CNC) MACHIN Computer Numerical Control involves the replacement of the conventional hard wired NC controller unit by a small computer (mini or microcomputer).CNC may be considered to be a means of operating a machine through the use of discrete numerical values fed into the machine, where the required ’input’ technical information is stored on a kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB Flash Drive, or RAM card. The machine follows a predetermined sequence of machining operations at the predetermined speeds necessary to produce a work piece of the right shape and size and thus according to completely predictable results. A different product can be produced through reprogramming and a low-quantity production run of different products is justified. History: In 1947, the U.S. Air Force found that the complex designs and shapes of aircraft parts such as helicopter rotor blades and missile components were causing problems for manufacturers, who could not keep up to projected production schedules. At this time, John Parsons, of the Parsons Corporation, of Traverse City, Michigan, began experimenting with the idea of making a machine tool generate a “thru-axis curve" by using numerical data to control the machine tool motions. In 1949, the U.S. Air Material Command awarded Parsons a contract to develop NC and in turn speed up production methods. Parsons subcontracted this study to the Servomechanism Laboratory of the Massachusetts Institute of Technology (MIT), which in 1952 successfully demonstrated a vertical spindle Cincinnati Hydrotel, which made parts through simultaneous three-axis cutting tool movements. In a very short period of time, almost all machine tool manufacturers were producing machines with NC. At the 1960 Machine Tool Show in Chicago, over a hundred NC machines were displayed. Most of these machines had relatively simple point-to-point positioning, but the principle of NC was now firmly established. From this point, NC improved rapidly as the electronics industry developed new products. At first, miniature electronic tubes were developed, but the controls were big, bulky, and not very reliable. Then solid-state circuitry and, eventually, modular, or integrated circuits were developed. The control unit became smaller, more reliable, and less expensive. The development of even better machine tools and control units helped spread the use of NC from the machine tool industry to all facets of manufacturing. Data Processing: NC data processing (with numbers, letters, and symbols) is done in a computer or machine control unit (MCU) by adding, subtracting, multiplying, dividing, and comparing. The computer can be programmed to recognize an A command before a B command, an item 1 before an item 2, or any other elements in their sequential order. It is capable of handling numbers very quickly; the addition of two simple numbers may take only one billionth of a second (a nanosecond). NC Evolves into CNC: The introduction of software-based controls in the early 1970s replaced the NC hardware design with complete computer logic that had more capacity and could be programmed for a variety of functions at any time. This made it possible to revise, modify, or update CNC programs or parts of programs at any time on a computer. In turn, CNC machines became easier to use with their menu-selected displays, advanced graphics, and ease of programming
4. 4 | P a g e 1.2 Classification of CNC Machine CNC: - CNC is stand for “Computerized Numerical Control”. A machine which is controlled by computer with Numerical values is known as CNC Machine. Applications: CNC machines are widely used in the metal cutting industry and are best used to produce the following types of product: • Parts with complicated contours • Parts requiring close tolerance and/or good repeatability • Parts requiring expensive jigs and fixtures if produced on conventional machines • Parts that may have several engineering changes, such as during the development stage. • In cases where human errors could be extremely costly • Parts that are needed in a hurry. • Small batch lots or short production runs.
5. 5 | P a g e 1.3 Coordinate System AXIS: - Horizontal and vertical lines are known as Axis. Horizontal Axis Vertical Axis Plane: - A plane has two axes. Plane selection in CNC: - Code Plane Selection Used G00 G01 X-Y VMC G02,G03 X-Z CNC MILLING G90 Y-Z HMC Types of Coordinates: - 1.Absolute Coordinate: - The value of any point will be taken with respect to center point. 2.Incremental Coordinate: - The value of any point will be taken with respect to previous point. 0 Center of Origin X + Y + - Y - X
6. 6 | P a g e 2. CNC SIMULATOR PRO ABOUT THE CNC SIMULATOR PRO The idea of CNCSimulator Pro is to provide the CNC community with a versatile and contemporary Full 3D CNC Machine Simulator with CAD/CAM capabilities. CNCSimulator Pro is for everyone with an Internet connection and a PC with the Windows operating system. In the simulator, you find different types of machines like Milling machines, Routers, Hobby machines, Lathes, Cutters, 3D Printer, and more. On our site, you will find many tutorials, examples, videos, and help articles that will aid in getting you started. Despite its name, CNCSimulator Pro is so much more than just a great CNC simulator. It is also a modern CAD/CAM system, an advanced CNC programming editor, a 3D model milling software, a gear creator, a training tool, and much more. Over the years, CNCSimulator Pro has become a whole suite of combined software tools for CNC people! Click picture to enlarge. Check out our demonstration Videos. FIG.CNC MILLING MACHINE
7. 7 | P a g e 3.1 TYPES OF CNC PROGRAMMING  CNC Programming is made of blocks & blocks are made by commands. Commands are provided for different functions.
8. 8 | P a g e 3.2 CNC Programming Elements I. Command, II. Block, III. Different Addressing Code, IV. Program Scan, V. Program Header, VI. Program Footer 1. Command: - Command is the combination of alphabetic character & numerical value where alphabetic is used for address & numerical is used for value. Alphabet A to Z, numerical 0-9. Ex - G0 X4 Z2 N1 2.Block: - Group of commands known as block. One block has one or more commands. Block is started from sequence Number & ended by end of block command Where sequence no. is optional. 3.Different Addressing Code: - G – Code:-These are Preparatory function codes & used for different function. Axis Movement:- G0/G01/G02/G03 codes are used for programming of any axis.  Code G00 = This code is used for tool positioning & free movement in air. Format – G00 X... Z…;  Code G01 = This code is used for linear movement of axis Format – G01 X... Z… F…;  Code G02 = This code is used for circular clock wise movement of any axis. Format – G02 X... Z… R… F…;  Code G03 = This code is used for circular anticlockwise movement of any axis. Format – G03 X... Z… R… F…;  Code G28 = This code is used for homing of any axis. Format – G28 U0.0 W0.0;
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12. 12 | P a g e 4.Map OF INDIA 4.1 2D DESIGN 4.2 Steps Including In CNC Simulator-: Start CNCsimulator pro>>New CNC Program Wizard..>>Select Program Type>>Enter New Workpiece data(i.e.X510 Y600 Z20)>>Final Program Data Like Prog.Name, Units etc.
13. 13 | P a g e GEOMETRY- Work Piece Size- X=510mm Y=600mm Z=20mm Tool Dia.- ET16=8mm (Embedded tool) Tip Angle=120 Tool Length=50mm Spindle Speed=1500rpm Feed Rate=50mm per min. Depth Of Cut=1.0mm Cutter Rotation= Clockwise & Anti-Clockwise CNC CODES USE:- G00:- Rapid traverse motion G01:- Linear interpolation motion G02:- CW Circular Interpolation G03:- CCW Circular Interpolation G90:- Absolute programming
14. 14 | P a g e G92:- Work offset M03:- Spindle ON CW M06:- Tool Change M08:- Coolant ON M09:- Coolant OFF M30:- End of Program 4.3 CNC Machine Selection- The CNC simulator pro software have many milling machine but our 2D design has large area and its coordinates have the large amount of numbers so we are selecting the UNLIMITED MILLING MACHINE from Open Machine icon. Fig.Unlimited Milling Machine 4.4 Programming Of Design- \$Millimeters \$Mill \$DefineMillTool "N:" 1 0.00 0.00 0.00 14.00 50.00 0 \$ReadTasDefinedTool \$AddRegPart 1 (MADE BY JAYANT TAILOR) #endregion % M21 (Close door for safety)
15. 15 | P a g e ET16 M06 G00 X0 Y0 Z22 G00 X164 Y45 Z18 G01 F50 S1000 M03 M08 X158 Y57 F100 X169 Y40 X176 X188 Y45 Y54 X200 Y59 X205 Y76 X213 Y94 Y103 X222 Y125 X218 Y137 Y145 Y153 Y160 X224 Y166 X233 X238 Y180 X246 X252 Y186 X257 Y191 X266 Y200 X273 X284 Y211 X298 Y225 X303 Y230 X311 Y238 X320 X326 Y244 X331 Y249 Y261 X337 Y267 X349 Y274 Y267 X358 X365 Y272 X361 Y290 X356 Y310 X360 Y314 Y319 X349 Y323 X354 Y328 Y333 X360 X364 X358 Y339 X353 Y344 X349 Y349 X354 Y354 Y359 X365 Y353 X370 Y348
16. 16 | P a g e X375 Y353 Y348 X380 Y343 X376 Y337 X381 Y334 X391 X401 X411 Y331 X417 X421 Y327 X413 Y321 X410 Y316 X400 Y306 Y301 X405 Y296 X408 Y293 X412 Y302 Y306 X417 X420 Y290 X423 Y278 X428 Y276 X433 Y281 X431 Y287 Y293 X435 Y297 Y305 X453 Y323 X467 Y355 X479 Y367 X493 Y381 X502 Y390 X484 Y398 X473 Y409 X460 X438 Y398 X423 Y383 X406 Y372 X417 X406 Y361 X385 X361 Y372 Y385 X349 Y372 X334 Y357 X310 X277 Y376 X237 Y386 X217 Y406 X228 Y417 X235 Y424 X203 Y446
17. 17 | P a g e X192 Y457 Y474 X200 Y466 X209 Y475 X197 Y487 X203 Y493 X197 Y499 X206 X214 Y507 X221 Y525 X206 Y540 X187 Y534 X180 Y527 X158 Y537 X151 Y544 X147 Y554 X142 X137 Y559 X131 X127 Y563 X123 Y559 X114 Y555 X106 X100 Y549 X94 Y543 Y536 X100 X106 Y530 X112 Y524 X118 Y518 X111 Y511 X106 Y506 X111 Y501 Y494 Y486 Y480 X123 Y474 X129 Y468 X135 X140 Y463 X127 Y456 Y446 X119 Y431 X107 Y419 Y410 X100 Y403 X89 Y392 X82 Y385 X68 Y380 X61 Y387 X51 Y377 X41 Y367 X51 Y357 Y348
18. 18 | P a g e X57 Y342 X66 Y333 X70 Y329 X65 Y316 X51 X36 X27 Y307 X38 Y296 X46 Y288 X56 Y298 X65 Y289 X37 Y282 X63 Y256 X75 X86 Y267 X92 Y284 X95 X100 Y254 X95 Y240 X101 Y221 Y208 X109 Y174 X119 Y154 X127 Y137 X133 Y118 X141 Y101 X150 Y82 X158 Y65 Y57 Y65 G00 Z50 X221 Y126 G01 F50 Z18 X222 Y125 F100 G00 Z50 X309 Y236 G01 F50 Z18 X303 Y230 F100 G00 Z50 X361 Y297 G01 F50 Z18 Y290 F100 G00 Z50 X358 Y303 G01 F50 Z18 X361 Y290 F100 X358 Y303 X360 Y301 G00 Z50 X444 Y307 G01 F50 Z18 X441 Y310 F100 X435 Y305 G00 Z50 X0 Y0 G01 F50 Z18 Y600 F100
19. 19 | P a g e X488 X508 Y2 G00 Z50 Y179 G01 F50 Z18 X493 F100 X461 Y163 X448 Y176 Y209 X432 Y242 X416 Y258 X384 Y290 X389 Y272 X361 G00 Z50 X365 G01 F50 Z18 X361 F100 X365 G00 Z50 X203 Y481 G01 F50 Z18 X197 Y487 F100 G00 Z50 X214 Y517 G01 F50 Z18 X219 F100 X214 Y507 G00 Z50 X113 Y424 G01 F50 Z18 X119 Y431 F100 G00 Z50 X2 Y327 G01 F50 Z18 X16 Y313 F100 X27 Y307 G00 Z50 X200 Y59 G01 F50 Z18 X208 F100 X216 Y51 X212 Y36 X213 Y25 X219 Y8 X234 X244 Y18 Y30 X236 Y46 X215 Y67 X220 Y62 X216 Y51 G00 Z50 X376 Y337 G01 F50 Z18 X381 Y334 F100 Y337
20. 20 | P a g e G00 Z50 X421 Y327 G01 F50 Z18 X417 Y331 F100 G00 Z50 X384 Y290 G01 F50 Z18 X389 Y272 F100 X384 Y290 G00 Z50 X406 Y383 G01 F50 Z18 Y372 F100 Y383 Y372 G00 Z50 X123 Y474 G01 F50 Z18 X129 F100 G00 Z50 X509 Y2 G01 F50 Z18 X1 Y0 F100 G00 Z50 X82.5 Y300 G01 F50 Z18 X107.5 Y300 G00 Z50 X95 Y300 G01 Z18 F50 X95 Y350 X82.5 Y350 X107.5 Y350 G00 Z50 X127.5 Y300 G01 Z18 F50 X127.5 Y350 X152.5 Y300 X152.5 Y350 G00 Z50 X172.5 Y300 G01 F50 Z18 X172.5 Y350 G02 X172.5 Y300 R25 G00 Z50 X217.5 Y300 G01 Z18 F50 X242.5 Y300 X230 Y300 X230 Y350 X217.5 Y350 X242.5 Y350 G00 Z50 X262.5 Y300 G01 Z18 F50 X275 Y350 X287.5 Y300 G00 Z50
21. 21 | P a g e X268.75 Y325 G01 Z18 F50 X281.25 Y325 G00 Z50 X81.5 Y290 G01 Z18 F50 X288.5 Y290 G00 Z50 X300 Y550 G01 Z18 F50 X300 Y450 G00 Z50 X290 Y540 G01 Z18 F50 X300 Y550 X310 Y540 G00 Z50 X310 Y460 G01 Z18 F50 X300 Y450 X290 Y460 G00 Z50 X250 Y500 G01 Z18 F50 X350 Y500 G00 Z50 X260 Y490 G01 Z18 F50 X250 Y500 X260 Y510 G00 Z50 X340 Y510 G01 Z18 F50 X350 Y500 X340 Y490 G00 Z50 X290 Y560 G01 Z18 F50 X290 Y580 X310 Y560 X310 Y580 G00 Z50 X380 Y510 G01 Z18 F50 X360 Y510 X360 Y490 X380 Y490 G00 Z50 X360 Y500 G01 Z18 F50 X375 Y500 G00 Z50 X310 Y428 G01 Z18 G03 X290 Y428 R10 G01 X310 Y422 G02 X290 Y422 R10 G00 Z50
22. 22 | P a g e X220 Y510 G01 Z18 F50 X225 Y490 X230 Y500 X235 Y490 X240 Y510 G00 Z50 X0 Y0 M30 FIG.2D DESIGN OF MAP MADE BY ABOVE PROGRAM 4.5 2D&3D DESIGN SNAPSHOTS-
23. 23 | P a g e FIG. 3D DESIGN OF MAP (MATERIAL RED PAINTED ABS) FIG. 3D DESIGN OF MAP (MATERIAL BLUE PAINTED ALUMINIUM)
24. 24 | P a g e 5 COST OF MATERIALS- 1. RED PAINTED ABS(Acrylonitrile-butadlene-styrene)= ABS (acrylonitrile- butadlene-styrene) is a low-cost engineering thermoplastic that is easily machined, fabricated and thermoformed. This thermoplastic material has excellent chemical, stress and creep resistance. ABS offers a good balance of impact, heat, chemical and abrasion resistance, dimensional stability, tensile strength, surface hardness, rigidity and electrical characteristics. Price/kilo- 0.25 Weight g/cm^3- 1.07 2. BLUE PAINTED ALUMINIUM- Aluminum is lightweight, durable, malleable and corrosion- resistant. This metal is widely used in the aerospace, transportation and construction industries.