CNC & 3D Printing Lab Manual

CNC & 3D Printing Course Code: MESBL 401 Lab Manual
© New Horizon Institute of Technology and Management www.nhitm.ac.in 1 | Page
New Horizon
Institute of Technology and Management, Thane
Affiliated to University of Mumbai
Program: Mechanical Engineering
Course: CNC & 3D Printing
Lab Manual
Course Code: MESBL 401
Academic Year: 2020-21
Faculty In-Charge: Prof. Prathamesh P Choughule
(Assistant Professor)
Mechanical Engineering Department
This document contains information that is proprietary and confidential to NHITM, which shall not be disclosed to any
external entity that is not involved in the project and shall not be transmitted, or duplicated, used in whole or in part for any
purpose other than its intended purpose. Any use/copy or disclosure in whole or in part of this information without express
written of permission of NHITM is strictly prohibited.

Program Outcomes (POs)
1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals,
and an engineering specialization to the solution of complex engineering problems.
2. Problem Analysis: Identify, formulate, review research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics, natural sciences,
and engineering sciences.
3. Design/Development of Solutions: Design solutions for complex engineering problems and design
system components or processes that meet the specified needs with appropriate consideration for the
public health and safety, and the cultural, societal, and environmental considerations.
4. Conduct Investigations of Complex Problems: Use research-based knowledge and research methods
including design of experiments, analysis and interpretation of data, and synthesis of the information
to provide valid conclusions.
5. Modern Tool Usage: Create, select, and apply appropriate techniques, resources, and
modern engineering and IT tools including prediction and modeling to complex engineering activities
with an understanding of the limitations.
6. The Engineer and Society: Apply reasoning informed by the contextual knowledge to assess societal,
health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.
7. Environment and Sustainability: Understand the impact of the professional engineering solutions in
societal and environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms
of the engineering practice.
9. Individual and Team work: Function effectively as an individual, and as a member or leader
in diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive clear
instructions.
11. Project Management and Finance: Demonstrate knowledge and understanding of the engineering
and management principles and apply these to one’s own work, as a member and leader in a team, to
manage projects and in multidisciplinary environments.
12. Life-long Learning: Recognize the need for, and have the preparation and ability to engage
in independent and life-long learning in the broadest context of technological change.

Course Outcome
CO Course Outcome
At the end of the course student will be able to:
Cognitive Level
(Remember,
Understand,
Apply, Create,
Analyze,
Evaluate)
Hours
Planned
MESBL401.1 Develop and execute part programing for any given
specific operation
Understand,
Create
8
MESBL401.2 Build any given object using CNC operations. Apply &
Evaluate
8
MESBL401.3 Demonstrate CAM Tool path and prepare NC-G code. Apply,
Evaluate
8
MESBL401.4 Develop 3D model using available biomedical data. Understand,
Apply
8
MESBL401.5 Build any given real life object using 3D printing process. Apply,
Evaluate
8
MESBL401.6 Convert 2D images into 3D model. Apply,
Evaluate
8
Total Hours Planned 48

Experiment List
Sr
No
Experiment Name
Hours
Planned Mapped CO:PO
1 6 MESBL401.1,2:
PO 1,2
2 6 MESBL401.1,2:
PO 1,2
3 6 MESBL401.3:
PO 1,2
4 6 MESBL401.1,2,3:
PO 1,2
5 6 MESBL401.4:
PO 1,2
6 6 MESBL401.5:
PO 1,2
7 6 MESBL401.6:
PO 1,2
8 6 MESBL401.3,6:
PO 1,2

IEN: - Batch: -
Name of the Student: - Div.: -
Date of Performance: -
Course Outcome: - MESBL401.1: Develop and execute part programing for any specific operation
MESBL 401.3: Demonstrate CAM Tool Path & Prepare NC-G Code
EXPERIMENT NO.: - 01
Title: Part Programming on CNC Milling Trainer
Aim: - Prepare a CNC Part program in word address format to drill 5 holes of 12mm
diameter using absolute form.
System Software/ Instruments/ Equipment’s Requirements: -
CNC Simulator Pro
Theory/ Working Principle: Various G & M Codes used to develop Program
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell

G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counter clockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling.
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
G27 - Reference return check; Mill and Lathe
G28 - Automatic return through reference point; Mill and Lathe
G29 - Move to location through reference point; Mill and Lathe (slightly different for each
machine)
G31 - Skip function; Mill and Lathe
G32 - Thread cutting; Lathe.
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe
G43 - Tool length compensation; Mill

G44 - Tool length compensation cancels; Mill (sometimes G49)
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe.
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe.
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe.
G81 - Drill cycle; Mill and Lathe
G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill

G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe
M00 - Program stop; Mill and Lathe.
M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counter clockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill

M06 - Tool change; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill

Layout/ Exp. Diagram/ Circuit Dia./ Any Fig. Applicable
Observation Table/ Expt. Reading/ Any other Notable Data

Part Program:

Result:

Conclusion: - CNC Drilling operation done with the help of G & M codes and program
develop for the same for CNC Simulator software & Verified.
Experiment Rubric:
Evaluation Criteria Marks
Signature of
Instructor with Date
Lab Performance
Topic Knowledge
Task Conclusion
Attainment Level (Out of 3)

IEN: - Batch: -
Aim: - Prepare a CNC Part program in word address format to machine the component
shown in figure.
CNC Simulator Pro
Theory/ Working Principle:
Various G & M Codes used to develop Program

Part Program:

Result:
$AddRegPart 2 30 30
G00 G90 G17 G94 G92 X30 Y30 Z15
M06 ET8 S600 F240 M08
G42 G00 X0 Y0 Z02
G01 Z-15 F240
X80 F240
X120 Y60
Y120
G03 X80 Y160 R40 F480
G01 X40 F480
G03 X0 Y120 R40 F480
G01 Y0 F480
G00 Z2
G40
G00 X0 Y0 Z50
M06 ET4 S800 F80 M08
G00 X60 Y40 Z02
G81 X60 Y40 Z-15 R2 F80
Y120
G80 G00 X0 Y0 Z50
M30

Conclusion: - CNC Drilling & Profile Milling operation done with the help of G & M
codes and program develop for the same for CNC Simulator software & Verified.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Aim: - Prepare a CNC Part program in word address format to machine the component
shown in figure.
CNC Simulator Pro

Part Program:

Result:
$AddRegPart 1 30 30
G92 X30 Y30 Z27
M06 ET1
G00 G90 G17 G94 S5000 F500 M03 M08
G00 X50 Y 50 Z02
G81 X50 Y50 Z-15 R02 F100
G00 X150 Y150 Z50
M06 ET6 S1000 F100 M03 M08
G00 X50 Y 50 Z02
G81 X50 Y50 Z-15 R02 F100
G00 X150 Y150 Z50
M06 ET8 S600 F240 M03 M08
G42 G00 X5 Y5 Z5
G01 Z-7 F240
X30 F480
Y30
X70
Y5
X85
X95 Y15
Y30
G02 X95 Y70 R20 F480
G01 Y85 F480
X85 Y95
X70
Y70

X30
Y95
X15
X5 Y85
Y70
G02 X5 Y30 R20 F480
G01 Y15 F480
X15 Y5
G00 Z2
G40
G00 X150 Y150 Z50
M30

Conclusion: - CNC Profile Milling operation done with the help of G & M codes and
program develop for the same for CNC Simulator software & Verified.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Title: Part Programming on CNC Turning Trainer
Aim: - Write A Part Program using G & M Codes for finishing a forged component as shown
in figure. Assume the speed & feed on turning centre as 500 RPM & 0.3 mm/Rev respectively.
Assume suitable data if necessary.
CNC Simulator Pro

Part Program:
Result:
$Lathe
$Millimeters
$AddRegPart 1
G92 Z106
ET1 M06
N10 G21 G90 G95
N20 M03 S500 M08
N30 G00 X100 Z50
N40 X29 Z0

N50 G00 X25 Z0
N60 G01 Z-25 F0.3
N70 X30 Z-43
N80 Z-55
N90 X36
N100 X38 Z-54
N110 Z-65
N120 X25 Z-100
N130 X40
N140 M30

Conclusion: - CNC Turning operation done with the help of G & M codes and program
develop for the same for CNC Simulator software & Verified.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Title: Part Programming on CNC Turning Trainer
Aim: - Write A Part Program using G & M Codes To demonstrate the threading operation
CNC Simulator Pro

Part Program:
#region
$Millimeters
$Lathe
$OverrideBufferQualitySetting 5
$DefineLatheWorkpiece "N::M:" 0 100.00 50.00 0.00
$AddDefinedPart 0
$ReadTasEmbeddedTool
#endregion

%
G92 Z-23
(Fine cut)
T2 M06
G00 X52 Z101
G01 X45.707 F70 S1000 M04 M08
Z99.854 F100
X50 Z97.707
Z89.293
X46 Z87.293
Z67.707
X49.414 Z66
G00 X53.414 Z68
Z101
X52
T25 M06
G00 X50 Z100
(G76 Threading Cycle)
G76 P010060 Q500 R0.05
G76 X46 Z88 P1024 Q200 F2
G00 Z203
M5 M9 M20
M30

Result:

Conclusion: - CNC Turning (Threading) operation done with the help of G & M codes
and program develop for the same for CNC Simulator software & Verified.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Title: Part Programming Simulation for Unconventional machining (wire
Electrical discharge machining)
Aim: - Prepare the part program for wire electrical discharge machining using
with the given parameters as shown in Figure
CNC Simulator Pro
Wire electrical discharge machining can machine any electrically conductive material. In this a thin
wire usually made of copper or brass, is electrically charged and is held between top and bottom holder
guiding the motion of the same. The applied voltage on the wire creates spark which melts the workpiece as
it approaches the same. For creating an isolated atmosphere, the presence of a dielectric is required in the
form of deionized water which apart from the environment also forces the debris to move out. It creates the
clear path for the wire to move forward and complete the machining.

Being a non-conventional machine, which means there is no physical contact between the tool and the
workpiece, the cutting forces involved is zero. This allows to produce very thin and delicate parts. So, this is
used to make products with very high accuracy and complexity where the conventional machines fail. Few
complicated programming associated with the wire electrical discharge machining samples are discussed
below.

Part Program:
$AddRegPart 1 0 0
G92 X25 Y25 Z15
M06 ET1
G90 G94 S800 F100 M03
G00 X0 Y0 Z35
G01 Z-15 M03 M08
G01 X150
G01 Y125
G03 X100 Y125 R25
G01 Y75
G02 X50 Y75 R25
G01 Y125
G03 X0 Y125 R25
G01 X0 Y0
G00 Z50
G00 X250 Y150
M09
M05
M02
Result:

Conclusion: - Unconventional Machining (Wire electrical Discharge machining)
operation learned & developed CNC G code program for the same for CNC Simulator
software & Verified.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Course Outcome: - MESBL401.4: Develop a 3D model using available biomedical data
Title: Segmentation in slicer’s segment Editor module for the purpose of 3D
printing (3D Slicer open source) (Application: Any Bone Part)
Aim: - Prepare the STL File for the spinal cord of human by segmentation in
slicer’s segment Editor module for the purpose of 3D printing
3D Slicer
A slicer is a program that converts digital 3D models into printing instructions for a given 3D printer to build
an object. In addition to the model itself, the instructions contain user-entered 3D printing parameters, such
as layer height, speed, and support structure settings.
Every 3D printing technology creates 3D objects by adding material layer-by-layer. Slicer software is
therefore appropriately named because it virtually “cuts” 3D models into many horizontal 2D layers that will
later be printed, one at a time.

Segmentation:

Result: -

Conclusion: - Segmentation in slicer’s segment Editor module for spinal cord is done for
the purpose of 3D printing
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

IEN: - Batch: -
Course Outcome: - MESBL401.4: Develop a 3D model using available biomedical data
MESBL401.6: Convert 2D images into 3D model
Title: Creation of 3D model from 2D images using any image processing
software and printing it. (Application: Any body organ)
Aim: - Prepare the 3D model File of the spinal cord of human from 2D image
(CTchest)
3D Slicer
3D printing

A slicer is a program that converts digital 3D models into printing instructions for a given 3D printer to build
an object. In addition to the model itself, the instructions contain user-entered 3D printing parameters, such
as layer height, speed, and support structure settings.
Every 3D printing technology creates 3D objects by adding material layer-by-layer. Slicer software is
therefore appropriately named because it virtually “cuts” 3D models into many horizontal 2D layers that will
later be printed, one at a time.
Ultimaker Cura works by slicing the user’s model file into layers and generating a printer-specific g-code.
Once finished, the g-code can be sent to the printer for the manufacture of the physical object.
The open source software, compatible with most desktop 3D printers, can work with files in the most
common 3D formats such as STL, OBJ, X3D, 3MF as well as image file formats such as BMP, GIF, JPG,
and PNG.

3D printing:
Result: -

Conclusion: - 3D file generated with G code file format for 3D printing of Spinal cord of
human from 2D image by image processing software.
Experiment Rubric:
Signature of
Lab Performance
Topic Knowledge
Task Conclusion

CNC & 3D Printing Lab Manual

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