Laboratory Manual for TA202A

Manufacturing Processes II

Prepared by:
Dr. Mohit Law, ME, IITK
[email protected]

Contributions by:
Mr. Karthik R, Mr. Pankaj Deora, Mr. Anurag Singh, Mr. Arijit Roy, Mr.
Govind Sahu, Mr. Pulkit Jain, Mr. Subhash N, and Mr. Srijan Bharati -
members of the Machine tools dynamics laboratory (MadLab), IITK

January 2020
 TA-202: Manufacturing Processes II – Schedule of labs for 2019-20, 2nd Semester

Introduction to machines and Project work

processes; Lab exercises; Formation Final project
Project drawing report must be submitted in week 6 to
of project groups; Finalization of evaluation
begin project work.
ideas; Preparation of detailed period
project models and drawings. Mid-term project evaluation during week 9.

Day Week 1 2 3 4 5 6 7 8 9 10 11 12 13
17th - 7th -
Mondays 6/1 13/1 20/1 27/1 3/2 10/2 22nd 24/2 2/3 15th 16/3 23/3 30/3 MU3
Feb Mar
Tuesdays 7/1 14/1 21/1 28/1 4/2 11/2 25/2 3/3 17/3 24/3 31/3 7/4
13th – 17th
Wednesdays 8/1 15/1 22/1 29/1 5/2 12/2 26/2 4/3 18/3 25/3 1/4 8/4 April; during
Mid Mid
lab hours
Thursdays 9/1 16/1 23/1 30/1 6/2 13/2 Sem 27/2 5/3 Sem. 19/3 26/3 MU2 9/4
Exam Recess
Fridays 10/1 17/1 24/1 31/1 7/2 14/2 28/2 6/3 MU1 27/3 3/4 MU4

MU1: In lieu of the lab you will most-likely miss on account of a Gymkhana holiday on 20th March for Techkriti there will be a make-up lab for the Friday
batch on Saturday, 28/3/2020 from 9 am – 12 pm.

MU2: In lieu of the lab you will miss on account of a holiday on 2nd April for Ram Navami there will be a make-up lab for the Thursday batch on Saturday
4/4/2020 from 9 am – 12 pm.

MU3: In lieu of the lab you will miss on account of a holiday on 6th April for Mahavir Jayanti, there will be a make-up lab for the Monday batch on Saturday
29/2/2020 from 9 am to 12 pm. 29/2/2020 has already been scheduled by DOAA as a working day that will follow Monday’s schedule. Hence, the last lab for
Monday’s batch will actually be 30/3/2020.

MU4: In lieu of the lab you will miss on account of a holiday on 10th April for Good Friday there will be a make-up lab for the Friday batch on Saturday
11/4/2020 from 9 am – 12 pm

1
General set of instructions for TA202 labs – read these very carefully

1. Safety first: since this course involves laboratory exercises with machines, students must
always practice the following safety procedures:
a. All students must come to the laboratory in shoes.
b. No student must wear loosely fitting clothes – these can get caught in rotating
machinery.
c. Students with long hair must tie their hair.
d. Students must take permission of the Lab Staff/Tutor before handling any machine.
e. Students must ensure that the floor around the machine they are operating is dry and
not oily to avoid slipping.
f. Students must not lean on any machine in operation.
g. When operating machines, students must wear safety glasses and gloves as
necessary. All students will be issued an apron, a set of safety glasses, and a set of
safety gloves. Students not wearing aprons will not be permitted to work on any
equipment.
2. Discipline also first: Lab runs from 2 – 5 pm. Please make sure you are in the TA202A labs by
1:50 pm. Those students who turn up after 2:05 pm will be marked absent from the day’s
exercise and will be given a ‘0’ for that exercise. Students will also loose a component of the
grade reserved for lab attendance if they are being marked absent on account of being late.
Guides/TAs/Tutors reserve their right to also deny students entry, if the students are late.
3. Printing a copy of this manual is not necessary and is discouraged. Copies can be issued from
the stores in the lab.
4. Students must handle all equipment in the lab with care.
5. While working on their respective projects, students may issue instruments and tools from
the tool room by depositing their ID card. ID cards will be returned on the safe return of
tools/instruments borrowed.
6. Power to the machines will be turned off 10 minutes before the end of the laboratory session
to allow students to return the tools/instruments they may have borrowed.
7. Students are required to clear off the chips from the machine they were using/operating and
lubricate the guides etc. at the end of the lab session.
8. Lab exercises 4 – 5 will require at least three students in every group to bring their laptops to
the lab. These exercises are to be conducted on the student’s own laptop during the lab. For
further instructions, please read the ‘Instructions for lab exercises 4 – 5’ section.
9. Students must pre-install the software necessary to complete the lab exercise 4 – 5. Links to
download the software to be used are provided in the ‘Download software for lab exercises’
section.
10. In the case any student misses any of the lab exercises 3 – 5 for valid reasons (duty leave,
medical leave, other valid reasons), those students must make up for the exercise within the
same week by joining another section. Please discuss this with the Instructor. If making up for
the exercise is not possible in the same week, students must contact the Instructor to work
out alternatives. If the student does not reach out to the Instructor to make up for a missed
exercise(s), even with valid reasons for missing the exercise, the student will be awarded a ‘0’
grade for the exercise(s) missed. In the case that a student has missed a lab exercise and has
no valid reason for missing the exercise(s), that student will be awarded a ‘0’ for that exercise.
No make-up of the missed exercise(s) will be permitted to such students.

2
Organization of this manual

Part A of this manual provides an overview of the lab exercises and part B details the exercises.

Please note

Since the manual spans 300+ pages, lets save some trees. Do not print the manual. Students are not
expected to possess a hard copy of the manual. Copies of this manual will be provided to you in the
labs, which must be issued from and returned to the stores in the labs.

3
Part A

4
Contents
General set of instructions for TA202 labs – read these very carefully .................................................. 2
Organization of this manual .................................................................................................................... 3
Please note.............................................................................................................................................. 3
Part A....................................................................................................................................................... 4
Overview of the lab and lab exercises for TA202A ................................................................................. 6
Lab exercise 1 and 2: Introduction to machines and machining processes ....................................... 7
Lab exercise 3: Assembling, printing with, and disassembling a 3D printing machine ...................... 7
Lab exercise 4: CAD – computer aided design .................................................................................... 7
Lab exercise 5: CAM – computer aided manufacturing + Arduino board-based DC motor control .. 7
Lab exercise 1 and 2: Introduction to machines and machining processes ........................................... 8
Turning on a lathe machine ................................................................................................................ 9
Milling machine................................................................................................................................. 11
Drilling machine ................................................................................................................................ 12
Lab exercise 3: Assemble + disassemble 3D printers (5% of grade) ..................................................... 13
Common instructions for lab exercises 4 and 5 .................................................................................... 14
Download software for lab exercises.................................................................................................... 15
Lab exercise 4: Computer aided design - CAD (5% of grade)................................................................ 16
Grading:............................................................................................................................................. 16
Lab exercise 5 – Part A: Computer aided manufacturing – CAM (5% of grade) ................................... 17
CAM for CNC machines ..................................................................................................................... 17
CAM for 3D printing .......................................................................................................................... 17
Grading.............................................................................................................................................. 18
Lab exercise 5 – Part B: Arduino board-based DC motor control (5% of grade) .................................. 19
Grading.............................................................................................................................................. 20
Note .................................................................................................................................................. 20
Instructions for submitting your project reports to start your project work ....................................... 21
General instructions for your projects: ............................................................................................. 21
Specific instructions for your project reports to be submitted before start of work ....................... 21
Instructions for preparing and submitting final project reports........................................................... 22
Final project evaluation metrics: ...................................................................................................... 22
Project report expectations: ............................................................................................................. 22
Log Sheet - To be submitted by Individual Students ............................................................................ 23
List of material available in the labs for you to use for your projects: ................................................. 24
Hand tools and measuring equipment you might encounter in the lab .............................................. 25
Part B ………………………………...................................................................................................................31

5
Overview of the lab and lab exercises for TA202A

TA202A is a lab-based course, with an emphasis on experiential learning, i.e., learning by doing and
making. Students, on being introduced to the working of machines, and on completion of certain lab
exercises, are expected to make a project in the lab during the semester. There will be five lab
exercises dedicated to introducing the working of machines and equipment to be used by students in
the lab during the semester. Each exercise will take place in one turn of the lab, i.e., in one week.
Hence, the first five weeks will be spent in exercises and preparatory work for the project, and the
remaining seven weeks will be dedicated solely for project work.

The project that students are expected to make in groups, consists of conceptualizing a
device/product/task, followed by designing the parts and making drawings for manufacturing those
parts, followed by planning of machining and other operations, and fabrication of the components,
including 3D printing some parts, followed by controlling some parts using a programmable board and
a motor, and finally, assembly of the device/product. A detailed project report must be submitted
during the final evaluation of the completed project. This report should contain general descriptions
of the completed project, design details, detailed drawings, and assembly drawings, followed by
suggestions for improvements, if any, and any other information the students think is important.

Each project must necessarily have at least one part that is 3D printed and one part that is made on
the CNC machine. Each project must also use the Arduino kit supplied to the group.

An outline of the week-wise lab schedule is:

Lab Activity Milestone Grades*

Intro. to machines and -

1 -
machining processes

Intro. to machines and Groups formed. Groups to -

2 machining processes. Assign brainstorm about ideas as
groups & guides homework

Assemble + Disassemble 3D Discussion on feasibility of 5% for the exercise + 1% for the project ideas
3
printers. project ideas conceptualize

CAD exercise + project 5% for the exercise + 1% for the quality of the project idea
4 Finalization of project idea
discussions

Groups to demonstrate 10% for the exercises + 3% for showing at least six 3D
CAM exercise + Arduino exercise
5 progress in modelling and models of the parts to be used in project, with three part
+ project discussions
drafting drawings of components

6 Start of project work Submit project files 5% for complete project file

6– There will be a mid-term project 10% for demonstrable progress made in the project.
Project work
13 evaluation during week 9

13 Final project evaluation See details provided later 22.5%

* Lab grades will also include 2.5% for attendance, and 10% based on your guide’s evaluation of your individual progress

An overview of the five lab exercises is provided below, and detailed instructions for all exercised are
provided in subsequent sections of this manual.

6
Lab exercise 1 and 2: Introduction to machines and machining processes
Emphasis in this lab and course is to use secondary manufacturing processes such as machining,
traditional and not, to make parts for the respective projects. Traditional manufacturing processes
that students will be introduced to in the labs are:

• turning (to make round parts)

• milling (to make parts of other shapes)
• drilling (to make holes)

Above processes will be introduced to students on manually operated machines, and on machines
controlled through computers, called Computer Numeric Controller machines, or CNC machines.
Students will also be expected to operate machines on their own to make parts necessary for their
projects. Students will be provided training before being allowed to use the machines on their own.
Detailed instructions on what this exercise will constitute is provided later in this manual. The
objective of this exercise to introduce machines and machining processes to you by having you
make/observe how to make a spur/bevel gear and a L-clamp assembly. These parts are representative
of things you might use in your projects.

Lab exercise 3: Assembling, printing with, and disassembling a 3D printing machine

In addition to using conventional machine tools, manual and/or CNC, students will also be introduced
to additive manufacturing, i.e. 3D printing. In one lab exercise, each group of students will be given a
machine in a box and students will be expected to assemble the machine, and then again disassemble
the machine. This will constitute a lab exercise and is aimed at introducing concepts of assembly
following a detailed set of instructions. Students will also be expected to print at least one or more
parts for use in their respective projects. Parts to be printed will be made of PLA. Detailed instructions
are provided later in the manual.

Lab exercise 4: CAD – computer aided design

Since the goal of this lab-based course is to make something, and since students are expected to make
3D CAD models of their parts and assemblies, and since students may or not have been introduced to
CAD before, an exercise on CAD is planned in the labs. More on this later in the manual.

Lab exercise 5: CAM – computer aided manufacturing + Arduino board-based DC motor control
This will be a three-part exercise.

Parts 1 and 2: Since each project is required to have at least one part made on a CNC machine,
and at least one part made by 3D printing, a lab exercise on generating CNC codes (G codes)
for representative parts to be made on the CNC machine and on the 3D printer will be
conducted. This will be a two-part exercise, and detailed instructions are provided later in the
manual.

Part 3: Since this is the era of DIY (do-it-yourself), and since a lot of DIY projects involve use of
programmable boards to control motors and other things, students will be introduced to
controlling a DC motor using a programmable Arduino board. A kit including an Arduino board,
a motor driver, a battery pack, and a DC motor will be issued to each group of students. A lab
exercise will instruct the use of these things to drive the motor. Each group is expected to use
the kit provided to them in their projects to drive whatever the group deems fit. Detailed
instructions on the exercise are provided later in the manual.

7
Lab exercise 1 and 2: Introduction to machines and machining processes

For this exercise, the students will be divided into two sections (A and B) as below. Each section will
conduct one activity in one week, and the other activity in the week after. Each section will have
approximately 45 students divided into groups of 7 or more students in every group – depending on
the number of students doing the exercise on that day. Each group will be assigned a guide. Guides
are trained technical staff in the TA202A labs. Guides will introduce working of the turning, milling,
and drilling machines in the labs along with the kind of possible machining operations on each of the
machines. The objective of this exercise to introduce machines and machining processes to you by
having you make/observe how to make a bevel gear and a L-clamp assembly. These parts are
representative of things you might use in your projects. Hence, we think it best to demonstrate
machines through making parts that you will also make during your projects.

Activity
Week
Making a gear Making a L-clamp assembly
1 A B
2 B A

Students will not be trained to operate machines during this orientation, instead the objective is
simply to introduce the machines that the students will use when they will make parts to execute their
respective projects. Training to operate these machines will be provided by guides assigned to groups
when the respective groups must use the machines, i.e., week six onwards, when actual project work
will begin.

CNC machines will not be introduced in this lab exercise. Working of CNC machines will instead be
discussed in class. Moreover, since each group must necessarily make at least one part of their project
on a CNC machine, its working will be explained to students by their respective guides, as and when
the group needs to use the machine in the labs. This will happen week six onwards, when actual
project work will begin.

In general, machining is a secondary manufacturing process, and it is subtractive in nature, i.e., the
part is given its final form by removing material. The mechanics of metal removal are complex in
nature and studying cutting mechanics is beyond the ambit of this course. However, the general
principle of material removal is by providing a relative motion between the work material being cut,
and the cutting tool. This relative motion can be obtained by a combination of rotary and translational
movements of either the tool or the workpiece, or both. Machine tools, in general, provide two kinds
of relative motions. The primary motion is responsible for the cutting action and absorbs most of the
power required to perform the machining action. The secondary motion of the feed may proceed in
steps or continuously and absorbs only a fraction of the total power required for machining. When
the secondary motion is added to the primary motion, machine surfaces of desired geometric
characteristics are produced. The tool shears away material, i.e. material transitions from elastic to
plastic and shears/chips away resulting in a new surface. The kind of surface that is produced by the
operation depends on the shape of the tool and the path it traverses through the materials.

Having outlined the general principle of material removal in machining, an overview of the machines,
their parts, and the possible machining operations on each of the machines is discussed below for the
benefit of those interested. Though there are plenty of types of machines and machining operations,
this lab, and hence this manual, will primarily involve the use only of turning, milling and drilling
processes, and as such, only these are outlined below.

8
Turning on a lathe machine
A schematic of a typical manually operated turning machine, also known as a lathe machine, is shown
below. Your guide will explain to you the working principle of this machine and will also outline the
function of different major components of the machine.

Fig. 1 Schematic of a lathe machine

Lathe machines are primarily used to make round parts. When the workpiece is rotated about an axis
and the tool is traversed in a definite path relative to the axis, a surface of revolution is generated.
When the tool path is parallel to the axis, the surface generated is a cylinder - as in straight turning or
boring operations. Turning machines can also be used for hole making, i.e. drilling. An overview of
some possible machining operations on the lathe machine is shown below. Your guide will provide
you an overview of some of these machining operations.

Fig. 2 Schematic of some possible machining operations on the lathe machine. Figure source:
Kalpakjian and Schmid’s book

9
Of all the possible machining operations on a lathe machine, straight turning, shown above is the most
common, and the tool used to perform this operation, with all its geometry is shown in the schematic
below. Your guide may demonstrate this geometry to you in the lab.

Fig. 3 Typical tool geometry for a turning tool. Figure source: Kalpakjian and Schmid’s book

Lathe machines, as well as all other machines can be operated over a range of feeds, speeds, and other
cutting parameters. Selection of these parameters is a function of the material being cut. More about
this will be discussed in class.

10
Milling machine
A schematic of a typical manually operated milling machine is shown below. Your guide will explain to
you the working principle of this machine and will also outline the function of different major
components of the machine.

Milling machines are usually used to make parts with varying shapes. Milling is also a multipoint
cutting operation as opposed to turning, which is usually only a single point machining operation. In
plane milling, the cutter revolves and moves over the work piece as shown. The axis of the cutter is
parallel to the surface generated.

Fig. 4 Schematic of a milling machine

An overview of some possible machining operations on milling machines is shown below. Your guide
will provide you an overview of some of these machining operations. The milling machine will also be
used in this lab for making gears using form cutters as shown below.

Fig. 5 Schematic of some possible machining operations on the milling machine. Figure source:
Kalpakjian and Schmid’s book

11
Drilling machine
A schematic of a typical manually operated drilling machine is shown below. Your guide will explain to
you the working principle of this machine and will also outline the function of different major
components of the machine. Pay attention to the continuously variable speed transmission
mechanism of this machine. It is interesting and different than the speed changes in the turning and
milling machines.

In drilling, the drill may turn and be fed into the workpiece that is clamped in the vice on the machine.
Drilling may also be performed on a lathe machine, in which the workpiece may revolve while the drill
is fed into it.

Fig. 6 Schematic of a drilling machine

An overview of some possible machining operations on drilling machines is shown below. Your guide
will provide you an overview of some of these machining operations, and will also show you the
geometry of typical drills.

Fig. 7 Schematic of some possible machining operations on the drilling machine. Figure source:
Kalpakjian and Schmid’s book

Having introduced the general operations possible on the turning, milling and drilling machines,
specific procedures and the steps involved in making a spur/bevel gear and the steps involved in
making a L-clamp assembly are detailed in part B of this manual.

12
Lab exercise 3: Assemble + disassemble 3D printers (5% of grade)

The goal of this lab exercise is to assemble a 3D printer followed by disassembling the same. Each
group of students will be given a machine in a box and will students will be expected to assemble the
machine, and then again disassemble the same machine – all within three hours. This will constitute
a lab exercise and is aimed at introducing concepts of assembly following a detailed set of instructions.

Please read these instructions carefully before start of this exercise:

1. This exercise is worth 5% of your grade.

2. For a full grade, the assembly and disassembly must be successfully completed with the
stipulated three hours of lab time. No extra time will be provided.
3. DO NOT TURN ON THE MACHINE. This is written in CAPS for a reason. If machines are turned
on with the wrong electrical connections made by the students, it may damage the machine.
Hence students should not turn on the machine. If any group turns on the machine, that group
will be awarded a ‘0’ for the exercise.
4. On successful assembly of the machine, the students must have the assembly checked by their
assigned guide/TAs/Tutor.
5. Once the guide assesses the assembly and is satisfied that the assembly is complete, students
must proceed with carefully disassembling the machine and putting back all components in
their respective pouches/boxes.
6. Successful completion of the exercise also includes:
a. no damage to any of the parts
b. no missing screws or any other parts
7. The guide/Tutor will asses the disassembled machine in the box, and:
a. if any screw is found to be missing, 1% will be deducted from all members of the group
for every missing screw
b. if any part is found to be damaged due to mishandling etc., depending on the criticality
of the part, the guide/TAs/Tutor may penalize all students in the group anywhere
between 0% - 5% of the grade.
8. If the group cannot complete this task in time, but has completed the assembly process – a
grade of 2.5% will be assigned to all students in the group, i.e. 2.5% will be deducted.
9. 3D printing will be demonstrated to the students on a separate pre-assembled machine during
this exercise. Each group will have the opportunity to print parts for their respective projects
and may operate the machines at a later stage during the semester.

Students are requested to be careful during this exercise. The disassembled machine in the box will
serve as the starting point for the lab exercise to be conducted on subsequent days. Furthermore, the
same 3D printers will be used during the lab for printing parts necessary for projects. Hence, further
care is encouraged during the exercise.

13
Common instructions for lab exercises 4 and 5

Please carefully note the following:

1. Lab exercise 4 is a fully computer-based exercise, and lab-exercise 5 is partly computer-based.

2. Lab exercise 4 is worth 5% of your grade, and lab exercise 5 is worth 10% of your grade. These
exercises must be done within lab hours only, i.e. the exercise must be started and completed
during the allotted three lab hours. Students who may have attempted the exercise before
coming to the labs, must repeat the exercise afresh in the lab. The guides/TAs/Tutors will
monitor this.
3. At least three students from every group are expected to bring their personal laptops with
pre-installed software for conducting these exercises in the labs.
4. Three plug points per group will be provided to help charge laptops as necessary.
5. If, for whatever reason, software necessary to conduct labs has not been pre-installed on the
laptops, i.e. pre-installation should be complete before coming to the labs, and if it is not,
students will be penalized at the rate of 2% of their grade.
6. Exercises have been designed such that they can be easily completed within the allotted three
hours. Yet, if student groups are not able to complete the exercise, student groups will be
graded based on what they have successfully completed within the allotted three hours.
Details for grading for each exercise is detailed in the relevant section for that exercise.

14
Download software for lab exercises

Please download and install the following software before coming to the labs

Lab Software Download link System requirements

4 CAD: Autodesk https://www.autodesk.in/products/inventor/overview? https://knowledge.autodesk.com/support/inventor-
Inventor referrer=%2Fproducts%2Finventor%2Foverview#0 products/troubleshooting/caas/sfdcarticles/sfdcarticles/System-
Professional 2020* requirements-for-Autodesk-Inventor-2020.html
5 CAM for CNC: https://www.autodesk.com/products/fusion- If you can install the above software, your system is fine to handle
Autodesk Fusion 360/students-teachers-educators these too
360*
CAM for 3D https://craftbot.com/craftware/
printing: Craftware
5 Arduino https://www.arduino.cc/en/Main/Software

*Select the free trial version, and the user category of a student or a teacher. Follow the instructions. Make sure to check for compatibility of your laptop
with the system requirements.

15
Lab exercise 4: Computer aided design - CAD (5% of grade)

Since the goal of this lab-based course is to make something, and since students are expected to make
3D CAD models of their parts and assemblies followed by making part drawings to manufacture things,
and since students may or not have been introduced to CAD before, this exercise on CAD is planned
in the labs to introduce and orient students in the use of CAD.

Since students have already taken the TA101 course, this exercise will assume students are familiar
with ideas of sketching, projections, dimensioning, sectional views, etc., and as such this exercise will
not review those ideas.

This exercise is more like a tutorial, with explicit and detailed instructions provided below for students
to be able to successfully complete five tasks (i) make a Geneva driving; (ii) make a Geneva driven
wheel; (iii) Assemble the mechanism in an support bracket with shafts; (iv) in the assembly also make
a pair of bevel gears; (v) make a part drawing. Students should have all tasks assessed by the
guide/TAs/Tutor. Grades will be assigned for each task.

An overview of the parts, assembly and drawing to be made is shown below:

Grading:
1. Geneva driving wheel (successful completion is worth 1%),
2. Geneva driven wheel (successful completion is worth 1%),
3. Assemble the mechanism in a support bracket with shafts (successful completion is worth 1%),
4. in the assembly also make a pair of bevel gears (successful completion is worth 1%), and
5. Making a part drawing (successful completion is worth 1%)

This exercise is designed such that it can be easily completed within the three hour lab duration. If any
group finishes before time, that group is expected to work on their respective project. If any group of
students is unable to finish this lab exercise in time, grades will be assigned for the tasks completed.
No extra time will be permitted.

The tutorials provided in part ‘B’ are self-explanatory. Please follow all steps shown for successful
completion of this exercise.

16
Lab exercise 5 – Part A: Computer aided manufacturing – CAM (5% of grade)

Since each project is required to have at least one part made on a CNC machine, and at least one part
made by 3D printing, a lab exercise on generating CNC codes (G codes) for representative parts to be
made on the CNC machine and on the 3D printer will be conducted. This will be a two-part exercise.
One part will involve a CAM exercise for milling the driven wheel of the Geneva mechanism, and the
other part will involve generating a G code to 3D print a spur gear.

Numerical controlled machines are more accurate than manually operated machines, and can produce
components more uniformly, faster and in the long-run tooling costs are smaller but the initial
investment is higher. Numerical Control (NC) involves a system in which actions are controlled by
direct insertion of numerical data. The system automatically interprets symbolic instructions to
control machine tools and other manufacturing systems. Symbolic instructions or the numerical data
required to produce a part is called a 'part program'. The CNC machine, and the 3D printer, are both
numerically controlled. Hence, this exercise is geared towards making such ‘part programs’ to control
these machines to make the desired parts.

CAM for CNC machines

Making a part program starts with a CAD model for the part. In the case of CNC machines, this is
followed by selection of the tools required to make the part, defining cutting parameters, and then
selecting a tool path to be followed. Modern ‘part-programming’ methods use advanced software
tools to do all this. Since your project will require you to make a part on the CNC machine, this lab
exercise will guide you through the requisite steps in making a part program using ‘Autodesk Fusion
360’ – a modern CAM software. The part for which the G code is to be generated is shown below.
Detailed steps are provided in the tutorial. The tutorial provided is self-explanatory.

CAM for 3D printing

In the case of controlling 3D printing machines, we will also start with the CAD model of the part to be
printed. This will be followed by defining parameters for printing speed, layer height, and also the
internal constructional details of the part to be printed. The part for which the G code is to be
generated in this lab exercise is shown below. There are several mechanisms for 3D printing. In this
lab we will use the ‘Fused deposition modelling – FDM’ type. An overview of additive manufacturing
processes will be discussed in class. The lab exercise is simply to outline the detailed steps involves in
generating G codes for the part to be printed. The tutorial provided is self-explanatory.

17
Grading
This lab-exercise is worth 5% of your grade:

• 2.5% for the CAM for the CNC, and

• 2.5% for CAM for the 3D printer.

This exercise is designed such that it can be easily completed within the three hour lab duration. If any
group finishes before time, that group is expected to work on their respective project. If any group of
students is unable to finish this lab exercise in time, grades will be assigned for the tasks completed.
No extra time will be permitted.

18
Lab exercise 5 – Part B: Arduino board-based DC motor control (5% of grade)

Since this is the era of DIY (do-it-yourself), and since a lot of DIY projects involve use of programmable
boards to control motors and other things, students will be introduced to controlling a DC motor using
a programmable Arduino board. A kit including an Arduino board, a motor driver, a battery pack, and
a DC motor will be issued to each group of students. This lab exercise will instruct the use of these
things to drive the motor. Each group is expected to use the kit provided to them in their projects to
drive whatever the group deems fit.

An overview about Arduino, sourced from: https://www.arduino.cc/ is provided below.

What is Arduino?

Arduino is an open-source electronics platform based on easy-to-use hardware and software. It's
intended for anyone making interactive projects.

What is an Arduino board?

Arduino senses the environment by receiving inputs from many sensors, and affects its surroundings
by controlling lights, motors, and other actuators.

Which board will you use?

Arduino Uno. This is a microcontroller board. It has 14 digital input/output pins (of which 6 can be
used as PWM - pulse width modulation outputs), 6 analog inputs, a 16 MHz quartz crystal, a USB
connection, a power jack, an ICSP header and a reset button. It contains everything needed to support
the microcontroller; simply connect it to a computer with a USB cable or power it with a AC-to-DC
adapter or battery to get started. You can tinker with your UNO without worrying too much about
doing something wrong, worst case scenario you can replace the chip for a few hundred rupees and
start over again.

What does the Arduino software do?

You can tell your Arduino what to do by writing code in the Arduino programming language and using
the Arduino development environment.

Overview of the lab exercise:

A schematic of what is expected in this lab exercise is shown below. You will write a program (detailed
instructions in the tutorial later). That program will instruct the Uno board, which will drive a DC motor
through a motor driver as shown. The motor driver will be powered by a 12 V DC battery pack as
shown below.

19
Grading
This lab-exercise is worth 5% of your grade:

• 1% for successfully making all electrical connections as per the schematic shown in the tutorial
• 2% for successfully using a light dependent resistor (LDR) and turn the motor ON and OFF by
interrupting the light falling on the LDR
• 1% for successfully controlling the speed of the motor, and
• 1% for successfully controlling the spin direction of the motor.

This exercise is designed such that it can be easily completed within the three hour lab duration. If any
group finishes before time, that group is expected to work on their respective project. If any group of
students is unable to finish this lab exercise in time, grades will be assigned for the tasks completed.
No extra time will be permitted.

Note
Kits have to be issued from the tool room, and must also be returned at the end of the exercise.
Students are liable to replace any item that they may damage in this kit.

20
Instructions for submitting your project reports to start your project work
General instructions for your projects:
1. All projects must have at least one 3D printed part, and up to a maximum of two 3D printed
parts. If specific designs call for the use of more 3D printed parts, how many and which parts
to print is something you and your guide will negotiate.
2. All projects must have at least one part made on the CNC machine(s) - turning and/or
milling. Again, how many and which parts to make on the CNC machine(s) is something you
and your guide will negotiate.
3. All other parts to be made for your projects must be made on the conventional machines
available in the TA202 labs.
4. All projects must use the Arduino kit to be provided. You may use this to do whatever you
like in the project. The kit includes:
• one DC motor (max speed of 30 rpm, and max torque of 1 Nm);
• two motor driver (one has a 1.5 Amp current rating, and the other is of 15 Amp);
• one 12 V batter pack, one SMPS power supply, and
• one Arduino UNO board, and several cables and wires
5. If you like and need to, you may use additional motors and sensors as you deem necessary.
We will not provide these. You will have to make your own arrangements. Please have your
guides approve any additional items you may wish to use.
6. All groups are expected to have finalized their project ideas by week 4. By week 5, we expect
you to show us substantial progress in modelling and drafting of parts for your projects.
Substantial progress includes showing us (your guides) 3D isometric views of your projects
made in CAD. Remember that your guides are continually evaluating individual performance
in all groups, as well as overall group progress.

Specific instructions for your project reports to be submitted before start of work
For your interim project reports to be submitted in the labs during week 6 please note the following:

1. You are expected to make two copies of the reports. One to be submitted to the lab stores,
and another to be with you and your guides.
2. All reports should be spiral bound or in a flat file with a transparent front cover.
3. All reports should be structured as follows:
• A cover page introducing your group number, project title, names of all group
members, and your guide's name.
• The second page must necessarily be a detailed isometric view of the entire project
assembly. Please make sure to label all main parts.
• The third page must necessarily be the bill of materials - which is essentially a list of
the raw materials, sub-assemblies, intermediate assemblies, sub-components, parts,
and the quantities of each needed to make your project. The more detail, the better.
• Following pages must have details of sub-assemblies as appropriate and part
drawings - each on a separate page. All part drawings must be dimensioned
appropriately with tolerances and scales and materials to be used. You may also
specify on these drawings which parts you plan to make traditionally, which on the
CNC machine, and which on the 3D printer.
• You may include any sizing calculations, as appropriate.

Timely submission of complete reports carries a 5% grade. Groups without reports will be marked
absent for the day, and hence will receive a ‘0’ grade.

21
Instructions for preparing and submitting final project reports
Final project evaluation metrics:
22.5% of your final grade will be decomposed into:

• Successful working demonstration of project objectives: 7.5%. If some part of the project is
not functional and/or demonstrable, you will be penalized accordingly.
• Everyone in the project group knowing how everything in the project was made: 5%. This
will be gauged by questions from the Tutors.
• Quantum and complexity of project work: 5%. This will be gauged by how many parts were
actually made in the project, how many were recycled, how difficult it was to make the
marks that were actually made, and how difficult it was to control the motor(s) to drive the
mechanism(s) of interest.
• Completeness of project report: 5%

Project report expectations:

All groups will submit their final reports to us. Report should be compulsorily structured as follows:

1. Cover page: Should include the project title, group number, list of group members, name of
your project guide, and an updated isometric view of the project or a photo of the
completed project.
2. Project overview: This is the second page of the report. The overview should have only four
sentences. The first sentence should state the project objective. Second sentence should
state how many parts were actually manufactured. The third sentence should summarize
the cost of the project (see below for how to estimate the cost). The fourth sentence should
suggest improvements that could be made to the project. Word count for these four
sentences should not exceed 150 words.
3. This is to be followed by a table of contents.
4. This should be followed by isometric assembly drawings with part labelling.
5. This should be followed by detailing how you sized and selected the motor(s) you may have
used. This section may also include any other design calculations you may have carried out.
6. Then a list of parts. List of parts should list in a five-column format: part name; the quantity
of each part; material used for each part; if the part was manufactured/bought; if
manufactured, the final column should list the machining operations to make the part.
7. This is to be followed by: detailed part drawings for all parts that were manufactured.
Drawings should be with dimensions and tolerances, as necessary, and should state who
made it, what material the part was made of, and what the scale of the drawing is. If any of
the drawings are found to not meet our expectations and/or do not reflect the real
manufactured parts, 1% of your grade will be deducted.
8. Finally, discuss cost analysis for your project. For this, you may assume that the material cost
for steel used in your projects is Rs. 100/kg, for aluminium it is Rs. 350/kg, and for Delrin it is
Rs. 400/kg. You must also estimate how long it took to make parts on the drilling, milling,
turning, CNC, and 3D printing machines. The rates for these machines are: drilling - Rs.
75/hour; milling - Rs. 250/hour; turning - Rs. 150/hour; CNC - Rs. 500/hour; 3D printing - Rs.
100/hour. In your cost analysis, you may assume that the electric kit (that includes the
battery, SMPS, motor, board, drivers, etc.) we have supplied costs Rs. 1000. If you have
bought additional motors/sensors, include those costs too.

22
 Log Sheet - To be submitted by Individual Students

Group # Sec.

Name:-

Job Assigned

(1) No. of parts fully completed from the planned and approved main drawing. (As per index
submitted earlier)

S.N. Part Name Work done

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

(2) No. of parts assembled together

S.N. Names of parts assembled

1
2
3
4
5
6
7

23
List of material available in the labs for you to use for your projects:

24
Hand tools and
measuring
equipment you
might encounter
in the lab

25
26
27
28
29
Part B

30
Contents for Part B Page
number

Lab Exercise 1 and 2 …………………………………………………………………………………………………………… 32

• Part A: make a bevel gear...……………………………………………………………………………………. 33
• Part A: make a spur gear...……………………………………………………………………………………… 51
• Part B: make a L-clamp assembly……………………………………………………………………………. 69

Lab Exercise on CAD …………………………………………………………………………………………………………… 84

Lab Exercise on CAM …………………………………………………………………………………………………………… 256

• G code of CNC machined part ………………………………………………………………………………… 256
• G code for 3D printed part …………………………………………………………………………………….. 316

Lab Exercise on Arduino ….…………………………………………………………………………………………………. 335

31
 Lab exercise 1 and 2
Part A and B
Objective: to introduce machines and machining processes to
you by having you make/observe how to make a bevel gear and
a L-clamp. These parts are representative of things you might
use in your projects.

Structure of the lab: half of you will conduct one exercise in one
lab turn and then the other in the next lab turn.

Machine Tool IIT Kanpur

Dynamics Laboratory 32
Part A: Making a spur/bevel gear.
This section first describes the procedure to make
a bevel gear, followed by description of making a
spur gear.

Machine Tool IIT Kanpur

Dynamics Laboratory 33
Nomenclature of bevel gear

Machine Tool IIT Kanpur

Dynamics Laboratory 34
Calculation of standard straight bevel gear
1. Shaft angle, 𝛴 13. Outer cone angle, 𝛿𝑎 = 𝛿 + 𝜃𝑎
2. Module, 𝑚 14. Root cone angle, 𝛿𝑓 = 𝛿 − 𝜃𝑓
3. Pressure angle, 𝛼 15. Outside diameter, 𝑑𝑎 = 𝑑 + 2 ℎ𝑎 cos 𝛿
4. Number of teeth, 𝑧1 𝑎𝑛𝑑 𝑧2 16. Pitch apex to crown, 𝑋 = 𝑅𝑒 cos 𝛿 − ℎ𝑎 sin 𝛿
5. Pitch diameter, 𝑑 = 𝑧 𝑚 𝑏 cos 𝛿𝛼
17. Axial face width, 𝑋𝑏 =
sin 𝛴 cos 𝜃𝛼
6. Pitch cone angle, 𝛿1 = tan−1 𝑧1 , 2𝑏 sin 𝛿𝛼
𝑧2
+cos 𝛴 18. Inner outside diameter, 𝑑𝑖 = 𝑑𝑎 −
cos 𝜃𝛼
𝛿2 = 𝛴 − 𝛿1
𝑑2
7. Cone distance, 𝑅𝑒 =
2 sin 𝛿2
𝑅𝑒
8. Face width, 𝑏 ≤ 𝑜𝑟 10𝑚
3
9. Addendum, ℎ𝑎 = 𝑚
10. Dedendum, ℎ𝑓 = 1.25 𝑚
ℎ𝑓
11. Dedendum angle, 𝜃𝑓 = tan−1
𝑅𝑒
ℎ𝑎
12. Addendum angle, 𝜃𝑎 = tan−1
𝑅𝑒

Machine Tool IIT Kanpur

Dynamics Laboratory 35
Production drawing of a typical bevel gear

Machine Tool IIT Kanpur

Dynamics Laboratory 36
 Steps in making a bevel gear
Step 1: Identify Step 2: Mount the Step 3: Measure the Step 4: Drill a Step 5: Move to
the raw material cylindrical work piece diameter and turn it through hole the milling
in the chuck to size machine

Step 6: Mount the gear Step 7: Adjust the Step 8: Mount the Step 9: Cut the
blank in indexing head angle of the indexing cutter on to arbor gear teeth one at a … and, finally:
head shaft time

Machine Tool IIT Kanpur

Dynamics Laboratory 37
Step 1: Identify the raw material – a cylinder in
this case

Drawing of the bevel gear

Select the diameter of the blank slightly more than the maximum diameter of the gear (please
refer to the drawing)

Machine Tool IIT Kanpur

Dynamics Laboratory 38
 Step 1 continued: select a lathe machine

Coolant supply

Tool post
Head stock
Chuck Tail stock

Gear lever
Cross slide
Saddle
Lead screw
Saddle handle
Lathe bed

Machine Tool IIT Kanpur

Dynamics Laboratory 39
Step 2: mount the cylinder in the chuck

Self centering chuck

Jaw

Cylindrical
work-piece

Machine Tool IIT Kanpur

Dynamics Laboratory 40
Step 3: Measure the diameter, and turn it to size

(a) Measure the diameter (b) Turn cylinder down to

with a Vernier caliper size

Drawing of the bevel gear

(c) Machine the conical

surface by taper turning (d) Gear blank

Machine Tool IIT Kanpur

Dynamics Laboratory 41
 Step 4: Drill a through hole

(a) First perform center (b) Drill a pilot hole with a

drilling bigger drill

Drawing of the bevel gear

(d) Gear blank is ready to be

(c) Enlarge the pilot bore
loaded on the milling machine
with yet a bigger drill

All three drills are mounted in a drill chuck that is mounted in the tail stock of the machine

Machine Tool IIT Kanpur

Dynamics Laboratory 42
 Step 5: Move to a milling machine
Arbor support
Over arm
Column
Indexing head
Cutter
Arbor shaft

Bed

Cross slide handle

Vertical travel handle Base

Machine Tool IIT Kanpur

Dynamics Laboratory 43
Step 6: Mount the gear blank on the Indexing head

Chuck

Index plate

Sector arm Index pin

Gear blank mounted on chuck

Indexing head

Machine Tool IIT Kanpur

Dynamics Laboratory 44
Step 7: Adjust the angle of indexing head

≅400

Scale for setting the required angle

Indexing head inclined at ≅400

Drawing of the bevel gear

Machine Tool IIT Kanpur

Dynamics Laboratory 45
Step 8: Mount the cutter on the arbor shaft

Arbor shaft
Cutter

(a) Remove the arbor support, (b) Insert the cutter on to the
bearing bushes and spacers arbor shaft

Arbor support

Spacers
Bearing bush
(c) Insert the bearing bushes and
spacers back (d) Mount the arbor support back

Machine Tool IIT Kanpur

Dynamics Laboratory 46
Step 9: Cut the gear teeth one at a time

Index

One tooth has been cut

Index and cut all teeth similarly

Machine Tool IIT Kanpur

Dynamics Laboratory 47
Finally, Your bevel gear should look like this:

Machine Tool IIT Kanpur

Dynamics Laboratory 48
You will have used
Cylindrical
blank

Gear cutter

Drill chuck

Single point
cutting tool

Machine Tool IIT Kanpur

Dynamics Laboratory 49
 Recounting all the steps in making a bevel gear
Step 1: Identify Step 2: Mount the Step 3: Measure the Step 4: Drill a Step 5: Move to
the raw material cylindrical work piece diameter and turn it through hole the milling
in the chuck to size machine

Step 6: Mount the gear Step 7: Adjust the Step 8: Mount the Step 9: Cut the
blank in indexing head angle of the indexing cutter on to arbor gear teeth one at a … and, finally:
head shaft time

Machine Tool IIT Kanpur

Dynamics Laboratory 50
Part A: Making a spur gear.
This section describes the procedure to make a
spur gear.

Machine Tool IIT Kanpur

Dynamics Laboratory 51
Drawing of the gear

Machine Tool IIT Kanpur

Dynamics Laboratory 52
 Steps in making a spur gear

Step 1: Step 2: Mount Step 3: Measure Step 4: Drill a Step 5: Assemble Step 6: Mount the
Identify the the cylinder in the diameter, and through hole the gear blank in mandrel in the
raw material the lathe turn it to size a mandrel machine

Step 7: Turn the Step 8: Move to Step 9: Mount Step 10: Mount Step 11: Cut the
… and, finally:
gear blank down the milling the mandrel the driving dog gear teeth one
to size machine and the cutter for indexing at a time

Machine Tool IIT Kanpur

Dynamics Laboratory 53
Step 1: Identify the raw material – a cylinder in
this case

Machine Tool IIT Kanpur

Dynamics Laboratory 54
Then, the machine – a lathe

Machine Tool IIT Kanpur

Dynamics Laboratory 55
Step 2: Mount the cylinder in the lathe

Machine Tool IIT Kanpur

Dynamics Laboratory 56
Step 3: Measure the diameter, and turn it to size

Cutting
tool

Measure the
diameter with
Turned
a vernier
diameter
caliper

Machine Tool IIT Kanpur

Dynamics Laboratory 57
Step 4: Drill a through hole

(i) Center drill (ii) Drill a pilot hole (iii) Enlarge the pilot
bore with a bigger drill

All three drills are mounted in a drill chuck that is in turn mounted in the tail stock of
the machine

Machine Tool IIT Kanpur

Dynamics Laboratory 58
Step 5: Assemble the stepped gear blank in a mandrel

What was
turned earlier
Mandrel (will be supported
between centers) Nut

Spacer
Gear teeth will be
cut on this diameter

Machine Tool IIT Kanpur

Dynamics Laboratory 59
Step 6: Mount the mandrel in the machine

Live center mounted

in chuck (rotating)
Mandrel supported To be Dead center
between two turned (not rotating)
centers

Cutting
tool

Lathe drive dog (secured on to mandrel

with friction. Dog is butted against the
chuck jaw, wherefrom it is driven )

Machine Tool IIT Kanpur

Dynamics Laboratory 60
Step 7: Turn the gear blank down to size

Turned
down to size

Machine Tool IIT Kanpur

Dynamics Laboratory 61
Step 8: Move to the milling machine

Machine Tool IIT Kanpur

Dynamics Laboratory 62
Step 9: Mount the mandrel in the milling machine between centres
(like in the lathe) + mount the form cutter for cutting gear teeth

Mount the gear

form cutter in
the milling arbor
(disassemble +
assemble the
arbor as
Gear blank necessary)
mounted on the
mandrel
between centers

Machine Tool IIT Kanpur

Dynamics Laboratory 63
Step 10: Mount the driving dog for indexing the blank

Milling arbor
Gear tooth
form cutter
Driving dog
for indexing

Gear blank
Indexing mechanism mounted on a
(each gear tooth is cut mandrel
individually and then
the blank is indexed to
cut the next tooth)

Machine Tool IIT Kanpur

Dynamics Laboratory 64
Step 11: Cut the gear teeth one at a time

One tooth has been cut Three teeth

have been cut

Index

Machine Tool IIT Kanpur

Dynamics Laboratory 65
Your spur gear should look like:

Machine Tool IIT Kanpur

Dynamics Laboratory 66
You will have used

Lathe dog
Mandrel
Drill chuck
Your gear!

Gear
cutter
Live
center Spanner
Cutting Drills Dead
tool (lathe) center

Machine Tool IIT Kanpur

Dynamics Laboratory 67
 Recounting all the steps in making a spur gear

Step 1: Step 2: Mount Step 3: Measure Step 4: Drill a Step 5: Assemble Step 6: Mount the
Identify the the cylinder in the diameter, and through hole the gear blank in mandrel in the
raw material the lathe turn it to size a mandrel machine

Step 7: Turn the Step 8: Move to Step 9: Mount Step 10: Mount Step 11: Cut the
… and, finally:
gear blank down the milling the mandrel the driving dog gear teeth one
to size machine and the cutter for indexing at a time

Machine Tool IIT Kanpur

Dynamics Laboratory 68
Part B: Making of a L-Clamp

Plate

Nut
Bolt

Hole

L clamp

Machine Tool IIT Kanpur

Dynamics Laboratory 69
Production drawing of L-Clamp

Dimensions are representative only.

Bill of material

Machine Tool IIT Kanpur

Dynamics Laboratory 70
 Steps in making a L-Clamp
Step 1: Identify raw Step 2: Mark location Step 3: Punch the Step 4: Move to Step 5: Mount drill
material for the hole marked location drilling machine chuck and drill

Step 6: Clamp the vice Step 6: Adjust the Step 7: Drill holes Step 8: Assemble
on the work table, and table position one at a time … and, finally:
parts
work-piece in the vice

Machine Tool IIT Kanpur

Dynamics Laboratory 71
Step 1: Identify raw material

Machine Tool IIT Kanpur

Dynamics Laboratory 72
Step 2: Mark location for the hole
Mark using the Height gauge

Base plate
Drawing of L Clamp

Location of
the hole

Height gauge Work-piece after marking

Note: Similar procedure should be followed for plate

Machine Tool IIT Kanpur

Dynamics Laboratory 73
Step 3: Punching marked location
Hammer

Center punch

Anvil
Punching

Work-piece after punching

Machine Tool IIT Kanpur

Dynamics Laboratory 74
 Step 4: Move to a drilling machine
Belt and pulley inside guard Spindle speed control

Column Feed handle

Spindle

Drill chuck

Table height adjustment

assembly
Work table

Base

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Dynamics Laboratory 75
Step 6: Mount drill chuck and drill
Drill chuck Mounting the
chuck onto the
spindle

Drill Insert the drill

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Dynamics Laboratory 76
Step 5: Clamp the vice on the work table, and
the work-piece in the vice

Clamping
the vice

Vice

Work-piece
T-slot Work table

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Dynamics Laboratory 77
Step 6: Adjust the table position

Machine Tool IIT Kanpur

Dynamics Laboratory 78
 Step 7: Drill holes one at a time

Burs
Removing the burs using flat file Clamp and plate after filing

Machine Tool IIT Kanpur

Dynamics Laboratory 79
Step 8: Assemble parts

Spanner

T-Spanner

Use nuts and bolts to assemble

Machine Tool IIT Kanpur

Dynamics Laboratory 80
Finally, your L-Clamp should look like this:

Plate

L-Clamp

Base plate

Machine Tool IIT Kanpur

Dynamics Laboratory 81
 Recounting all the steps in making L-Clamp
Step 1: Identify raw Step 2: Mark location Step 3: Punch Step 4: Move to Step 5: Mount drill
material for the hole marked location drilling machine chuck and drill

Step 6: Clamp the vice Step 6: Adjust the Step 7: Drill holes Step 8: Assemble
on the work table, and table position one at a time … and, finally:
parts
work-piece on the vice

Machine Tool IIT Kanpur

Dynamics Laboratory 82
You will have used

V-block

Vernier caliper

Drill (φ 12.5 mm)

Drill (φ 6.5 mm)

Drill (φ 8 mm)
Center punch

Center drill

Drill chuck

Height gauge
Hammer

Machine Tool IIT Kanpur

Dynamics Laboratory 83
 CAD Exercise

Contributed by:
Karthik R,
Senior Project Associate, MadLab, IITK

84
 CAD Exercise
Objective: To familiarize you with CAD by requiring you to make parts and
assemblies similar to what we expect you will need to make for your projects.
In this CAD exercise you will create parts required for a Geneva Mechanism driven
by a set of bevel gears and assemble all the parts. You will also learn to make a 2D
manufacturing drawing of a part.

85
 Preliminaries

Load the software

86
You might see an interface like this after loading the software
First, configure default units to SI

87
Click on File and then click on options

88
Click on “File” and then click on “Configure Default Template”

89
Change Measurement units to Millimeters and Drawing Standard to ISO,
and ‘Apply’ the changes. Your default units should now be SI.

90
Click on “Part”, to begin Part Modeling

91
Your interface should look like this
Most of the common tools like Undo(Ctrl+Z), Redo(Ctrl+Y),
Copy(Ctrl+C) and Paste(Ctrl+P) work the same here

This is your ribbon consisting of panels with different set of tools

Hovering the mouse over any tool will give you a detailed description

This is your model browser

This is your view cube and view panel tools

92
 Task 1
To make a Geneva Driven Wheel

93
Click on Start 2D sketch and select the XY plane

94
You will see the cross-hair

95
Click on “Circle” and click on the origin to set the center
You can enter the dimension directly.
Set the diameter to 56mm and press enter.

Enter the dimension here

96
Press “Esc” to exit circle mode.

97
Click on “Finish Sketch” to exit the sketch mode.

98
In 3D Modeling mode click on “Extrude”

99
Extrude the circle into a cylinder of 5mm in positive Z direction and click “OK”

Enter the dimension here

100
Click on “Start 2D Sketch” and select the top face of the cylinder

101
Click on “Rectangle (Two Point)” and click on the origin to begin

102
Enter the dimension 30mm and press Tab to switch to second dimension
Enter 30mm again and press Enter to create a square

Enter the dimensions here

103
Create a Circle (1) of diameter 60mm with the origin as the center

Circle(1)

104
Create Circle (2) with the top right corner of the square as the center
and a diameter of 60mm
Create Circle (3) with origin as center and click on the circumference of the circle (2)
to make them touching circles

Circle(2)

Circle(3)

105
Left click on your mouse and drag towards left to select all the shapes
Left drag selects every geometry that the selection box touches

106
Right click and select “Construction” to convert the selected geometries into
construction lines

107
Your drawing should look like this

108
Draw circle(4) concentric to circle(2) with a diameter of 50mm
Draw circle(5) concentric to the origin with a diameter of 8mm

Circle(2)
Circle(4)

Circle(5)

109
Click on “Rectangle (drop down)” and select “Slot (center to center)”

110
Click on the intersection of Circle(3) and X axis to set first center of the slot
Click on the right bottom vertex of the square to set the second center
Enter the slot width 6mm and press “Enter” then click “Finish Sketch”

Circle(3)

First center Second center

111
Click on “Extrude” and select “cut” to remove the selected profiles from the
existing model and click “OK”

112
 Click on “Circular (Circular pattern)”
Click on the “Extrusion2” from the model browser and then click “OK”

Extrusion2

113
Click on “Rotation Axis” and click on the hole circumference to define rotation axis

Hole circumference

114
Enter the Occurrence count 4 in the Placement box and click “OK”

Enter 4 here

115
Your model should look like this

116
Click on “File” and select “Save”

117
Enter the part name and click “Save”

118
This ends your task 1. Please show
your progress to your
guide/TA/Tutor. Proceed after.

119
 Task 2
Make a Geneva Driver Wheel

120
 Click on “New” icon, select “Metric” and then select “Standard(mm).ipt”

New

121
Click on Start 2D sketch and select the XY plane

122
Click on “Rectangle”. With origin as the first point, draw a 30mmx30mm square as shown
Click on “Circle” and draw Circle(1) of diameter 60mm with origin as the center
Draw Circle(2) of diameter 60mm with top right corner of the square as the center

Circle(2)

Square
30mmx30mm

Circle(1)

123
Left click on your mouse and drag towards left/right to select all the geometries(Square,
Circle(1) and Circle(2))
Right click and select “Construction” to convert the selected geometries into construction
lines

124
Create Circle(3) of diameter 70mm and Circle(4) of diameter 50mm, both concentric to
Circle(2)

Circle(4)

Circle(3)

Circle(2)

125
Click on “Arc (drop down)” and select “Arc - Center Point”

126
Select the origin as the center and draw an arc by clicking on the intersection points
between Circle(1) and Circle(4)

Circle(4)

Circle(1)

127
Your drawing should look like this now

128
Click on “Trim”

129
Click on the smaller circumference of circle(4) that is intersected by the Arc

Circle(4)

130
The part clicked on will be trimmed as shown below
Click on “Line” and draw a diagonal line between the top right and bottom left vertices
of the square

Diagonal line

131
Right click on the line and select “Construction” to change the line to Construction
line

132
Click on “Circle” and draw a circle (5) of diameter 8mm concentric to circle(2)
Draw circle(6) of diameter 6mm with center at the point of intersection of circle(2) and
diagonal of the square
Click on “Finish Sketch”

Circle (2)

Circle(5)

Circle(6)

133
Click on “Extrude” and select the crescent profile and the off-centered circle

Profile 1

Profile 2

134
Enter the Extrusion distance as 5mm and click on “+ (apply and create new extrusion)”

Enter the dimension here

135
Your first side will be extruded
Now select the entire profile except the central hole and click on “Flipped”

136
Your new extrusion will change the direction of extrusion
Enter the extrusion distance as 5mm and click “OK”

137
Your part should look like this

138
Click “File” and then click “Save”
Enter the part name and click “Save”

139
This ends your task 2. Please show
your progress to your
guide/TA/Tutor. Proceed after.

140
 Task 3
Make a Support Plate

141
 Click on “New” icon, select “Metric” and then select “Standard(mm).ipt”

New

142
Click on Start 2D sketch and select the XY plane

143
Click on “Line” and draw the sketch as shown below using lines
Click on “Dimensions” and add the dimensions as shown below

L2 (10mm)

L1 (105mm) L3 (95mm)

L4 (10mm)

L5 (40mm)

144
Click “ Extrude” and extrude the profile to a distance of 80mm
Click “OK”

145
Click on “Start 2D sketch” and select the face(highlighted below)

146
Ensure that the sketch orientation is the same as shown below
Click on “Circle and create a circle of diameter 8mm
Click on “Dimension” and click on the center of the circle and the vertical line then
click on a blank place to create the dimension

147
Double click the dimension to edit the value and set the value to 34mm
Add the dimension from the center of the circle to the horizontal axis and
edit the dimension to 40mm

34mm

Edit this dimension

to 40mm

148
Ensure that the dimensions are as shown below and click on “Finish Sketch”

149
Click “Extrude” and select the circle
Click on “Through All” to create a hole through the entire solid
Click “OK”

Circle to be selected
Through All

150
Click on “Rectangular Pattern”

151
Click on “Extrusion 2” in the model browser

152
Click on the “Direction 1” and select the edge as shown below
to create a pattern along the same direction
Click on “Flip” if the direction of pattern is not as shown
Enter the Distance 42.5mm in the distance box and click “OK”

Direction 1 Flip

Edge to be selected for pattern direction

Enter the distance of 42.5mm here

153
This is how the part should look

154
Click on “Start 2D sketch” and select the plane shown below

155
Click on “Circle” and draw a circle of 8 mm diameter
Click on dimension and add the dimensions as shown below
Click on “Finish Sketch”

26mm

Circle (8mm)

40mm

156
Click “Extrude” and select the circle to create a hole
Click on “Through all” and click “OK”

Through All

Circle to be selected

157
Click on “File”, select “Save” and save the part

158
 Task 4
Make a Shaft

159
 Click on “New” icon, select “Metric” and then select “Standard(mm).ipt”

New

160
Click on Start 2D sketch and select the XY plane

161
Click on “Line” and using lines, draw the sketch as shown below with dimensions
* Make sure to create a closed sketch by drawing all six lines (L1 to L6) as shown

L2 (5mm)

L3 (2mm)

L4 (1mm)

L1 (30mm) L5 (28mm)

L6 (4mm)

162
Click on “Revolve” and select the axis about which the profile is to be revolved

Axis

163
Click on “OK”

164
Click on “File”, select “Save” and save the part

165
 This ends your task 3 and 4 too.
Please show your progress to your
guide/TA/Tutor. Proceed after.

166
 Task 5
Assemble all the parts

167
Click on “File”, click on “New” drop down and select “Assembly”

168
Click on “Place” to place the parts in the Assembly

169
Select the “Support plate” and click on “Open”

170
Right click and select “Place Grounded at Origin” to fix the position of the part at the origin
Press “Esc”

171
Your screen should look like this once you have placed the part

172
Click on “Place”, select “Geneva driver” and click “Open”

173
Click on the screen where the part is to be placed and press “Esc”
Geneva driver will be placed in the assembly

174
Click on “Free Rotate” and rotate the Geneva driver in order to align it as shown below

Geneva driver

175
Click on “Constrain” and select the faces as shown below
Click “OK”

Face 1

Face 2

176
At this stage, your assembly should look like this

177
Click on “Constrain” select the axis of holes as shown below
Click “OK”
*The hole behind the Geneva driver may not be visible, hover the mouse
pointer around the hole in order to select the hole axis on the Support plate

Axis 1

Axis 2

178
At this stage, your assembly should look like this

179
You can now rotate the Geneva Driver Wheel about its axis
*Left click on the part and hold the mouse button. Now, move your mouse to rotate
the part

180
Click on “Place”, select “Geneva driven wheel” and click “Open”
Click on the screen where the part is to be placed and press “Esc”

181
Click on “Constrain” and select the two faces as shown below
Click on “OK”

Face 2

Face 1

182
Click on “Constrain” and select the axis of the holes as shown
Click “OK”

Axis 2

Axis 1

183
At this stage, your assembly should look like this

184
You will now be able to rotate and orient the Driven Wheel about it’s axis as shown
below

185
You can click on “View” and change View Style to “Shaded with Edges” for better visibility

186
Click on “Place”, select the “Shaft” and click “Open”

187
Click on the screen where the part is to be placed
Click at three different places on the screen as shown below and press “Esc”

188
Click on “Constrain” and select the axis of the shaft and axis of hole in the driven wheel as
shown
Click “OK”

Axis 2

Axis 1

189
If the shaft is inverted as shown, click on “Opposed” to set the orientation right
Click “OK”

Opposed

190
Check for orientation of Shaft 1

Shaft 1

191
Click on “Constrain” and select the two faces as shown below
Click “OK”

Face 1

Shaft 1

Face 2

Shaft 1
192
Click on “Constrain” and select the axis of Shaft 2 and axis of hole in the driver as shown
Click “OK”

Axis 2

Axis 1

Shaft 2

193
Click on “Constrain” and select the two faces as shown below
Click “OK”

Face 1

Face 2

Shaft 2

194
Click on “Constrain” select the axis of Shaft 3 and hole on the Support plate as shown
below

Axis 2

Axis 1

Shaft 3

195
Click on “Aligned” to get the orientation right
Click “OK”

Aligned

196
Click on “Design” and click on “Spur Gear” drop down
Select “Bevel Gear”

197
Click on “OK” and save the Assembly

198
Enter the file name and click “Save”

199
Enter the Module as 1.5mm
Enter Number of teeth as 20 for Gear 1 and 15 for Gear 2
Change Gear 2 to “No model”

No Model

200
Make sure the other values are as shown below

201
Click on “Calculation” and enter the values of Power as 100W and Speed as 1000rpm
Click “OK” and place the gear at required location by left clicking your mouse button

202
At this stage, your assembly should look like this

203
Click on “Start 2D Sketch” and select the top face of the Bevel gear(highlighted below)

204
Click on “Point” and click on the origin as shown below to draw a center point on the
face of bevel gear
Click “Finish Sketch”

Origin

205
Under “3D Model” tab, click on “Hole” and enter the hole diameter as 8mm
Click “OK”

Enter the Hole Diameter here

206
Click on “Constrain” and select the axis of Shaft 2 and hole axis of the Bevel Gear as shown
Click on “Aligned” to get the orientation right
Click “OK”

Aligned

Axis 2

Axis 1

207
At this stage, your assembly should look like this

208
Click on “Design” and select “Bevel Gear”
Enter Module as 1.5mm
Enter Number of teeth in Gear 1 as 20 and Gear 2 as 15
Change Gear 1 to “No Model” and Gear 2 to “Component”
Click “OK” and place the gear at required location by left clicking your mouse button

Component
No Model

209
At this stage, your assembly should look like this

210
Click on “Start 2D Sketch” and select the top face of the Bevel Gear 2(highlighted below)

211
Click on “Point” and create a point on Bevel gear 2 at the origin as shown below
Click “Finish Sketch”

Origin

212
Under the “3D Model” tab. Click on “Hole” and enter the hole diameter as 8mm
Click “OK”

Enter the Hole Diameter here

213
Click on “Constrain” and select the axis of Shaft 3 and Bevel Gear 2 as shown below
Click “OK”

Axis 2

Axis 1

214
Click on “Constrain” and select the two points of the bevel gears as shown below
Click “Ok”

Point 1 Point 2

215
At this stage, your Assembly should look like this

216
Click on “Constrain” and select the face of Shaft 3 and the top face of Bevel Gear 2
and as shown below
Click on “Flush” and click “Ok”

Face 2

Face 1 Shaft 3

217
Click on “Constrain” and select “Motion
Enter the Ratio as 20/15 and click on “Reverse”
Select the faces of two Bevel Gears as shown below and Click “OK”

Reverse

Enter the Ratio here

218
Click on “Constrain” and select “Motion”
Enter the Ratio as 1
Select the faces of Shaft 3 and Bevel Gear 2 as shown below and click “OK”

Face 2
Face 1

Bevel Gear 2
Shaft 3

219
Follow the exact same steps as given in the previous slide and give motion constrain to
Shaft 2 and Bevel Gear 1 keeping the Ratio as 1

Bevel Gear 1
Shaft 2

220
Give motion constrain to Shaft 2 and Geneva Driver Wheel keeping the Ratio as 1

Geneva Driver Wheel

Shaft 2

221
Holding the control key, select both Geneva driver and the driven wheel
Right click and select “Contact Set

222
Click on “Inspect” and select “Activate Contact Solver”
Now the Geneva Driven Wheel should move when you rotate Shaft 3
*Finally, save your assembly

Shaft 3

Geneva Driven wheel

223
This ends your task 5. Please show
your progress to your
guide/TA/Tutor. Proceed after.

224
 Task 6
To make a 2D manufacturing
drawing from a 3D part

225
Click on “New”, select “ISO.dwg” and click “Create”

226
This is what you should see. The default layout is an A3 sheet, which we want to
make into an A4 sheet.

227
Right click on “Sheet” and select “Edit Sheet”

Sheet

228
Select the required Sheet Size (A4) and Orientation (portrait)
Click “OK”

229
This is what you should now see. We will now bring in the “Support Plate” to make
manufacturing drawing for it.

230
Click on “Base”

231
Click on “Browse” icon

232
Select the required file and click “Open”

233
This is what you should see

234
Select the required Base View with the help of “View Cube”, set the scale(1:2 in this case)
Click “OK”
Note: 1:1, 1:2, 1:5 and 1:10 are standard scales generally used in Engineering drawings

View Cube

235
Click on the dotted border around the base view and drag it to the required location
in the sheet

Dotted Border

236
Click on “Projected”

237
Place the required views
Right click and select “Create”.

238
You may end up with something like this

239
To create Section View:
Click on “Section” and select the view from which you need the Sectional View

Select this view

240
Draw a line along which you need sectional view
*Make sure that the start point and the end point of the sectional line are outside the part
*Make sure that the sectional line passes through the center of the hole
Right click and select “Continue”

Start point

End point

241
Place the view and click “OK”

242
You may end up with something like this

243
To add Center Mark for the holes
Click on “Center Mark” and click on center points of the holes
*You should see a green dot when you hover your mouse around the hole indicating
center of the hole

Center Mark

Center points of the holes

244
To add Centerlines
Click on “Centerline”

245
Draw centerlines for holes as shown below
*While selecting the start and end points of the line, make sure to select midpoints as
shown below. You should see a green dot when you hover your mouse around the line
indicating the midpoint
Zoom In, if necessary

Start point

End point

246
Right click and select “Create” to create Centerlines

247
To give dimensions:
Click on “Annotate” and click on “Dimension”

248
Your drawing may look something like this after dimensioning

249
To add text in the drawing sheet
Click on “Text”

250
Select a location where you would like to place your text.
Type the text and click on OK

Click here, to select the location of text

251
Following the aforementioned steps add the text as shown below

252
Your drawing should look like this

253
Click on File and Save your drawing

254
 This is the end of this exercise. If
you’ve reached this far, well done.

255
 CAM Task A

Generate a G code for a part to be

CNC machined (milled)

Contributed by:
Pankaj Deora (Y16), MadLab, IITK

256
 CAM Exercise
Objective: to learn how to make a computer aided manufacturing (machining) program

using software. This program is otherwise known as a G code. The program can be

directly loaded on to the machine to command it to make parts that you need and want.

This example is representative of parts that you might need to make for your projects.

257
Preparatory steps

258
Load the software

259
In general, to generate a CAM program, you need a CAD file. The CAD file has features
and dimensions of the part to be made. In this exercise, the CAD file is provided to
you. To open the CAD file for the Geneva Wheel, click on “open” under “File ” tab.

260
Click on the ”Open from my computer”

261
Locate the file and click “Open”

262
The window should look like this

263
To start with the CAM exercise, click on “Manufacture” from the drop down as shown

264
Make sure that “Manufacture ” tab is selected

265
First we will setup the environment. To start with, click on the “setup” option

266
A box will appear on the right. This is where we define the stock (raw material size) for our model

267
We are going to perform milling operation. In the “operation type ”, make sure that “milling ”
option is selected.

268
Under the “stock” tab, select “Relative size box” under “mode” tab

269
Make all the entries shown in the circle below ‘zero’ because we don’t need any extra stock
for our work

270
Again go to “setup” and select the option shown under “orientation” option

271
Then select the top surface of the Geneva wheel by clicking on it

272
Now we have to define the work coordinate system (WCS) for the work-piece. For which, click
on the “Box Point” option

273
Click on the dot as shown. This will be the WCS and the G Code generated will be defined
relative to this coordinate system now. Ensure that WCS orientation as shown below. If yes,
Click “OK”.

274
You can now see that your setup is ready on the left side of the window. Now we will cut the
stock to manufacture the Geneva

275
Click on the “2D Adaptive clearing” under “2D” drop down. You can read about 2D adaptive
clearing by positioning the mouse cursor on it for a while

276
A box will appear. Click on “select” as shown. This is where we select the tool for our job

277
In the new window, scroll down to the end, and click on “Tutorial - Metric”. It will show all the
tools that we can select for the milling operation

278
Select a regular end mill with 10mm diameter as shown. Click “OK”

279
Disable the coolant by clicking on “Disable” under “coolant ” option

280
‘Feed and speed’ is explained on the next slide. Keep the values as is for now

281
If you had to, this is how you can define speeds and feeds

282
Click on the “Geometry ” tab. It asks us to select a pocket which is ‘nothing’ by default. For
selecting a pocket, click on the boundary of the wheel as shown

283
You can now see that a “chain” is selected.

284
Under “Passes” tab, enter the value “5mm” in the “optimal load” option. Optimal load on a tool
is the percentage of the tool that is engaged with the work-piece. You can read more about this
by placing the cursor on it

285
Check the “Multiple depths” box

286
Under “Maximum roughing stepdown” option, put a value of 3mm. Stepdown means that how
much part of the tool is engaged with the workpiece in the vertical direction (z-axis)

287
Uncheck the “Stock to leave” box. Click “OK”

288
This will generate a toolpath. You can simulate the tool path generated by clicking on
“Simulate” as shown in the next slide

289
290
Under “Mode” option, select “Tail”. This is only done for clarity

291
Check the “Stock” box

292
Click on the “Play” button to start the simulation. You can control the simulation speed by
dragging the pointer as shown in left or right direction

293
If you are able to successfully simulate this step, please show it to your
guide/TA/Tutor before proceeding further.

294
To cut the bottom part , we select a different strategy called ‘2D contour’ as shown

295
Again select the same 10mm diameter tool following the same steps defined earlier. Also ensure
that the coolant is disabled

296
Go to “Geometry” tab and select the contour as shown below

297
After selection, it will appear like this

298
Go to “Heights” tab and click on “selection” under “Top height” option

299
300
Select the top face of the wheel as shown

301
Under “Passes” tab, check “Multiple Depths” box

302
Again enter 3mm value under “Maximum Roughing Stepdown”

303
Uncheck “Stock to leave” box

304
Go to “Linking” tab and click on “Entry positions” as shown

305
Select a point on the wheel as shown. This is the point from where the tool starts entering into
the workpiece. Click “OK”

306
Click on the Setup as shown

307
Start the simulation

308
You can see the final part generated after cut. Now generate the G Code for the part
manufactured.

309
Click on “Post Process” tab as shown

310
In the new window that follow, give a program number as shown. Here it is given ‘1001’

311
Select “Milling ” as shown

312
Select a post processor. For our purpose, we select “Fanuc” as shown. Click “Post”

313
Save the code. To open the code generated, go to the folder where you saved the code and
right click on the file and click on ‘open with’ and select Notepad or MS Word.

314
Show the G code you have generated to
your guide/TA/Tutor. If you have
generated the G code successfully, your
exercise is complete.

Note that you will be expected to do

similar things for your project, in which
you must make one part on a CNC
machine using a G code that you will
generate using CAM
315
 CAM Task B

Generate a G-Code for a part to

be 3D Printed
Contributed by:
Srijan Bharati, Govind N Sahu, Pulkit Jain
MadLab, IITK

316
Objective
Generate a G-code to manufacture a gear using the 3D printing
machine. CAD model for the part will be provided to you.

317
About the Printer and method of 3D printing
• We will use the Fused Deposition Modeling (FDM) method of rapid
prototyping, i.e. 3D printing. There are other methods too. Those will
be discussed in class.
• The printer is a cartesian Printer (x-y-z)

318
About the printer

Cartesian Printer
1. X Direction
2. Y Direction
3. Z Direction
4. Filament
5. Extrusion Nozzle
6. Heated Platform
7. Printed Part

319
Printing Procedure

CAD file Slicing to G code 3D Printing Product

320
 At first, you must export the CAD model in a neutral format
• Go to file→ Export → CAD Format and select file type as STL files (*.stl)

321
Exporting the CAD model
• After selecting file type click on options to save the file with high
resolution.
• Select resolution as high and save the file
• A high resolution file makes for a better
printed product

322
Open the Craftware software and click on ‘Options’ to set the
printer properties in the software.

323
The procedure to slice to generate a G-code involves many
steps. Start with:
• Go to the Printer in the popup
window and put the following
properties of printer we will be
using – the same one you
assembled.
• Width (X) = 220 mm;
• Depth (Y) = 220 mm;
• Height (Z) = 250 mm;
• Offset (X) = 5mm;
• Offset (Y) = 5mm;
• Click on store to save
• Click Ok.
324
Next, click on ‘Add’ to import the saved .stl file.

325
Next, Click on ‘Drop’ and select the base surface.
We would like that we build from the base up.

326
Next, Click on the ‘Move’ button to move the part in the middle
(approximately). You can select any axis and move the part in that
particular direction.

327
Next, Click on the ‘Slice’ button and select ‘Switch to expert
mode’ if prompted and go to ‘Basic’. There are five steps (1-5)
to be followed now, detailed in the next slides

1. 4.

2.

3.
5.

328
1. Section: Resolution under the ‘Basic’ tab
• Set the ‘Extrusion width’ to 0.4 mm. This is determined by the nozzle diameter on the
machine you will use, which has a 0.4 mm opening.
• Layer Height is the Z axis resolution and defines thickness of each layer. Set this value
to be 0.2 mm. The finer this layer thickness, the better the printed product, but more
the time it will take.
• Draw speed controls the speed at which the filament is drawn from the spool. This
also governs the printing speed and quality. Set this value to be 60 mm/s.
2. Section: ‘Extruder’ under the ‘Basic’ tab
• Filament diameter helps software to calculate material flow. We will be using a
filament of diameter 1.75 mm. Set this value.
• Keep the ‘flow adjust’ at 100 %. If underflow or over flow occurs, flow adjust is used
to correct it
329
3. Section: Vertical Shell under the ‘Basic’ tab:
This section determines the properties of the vertical layer at the boundary of the part.
• Set the ‘Loop count = 6 loops’
• ‘Unlock’ the H and V Shell Thickness to manually set the top and vertical layer properties
• Set the ‘Vertical Shell Offset = 0 mm’; the ‘Perimeter Width = 100%’, and the ‘Perimeter Speed =
60%’

4. Section: Top/Bottom Shell under the ‘Basic’ tab:

This section determines the Properties of the Top and Bottom layer at the boundary of the part.
• Set the ‘Type = Parallel Lines’, and se the ‘Top and Bottom Layers = 6 (both)’
• Leave all the other parameters unchanged, i.e., keep them the same as in the screenshot shown
in the slide before last.

5. Section: Infill under the ‘Basic’ tab:

This section determines the properties for printing inside of the object.
• Set the ‘Type = Triangle Grid’; ‘Density/Width = 80% and 120 %’ and ‘Speed = 150%’
330
Next, Go to ‘Foundation’ and select ‘Brim’ and don’t change
the default values
Types
• Brim – Creates few loops at a
distance from the main object and
is useful to determine levelling
problems.
• Skirt – Creates an extra layer
connected around the perimeter of
the main object which helps better
sticking and prevents warping
when print cools down.
• Raft – Creates a support platform
on which the main object is
printed. Raft is used to prevent
warping, levelling problems and
unsticking of the print but
consumes more material.
331
 Next, go to the ‘Temperature’ tab, and

Set the following:

• Bed Temperature = 600 𝐶
• Head Temperature =
2150 𝐶

On completion of the above

steps:
• Click on slice button

332
If you’ve done everything correctly, you may now:
• In the bottom, move the Layer slider to view the printing simulation
• Click on Save button to save the G-code.

333
• Open the saved G-code in the note pad

• Done, this is the exercise!

• Congratulations!
• You will need to do something similar
when you actually make a G code to print
a part that goes into your project.

334
 Arduino board-based DC
motor control

Contributed by:
Mr. Srijan Bharati, Mr. Anurag Singh (Y16) and Mr. Arijit Roy, MadLab, IITK

335
Objectives:
• To be introduced to Arduino programming
• To program Arduino UNO to run a DC motor
and control its speed
• To program Arduino UNO to run a DC motor
with spin (direction) control
• To use a light dependent resistor (LDR) and
turn the motor ON and OFF by interrupting
the light falling on the LDR

336
Your kit includes:
Arduino Uno board Motor driver DC motor Light dependent
resistor

Jumper wires Resistors USB AB Cable 12 V battery

Your laptop with
Arduino software
installed

337
Arduino Uno pin diagram

• You will power the board

using the USB cable from
the laptop
• You will only control one
motor is this lab, and as
such, only pins 5, 6, 7 and
+5V will be used for
output and pin A5 will be
used for input in this
exercise

https://www.ntu.edu.sg/home/ehchua/programming/arduino/Arduino.html
338
 Motor driver pin diagram • You will power the board
5V VOLTAGE REGULATOR H BRIDGE DRIVER IC using 12 V battery supplied

OUTPUT INDICATOR LEDS

POWER INDICATOR LED

OUTPUT TERMINAL
15A MAX CURRENT
USE HEATSINK BEYOND 5A CURRENT

INPUT TERMINAL 12V DC

36V MAX, 18V SAFE LIMIT CONTROL INPUT PINS
(FROM LEFT TO RIGHT)
PWM : PULSE WIDTH CONTROL (UPTO 10 kHz)
INB : INPUT FOR ONE SIDE OF H BRIDGE
STABLIZATION CAPACITOR INA : INPUT FOR OTHER SIDE OF H BRIDGE
CS : CURRENT SENSE ANALOG OUTPUT
EN/DIAG : ENABLE ENTIRE DRIVER
GND : GROUND
+5V
https://www.instructables.com/id/Tutorial-for-VNH2SP30-Monster-Motor-Module-Single-/
https://www.st.com/resource/en/datasheet/vnh3sp30-e.pdf 339
Additional resources

• For more on how the Arduino board works, see:

https://www.ntu.edu.sg/home/ehchua/programming/arduino/Arduino.html

• For more on how the driver works, including what a H-bridge is, and what a PWM signal is, please see:
https://howtomechatronics.com/tutorials/arduino/arduino-dc-motor-control-tutorial-l298n-pwm-h-bridge/

• For more on how to use the motor driver used in the exercise: https://www.instructables.com/id/Tutorial-for-
VNH2SP30-Monster-Motor-Module-Single-/

• For more on Light dependent resistors:

https://www.electronics-tutorials.ws/io/io_4.html

http://technologystudent.com/elec1/ldr1.htm

https://www.electronics-notes.com/articles/electronic_components/resistors/light-dependent-resistor-ldr.php

http://www.resistorguide.com/photoresistor/
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Schematic of connections to be made. Details on next slide.

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Schematic of connections to be made:
Pin connections :-
1. Connect pin 5 of Arduino to pin PWM of
the motor controller (PWM Output)
2. Connect pin 6 of Arduino to pin INB of
the motor controller (Digital output)
3. Connect pin 7 of Arduino to pin INA of
the motor controller (Digital output)
4. Connect LDR and 3.3kOhm resistor in
series and connect the free end of the
resistor to any GND pin on Arduino
5. Connect the common end of LDR and
resistor to pin A5 of Arduino (Analog
input)
6. Connect +5V of Arduino to EN of the
motor controller and free end of the LDR
7. Connect 𝑉 − of the battery to any GND
pin on the Arduino.

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Schematic of connections to be made:
Pin connections :-
8. Connect DC motor with OUTA,
OUTB of the MOTOR DRIVER
9. Connect 𝑉 + of battery to the
‘+’ pin (+5 to +36V DC input) of
the motor controller
10. Connect 𝑉 − of the battery to the
Ground pin of the motor
controller

Note :- Connect battery in the

last step i.e. after uploading the code
to Arduino board
If the circuit doesn’t work check for
lose connections and faulty jumper
wires

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Make sure that the battery is not connected to the
motor driver!

After successfully making all pin connections as per

the schematic, have it assessed by your
guide/TA/Tutor before proceeding further.

Once assessed, load the Arduino software on your

laptop.
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On loading the software, you should see something like:

Open a new sketch

345
New sketch default window:

346
Selection of Board: Under ‘Tool’s, select the board correctly – in this case
‘Uno’.

347
Selection of port: Under ‘Tools’, after connecting the USB AB cable to your
computer and Arduino board, check the port connection as shown. Make
sure to do this every time you connect the board to the computer

348
Type out the following code as is. Comments should be self-explanatory.

349
Type out the following code as is. Comments should be self-explanatory.

Note: You’ll have to play with the variables ‘SPEED’ and ‘THRESHOLD’ to get the desired results

350
 Save the code
1 2

351
Verify the code as shown. If you find any errors in the code, correct them.

Press here to verify the code

352
After verifying the code and connecting the USB AB cable to Arduino and
computer, upload the code into Arduino board : -

Press here to upload the code

If you are getting any error in code correct it. Sometimes the error may also be due to not selection of ‘port’ option. 353
Now, after uploading the program into the Arduino board and doing connections
other than connecting battery.

Connect battery to motor controller as shown in figure below.

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Your setup should look like this, only that the shaft on your motor should be
spinning with the speed you have programmed when you cover the LDR:

Have this assessed by your

guide/TA/Tutor before
proceeding to the next step.

355
Now, load a new sketch – as you did earlier. And type out the code below – as is. This code is
for spin direction control. Save the code. Verify it. Upload it. If all is well, you can now change
the spin of the motor by changing levels form ‘HIGH’ to ‘LOW’ as shown in the table

INA Input INB Input Motor State

HIGH HIGH Brake
HIGH LOW Forward direction motion
of motor

LOW LOW Brake

LOW HIGH Reverse direction motion
of motor
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 Done!

If you’ve been able to control the speed and the

spin direction, your exercise is complete.

Arduino has some lovely tutorials for those

interested.

You will have to use this kit in your project to drive

and control whatever it is that you like.
357
Some references:
• https://lastminuteengineers.com/l298n-dc-stepper-driver-arduino-
tutorial/
• https://www.arduino.cc/
• https://slideplayer.com/slide/3255631/
• https://www.theengineeringprojects.com/2018/06/introduction-to-
arduino-uno.html
• https://www.teachmemicro.com/use-l298n-motor-driver/
• https://www.tutorialspoint.com/arduino/arduino_dc_motor
• https://youtu.be/m9J3mDYy0Sg
Software:
• Arduino - https://www.arduino.cc/en/Main/Software
• Electrical circuit schematic diagram - http://fritzing.org/home/
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