Manglesh Kanwar

1 Manglesh Kanwar
Project report on creo 2.0
GNa -UNIVERSITY (PHAGWARA)
Submitted to - Faculty Of Design and Innovation

GNA UNIVERSITY
Submitted by-
Manglesh Kanwar
Roll no. DES/CC/3671
Registration No. GU14-0116
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ACKNOWLEDGEMENT
It is my esteem privilege, to express deep sense of gratitude and indebtedness to my major

advisors, Mr. Balbir Singh (personnel department officer) & Mr. P S Nanda (Manager of the
Unit) GNA Duraparts (GNA auto parts), Mehtiana for their expert and inspiring guidance,
constructive criticism and constant encouragement during the course of this practical
industrial training.
I am also very thankful to Mr. C R Tripathy{Principal CAD/CAM department}, who

facilitated and boosted our knowledge with their lectures. I would be failing in my duties if I
do not thank Mr. suninder, who always cleared our doubts whether its about software or
regarding any technical topic.
I am very thankful to my contact persons i.e. incharges of the various shops/departments and
personnel department officers who gave me such a use full guidance.
I would like to thank Mr. Gurdeep Singh Director, GNA Duraparts Mehtiana, Who
allowed me to undergo practical industrial training visit.
Thanks are also due to all staff members of GNA IMT and others who took lots of interest
in assisting me during the training period and in making the repot a success.
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PREFACE
A sincere attempt has been made in the report to present a simplified face of new tech.
equipments used in the unit for various purposes, which were seen and practiced during the
period of practical industrial training held at GNA IMT, Phagwara
.
The pure emphasis throughout is of a practical nature. However, attempts have been
made to enter into wider theoretical aspects. Scientific explanations and descriptions have,
however, been included, wherever applicable.
In addition to the in-plant training report, it also includes a Project Report.
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CONTENTS
Industrial visit report
Creo 2.0
NX 9.0
RAPID PROTOTYPE TECHNIQUE
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INDUSTRIAL VISIT REPORT
GNA DURAPARTS
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PURPOSE OF INDUSTRIAL TRAINING
It is a well-known fact that theoretical knowledge is totally handicap without the practical
approach to the thing. Main purpose of the industrial training is to expose the trainees with
practical experience of actual industrial conditions in which they will require to work in future
and make them aware of the difference between the environment of industrial and college or
homes.
Thus the aim of the industrial training is to understand the layout of the industry,
dealings with the various operations going in it and makes trainees to learn from the
experiences of the professional Managers and skilled workmen with whom they are placed for
training who have to work together with cooperation to achieve the common goal of the
industry.
This type of training gives chance for future advancement, thus giving trainees
chance for specialization in particular fields.
In industry, we perform the work, which we have studied in our theory portions. We
get an extra knowledge by working in an industry and we also came to know the problems to
be faced in future. This type of training gives chance for further advancements. Thus, it gives
the trainees a chance for specialization in particular fields.
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INTRODUCTION TO THE UNIT
The existence of GNA came into being in 1946, in a small village called Bundala in District
Jalandhar of Punjab. GNA has made its presence prominent not only in India but also across
the world.
Today, more than 6000 families are proud to be associated with this giant colossal tree that
bloomed from a seedling sown 62 years ago. Founded with a modest beginning by Late Mr.
Amar Singh Ji and nourished by his sons Mr. Rachhpal Singh and Mr. Gursaran Singh, with
the artistic creativity that was gifted to the next generation by tradition, GNA is now boosted
and taken care by the third generation Mr. Jasvinder Singh, Mr. Maninder Singh, Mr. Ranbir
Singh and Mr. Gurdeep Singh. Today GNA group has created an important place for itself in
Indian as well as Global Automotive Industry.
GNA group is on a fast moving track towards growth and globalization. The company has a
large customer base covering different sectors of the automotive industry with diversified
product range. Along with this the company shows steady growth profile even during the
time when there is demand fluctuations in the automotive sector.
GNA is an Original Equipment supplier to various Automobile Majors besides having a

strong presence in the replacement market.GNA has been accredited with ISO 9002 and QS
9000 certifications for its quality systems holds a reliable name in the world of automotive
components.
Quality Management at GNA is a timeless concept wherein, changes in customer

expectations are a driving force to go beyond conformance to standards. GNAs quality
assurance is equipped with the finest equipment ranging from metallurgical microscope to
mobile spectrometer, ultrasonic flow detector, micro hardness testers, surface roughness
testers, profile projectors and involutes profile testers.
GNA sincerely believes in technology up-gradation for keeping a competitive edge. Indeed,
this explains the continuous replacement of conventional manufacturing equipment with
modernized transfer lines resulting in increased productivity and efficiency at low cost.
GNAs core competency lies in its strong knowledge base of engineering and over 59 years
of experience in manufacturing. GNA has come a long way yet journey toward excellence is
never ending
Sri. Amar Singh Ji made a modest beginning with an atta-chakki {Flour mill. Late
Sardar Amar Singh established a small unit for the manufacture of axles under the name of
Nirankar Auto Engg. works in the late 1946. Through the last 62 years the company has
grown in leaps and bounds and established itself as a major source of vehicle paets in India as
well as in world. Exports market of GNA range of products have a wide spectra of
applications in heavy, medium and high commercial vehicles i.e. passenger cars, jeeps,
tractors, trucks etc.
GNA group is today spread over area of 3, 50,000 sq.mts. employing a total man
power of about 2000 personnel with a turn over of 29.78 million US $ coming from all units.
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DIVISIONS
Developing on the bases of Quality, GNA has come a long way since its beginning (more
than fifty years ago) with an annual turnover nearly Rs200 Crores per annum coming from
four divisions GNA Axles Ltd, GNA Duraparts, GNA Udyog Ltd.
The following data gives details of GNAs different plants:
DIVISION PLACE COVERED PRODUCTS INSTALLED

AREA CAPACITY
(sqrmtrs)
GNA Duraparts Mehtiana 1550 Super, bevel & 100,000 sets

Pinions
GNA Axles Ltd Mehtiana 2400 Rear axle shafts, 500,000 pcs
Hydraulic lift shafts,
Powers take of 100,000 pcs
shafts.
100,000 pcs
GNA Udyog Ltd Bundala Propeller shafts 70,000 pcs
assembly,
2020
Inter drive shaft 25,000 pcs
assembly,
Steering components
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ENGINEERING DEPARTMENT
INTRODUCTION
Engineering department is the backbone of the plants. This is because it accomplishes the
tasks that are vital for the functioning of the other plants. This department possesses a team of
sound and ingenious engineers, managed by qualified and experienced technical managers.
The major functions of this department are performed before the actual production begins.
The department makes the quotations before the order received and also conducts the
feasibility study of new products. It planes the system (the process flow, tooling and facilities
required inspection techniques etc) for the development of new products.
Apart from this the department meets with the routine production requirement like
modification of the existing systems and tooling methods etc. it also provides documentary
support to the manufacturing and inspection sections in the form of process instruction sheets
and inspection parameters list etc. a tool room is there the function of which is to calibrate the
inspection equipments, inspection of various gauges and tools used after the completion of
pre-settled time period. It also inspect the tools and master components being manufactured
in the tool room
As stated earlier the functions of the engineering department are classified into three
divisions vi:
New Product Development
Routine Production Requirement and
Data Collection
Each of the functions is given below:

NEW PRODUCT DEVELOPMENT
DRAWINGS
QUOTATION MAKING
SAMPLE DEVELOPMENT ORDER
SENDING TO THE CLIENT
PILOT BATCH MAKING
HAND OVER TO THE PRODUCTION DEPARTMENT
The Production Department is submitted the following documents:

1. Tooling
2. Tool specifications
3. Production Drawings
4. Check sheets
5. Order to the store for the issuance of material from inventory
6. Process instruction sheets etc.
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STANDARD ROOM
INTRODUCTION
Standard room is situated in a separate building, yet its functioning is controlled by the
engineering department. The main reason for the existence of the standards room is to check
the various dimensions of the master pieces, inspection equipments, gauges etc. specified by
the engineering department. It also checks the quality of the purchased equipments.
The details of the responsibility of the standards room can be had from the following text:
The responsibilities of the engineering department can be divided broadly into two headings:
a. Inspection of Incoming Materials:
1. Receive the material against drawing number/work order number.
2. Put some identification number on tooling.
3. List out the equipments required for inspection
4. Inspect the tools
5. Make the report against drawings
6. Get it checked by the authorized signatory
7. Hand over the inspection report to the concerned departments.
b. Periodic Calibration:
1. List out the tooling whose calibration is to be done.
2. Recall the tooling against the corresponding drawing
3. Inspection the tooling against the corresponding drawing
4. Make periodic inspection report
5. Get the reports checked by the authorized persons
6. If O.K. send back to the shop after revising calibration status code
7. Make entries in the corresponding History Card
8. If the tools are rejected handover to Engg Department with reports
9. Issue new tools to the shop.
GNA Tool Inspection Report

TOOL DESCRIPITION:
TOOL DRAWING NUMBER.
SUPPLIER:.
APPLICABLE TO:.
SR. SPECIFIED DIMENSIONS ACTUAL DIMENSIONS
NO.
Inspection Report: This report contains the information in the tabulated format regarding the
periodic inspection of some tool or gauge etc. The format followed in the GNA Axles Ltd is
as followed:
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Some Equipments used in Standard room:

CMM(coordinate measuring machine)
Machine body
Mechanical probe
Micrometrology Probes
Slip Gauge
Pressure gauge
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DIE DESIGN SHOP

INTRODUCTION
A die is a specialized tool used in manufacturing industries to cut or shape material
using a press. Like molds, dies are generally customized to the item they are used to create.
Products made with dies range from simple paper clips to complex pieces used in advanced
technology. The die making process is Based on 3D CAD data prepared by the customer, the
die maker prepares NC data and makes dies by CAM. The customer adds detailed
modifications to the original dies and molds products with the modified dies. When the dies
are worn out from long-term use, the die maker is asked to re-model the dies. The original 3D
CAD/CAM data cannot be used because the customer added modifications to them .Thus, the
die maker re-models the dies based on the original dies that have been modified by the
customer. The die making process is start from the CAD/CAM section. Where the 3D design
of a model is to be ready by the designer and then the model is send to the moulding section
inside the CAD(computer Aided Design) where designer made a injection moulding of the
component .There are various step are for making the injection moulding or the CORE AND
CAVITY of the component. After that the CORE AND CAVITY is ready with the help of
the CAD software.
After the core cavity making the core and cavity is going for the further process
where in theCAM software the die making virtually. And all the operation is done on the the
die makingand make a program so that the CNC machine make a die.
Tool and die makers are workers in the manufacturing industry who make jigs,
fixtures, dies, molds, machine tools, cutting tools (such as milling cutters and form tools),
gauges, and other tools used in manufacturing processes. Depending on which area of
concentration a particular person works in, he or she may be called by variations on the name,
including tool maker (toolmaker), die maker (diemaker), mold maker (moldmaker), tool fitter
(toolfitter), etc.
DIE:A die is a specialized tool used in manufacturing industries to cut or shape material
using a press. Like molds, dies are generally customized to the item they are used to create.
Products made with dies range from simple paper clips to complex pieces used in advanced
technologyForming dies are typically made by tool and die makers and put into production
after mounting into a press. The die is a metal block that is used for forming materials like
sheet metal and plastic. For the vacuum forming of plastic sheet only a single form is used,
typically to form transparent plastic containers (called blister packs) for merchandise.
Vacuum forming is considered a simple molding thermoforming process but uses the same
principles as die forming. For the forming of sheet metal, such as automobile body parts, two
parts may be used, one, called the punch, performs the stretching, bending, and/or blanking
operation, while another part, called the die block, securely clamps the workpiece and
provides similar, stretching, bending, and/or blanking operation. The workpiece may pass
through several stages using different tools or operations to obtain the final form. In the case
of an automotive component there will usually be a shearing operation after the main forming
is done and then additional crimping or rolling operations to ensure that all sharp edges are
hidden and to add rigidity to the panel.
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Die operations and types

Bending
Blanking
Broaching
Bulging
Coining
Compound operations
Compound die
Curling
Cut off
Drawing
Extruding
Foaming
Cold forming
Horning
Piecing
Shaving
Swaging
trimming
For the die making process, the different devices available in the DIE SHOP are:
Lathe Machines
Planar
Shaper
Boring Machine
Grinding Machine
Vertical Milling Machines
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FORGING SHOP
INTRODUCATION
This shop is the first shop carry out the manufacturing operations on the raw material. The
raw material is in form of cylindrical blanks of steel which are unloaded here from the truck
after the necessary inspection by the chemical laboratory. Forging is a process of giving
required shape to metals or alloys at sufficiently high temperature. This is the shop where
these blanks acquire the shape similar to that of an axle shaft or any other shaft (PTO or rock
shaft) excellent forging facilities for the forging are provided which include both drop forging
as well as up-setting forging. Continuous shaft oil furnaces are provided to heat the metal
stock. The report about this shop, which follows this text, explains the capacities and the
process description of the shop in a systematic way.
BAND
UPSET SAWS
UPSET VERT
FORG- FORG FORGIN
HAMM-
ING G
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M/C-1 M/C-2
MONO RAILS
FU FU
RN RN
AC AC
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EXIT
LAYOUT
Forging is the process by which metal is heated and is shaped by plastic deformation by
suitably applying compressive force. Usually the compressive force is in the form of hammer
blows using a power hammer or a press. Forging refines the grain structure and improves
physical properties of the metal. With proper design, the grain flow can be oriented in the
direction of principal stresses encountered in actual use. Grain flow is the direction of the
pattern that the crystals take during plastic deformation. Physical properties (such as strength,
ductility and toughness) are much better in a forging than in the base metal, which has,
crystals randomly oriented.
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Forgings are consistent from piece to piece, without any of the porosity, voids, inclusions and
other defects. Thus, finishing operations such as machining do not expose voids, because
there aren't any. Also coating operations such as plating or painting are straightforward due to
a good surface, which needs very little preparation.
Forgings yield parts that have high strength to weight ratio-thus are often used in the design
of aircraft frame members.
A Forged metal can result in the following
Increase length, decrease cross-section, called drawing out the metal.

Decrease length, increase cross-section, called upsetting the metal.
Change length, change cross-section, by squeezing in closed impression dies. This
results in favorable grain flow for strong parts
PROCESSES
Blank cutting
Heating
Forging
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HEAT TREATMENT
INTRODUCTION
Forgings produced in forging shop have developed a considerable amount of harmful internal
stresses. These internal stresses are harmful as far as the end use of the product is concerned.
These internal stresses are to be removed now and also the axles are to be hardened in the
Heat Treatment Shop.
PROCESS FLOW: The forgings are brought from the forging shop and are heat treatment in
the suitable furnace. This includes a number of heat treatment processes (e.g. normalizing,
annealing, hardening and tempering etc.) All the heat treatment consists for the sufficient
time viz: heating to a suitable temperature, soaking at that temperature for the sufficient time
and cooling by a suitable method. After that the heat treatment axles are checked against the
requirement value of hardness. If the axles are O.K then further processing is done otherwise
reworking is required.
FACILLITIES: The heat treatment shop of GNA Axles Ltd is equipped with the Facilities
to carry out normalizing, annealing, hardening and tempering. The shop also has the
equipments to check the hardness obtained during the heat treatment and hence to decide
whether further processing should be done or not. Following machine and equipments are
installed:
1. Heat Treatment Furnaces:
2. Oil Tank For Quenching:
3. Water Storage Tank for Quenching
4. Cooling Tower
5. B.H.N Testing Machine
In the HEAT TREATMENT shop, the raw material is the finished product of the CNC
shop discussed earlier. The material after the CNC shop may be more shiney and look
attractive, but it lacks the basic extra hardness that it will require to withstand the forces to be
applied on it when put to use. After all, the gears as well as the shafts need to withstand a
long time as in case of the gearboxes which are rarely opened to replace a component. In such
a case, the maintenance costs will rise drastically. The sequence of steps that take place when
raw material arrives in the HEAT TREATMENT shop:
Punching
Batch Loading
Washing
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Preheating
Sealed Quench Furnace
Gas Carburizing
Diffusion
Cooling
Hardening
Quenching
Washing
Tempering
Shot Blasting
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CNC MACHINE SHOP

INTRODUCTION
This is the shop where most of the work is performed on different machines. In machine
shop, the raw material which had under gone Forging, Hot Blasting etc. is machined to final
product with the help of different machines. Different types of machines used in machine
shop are:
1. Lathe machine 6. Hobbing machine

2. High speed lathe (Churchill) 7. Drilling machine
3. Straightening machine 8. Tapping machines
4. Horizontal machining centre 9. CNC lathe machines
5. Milling machine 10. Grinding machine
WHAT DOES 'CNC' MEAN?
CNC means Computer Numerical Control. This means a computer converts the design
into numbers which the computer uses to control the cutting and shaping of the material.
HOW TO USE A TYPICAL CNC MACHINE
1. The design is loaded into the computer which

is attached to the CNC machine. The computer
changes the design into a special code
(numerical) that controls the way the CNC cuts
and shapes the material.
2. The material to be shaped is taped on to a

block with double sided tape. This must be done
carefully so that it does not come off the block
during machining.
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3. The block is then placed in the vice, inside the

CNC. It must be tightened up carefully. If it is
not secure when the machine starts to cut the
material it can come away from the vice. When
the machine starts working, the vice moves up,
down, right and left according to the design.
4. The guard is placed in position. It protects the

machine operator in case the material is pulled
out of the vice by the power of the cutter. For
safety reasons, if the guard is not in position the
motor will not start.
5. The CNC is turned on and the shape is cut

from the material. When the cutter has stopped
the shaped material can be removed from the
vice. Total time - for simple designs - 15
minutes.
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VARIOUS CNC MACHINES:
Gear shaper machine
Hobbing machine
Gear shaving machine
Surface broach machine
Simple broach machine
Spiral gear cutting machine
Rack rolling machine
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INDUCTION HARDENING
Induction heating is a non-contact heating process. It uses high frequency electricity to heat
materials that are electrically conductive. Since it is non-contact, the heating process does not
contaminate the material being heated. It is also very efficient since the heat is actually
generated inside the work piece. This can be contrasted with other heating methods where
heat is generated in a flame or heating element, which is then applied to the work piece. For
these reasons Induction Heating lends itself to some unique applications in industry.
Definition: A widely used process for the surface hardening of steel. The components are
heated by means of an alternating magnetic field to a temperature within or above the
transformation range followed by immediate quenching. The core of the component remains
unaffected by the treatment and its physical properties are those of the bar from which it was
machined, whilst the hardness of the case can be within the range 37/58 Rc. Carbon and alloy
steels with carbon content in the range 0.40/0.45% are most suitable for this process.
Common Heat Treatments
Softening: Softening is done to reduce strength or hardness, remove residual stresses,

improve toughness, restore ductility, refine grain size or change the electromagnetic
properties of the steel. Restoring ductility or removing residual stresses is a necessary
operation when a large amount of cold working is to be performed, such as in a cold-rolling
operation or wiredrawing. Annealing full Process, spheroidizing, normalizing and tempering,
austempering, mar tempering are the principal ways by which steel is softened.
Hardening: Hardening of steels is done to increase the strength and wear properties. One of
the pre-requisites for hardening is sufficient carbon and alloy content. If there is sufficient
Carbon content then the steel can be directly hardened. Otherwise the surface of the part has
to be Carbon enriched using some diffusion treatment hardening techniques.
Material Modification: Heat treatment is used to modify properties of materials in addition

to hardening and softening. These processes modify the behavior of the steels in a beneficial
manner to maximize service life, e.g., stress relieving, or strength properties, e.g., cryogenic
treatment, or some other desirable properties, e.g., spring aging.
The working of induction hardening based on Faradays law and according to it:
Faraday's law of induction (more generally, the law of electromagnetic induction) states
that the induced emf (electromotive force) in a closed loop equals the negative of the time
rate of change of magnetic flux through the loop. This simply means that the induced emf is
proportional to the rate of change of the magnetic flux through a coil.
In layman's terms, moving a conductor (such as a metal wire) through a magnetic field
produces a voltage. The resulting voltage is directly proportional to the speed of movement:
moving the conductor twice as fast produces twice the voltage. (The magnetic field, the
direction of movement, and the voltage are all at right angles to each other. Whenever
movement creates voltage, Fleming's right hand rule describes the direction of the voltage.)
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Components Group: Axles and Rods
The high production volume of motor shafts requires horizontal in-line machines and
progressive hardening with rotation. The very high feed rate requires precise and fast control
for the power source and machine to achieve exact and reproducible hardening zones at the
beginning and end of the component. A tempering process can follow.
Hardening requires a horizontal machine with continuous feed and work piece rotation. The
low wall thickness of the hollow shaft calls for precise power and frequency to reduce
bending and to avoid through hardening. The machine is ideal for integration in the
production line. Process control in connection with a rejecting chute ensures that only good
work pieces leave the machine.
Piston rods are preferably hardened on a horizontal machine independent of the machining
condition of the end face. In-line or separate machines with loading magazine can be realized
-induction tempering after hardening is possible.
The relation between the rate of change of the magnetic flux through the surface S enclosed
by a contour C and the electric field along the contour:
where
E is the electric field,

dl is an infinitesimal element of the contour C,
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Project report
0n
CAD SOFTWARE creo 2.0
GNA University (PHAGWARA)
BASIC KNOWLEDGE ABOUT CAD/CAM SOFTWARE

CAD/CAM is the technology not a software.
Group of techniques is called technology. Many software are works on CAD/CAM
technology.
For ex; NX, creo, CATIA, SOLID EDGE, SOLID WORKS DELLCAM etc.
CAD/CAM SOFTWARE ARE CLASSIFIED ON THE BASIS OF TWO CRITERIAS
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ON THE BASIS OF DESIGN CAPABILITY.

ON THE BASIS OF MODIFICATION CAPABILITY.
1. ON THE BASIS OF DESIGN CAPABILITY CAD/CAM SOFTWARE ARE

OF TWO TYPES
1. HIGH END SOFTWARE :-(NX, creo, CATIA, SOLID EDGE etc.)
2. LOW END SOFTWARE:- (AUTO-CAD, CADDIAN etc.)
2. ON THE BASIS OF MODIFICATION CAPABILITY CAD/CAM SOFTWARE

ARE OF TWO TYPES.
1. PARAMETRIC SOFTWARE(NX, creo, CATIA, SOLID EDGE etc.)
2. NON PARAMETRIC SOFTWARE(AUTO-CAD, CADDIAN etc.)
Welcome to creo 2.0.If you are a new user of creo software package , you are going to join
hands with thousands of users of this high-end CAD/CAM/CAE tool worldwide.If you are a
user of the previous releases of this software, you are going to upgrade your designing skills
with the tremendous improvement in this latest release.
Creo 2.0 is a powerful program used to create complex designs with great precision. The
design intent of any three-dimensional (3D) model or an assembly is defined by its
specification and its use. You can use the powerful tools of creo 2.0 to capture the design
intent of any complex model by incorporating intelligence into the design.
PARAMETRIC NATURE
Creo 2.0 is parametric, which means that the features of a part become interrelated if they are
drawn by the reference of each other. You can redefine the dimensions or the attributes of a
feature at any time. The changes will propagate automatically throughout the model. Thus
they develop a relationship among themselves. This relationship is known as the parent
child relationship. So if you want to change the placement of the child feature, you can make
alterations in the dimensions of the references and hence change the design as per your
requirement. The parent-child relationship will be discussed in detail while discussing the
datum in later chapters.
CREO 2.0 is a feature-based, parametric solid modeling system with many extended design
and manufacturing applications. As a comprehensive CAD/CAE/CAM system, covering
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many aspects of mechanical design, analysis and manufacturing, creo 2.0 represents the
leading edge of CAD/CAE/CAM technology.
MODEL TREE:-
The model tree stores and displays all features in a chronicle. You can select any desired
feature of a model or an assembly from the MODEL TREE and apply different operations on
the selected features. You can also select the features by right-clicking on it; a shortcut menu
will be display.
The main purpose of using constraint, in the designing software is following

1. To restrict motion of the entity.
2. Proper definition of the geometry using constraint symbol is well
defined.
TYPE OF CONSTRAINT
The main type of constraint is follow
(1) fully constraint
(2) partial constraint
(3) over constraint
(4) no constraint
AUTOMATIC
The main automatic constraint use in creo software is below
(1) HORIZONTAL CONSTRAINT
(2) PERPENDICULAR CONSTRAINT
(3) TANGENT CONSTRAINT
(4) MIDDLE CONSTRAINT
(5) COLLINEAR CONSTRAINT
(6) SYMMETRICAL CONSTRAINT
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(7) EQUAL CONSTRAINT

(8) PARALLEL CONSTRAINT
USE OF CONSTRAINT
VERTICAL CONSTRAINT
It is use to converting any type of line in to a vertical line.
Procedure
Choose vertical constraint from the constraints box showing above feature
Select any line to convert in to a V.L.
Done
HORIZONTAL CONSTRAINT
It is use to converting any type of line in to a horizontal line.
Procedure
Choose horizontal constraint from the constraints box showing above feature
Select any line to convert in to a H.L.
Done
PERPENDICULER CONSTRAINT
It is use to convert any type of two line in to a Perpendicular line.
Procedure
Choose perpendicular constraint from the constraints box showing above feature
Select first line
Select second line
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TENGENT
It is use to convert any type of line in to a tangent line between two entity.
Procedure
Select a line
Select a circle
MIDDLE CONSTRAINT
It is used to fixing the any entities point at the middle point of a line.
Procedure
Select a point of the entity
Select a line
COLLINEAR CONSTRAINT
It is use to fixing the entity over any entity
Procedure
Choose collinear constraint from the constraints box showing above feature
Select entity
Select fixing point of the entity
SYMMETRICAL CONSTRAINT
It is use to drawing a symmetrical line or entity

About a center line.
Choose symmetrical constraint from the constraints box showing above
feature
Select a centre line
Select both corner of the entity
EQUAL CONSTRAINT
It is use to convert any type of two line in to an equal length line.
Choose equal constraint from the constraints box showing above feature
Select first entity
Select second entity
PARALLEL CONSTRAINT
It is use to convert any type of two line in to an parallel line
Choose parallel constraint from the constraints box showing above feature
Select first entity
VERTICAL CONSTRAINT I
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t is use to converting any type of line in to a vertical line.
Procedure
Choose vertical constraint from the constraints box showing above feature
Select any line to convert in to a V.L.
Done
HORIZONTAL CONSTRAINT
It is use to converting any type of line in to a horizontal line.
Procedure
Select any line to convert in to a H.L.
Done
PERPENDICULER CONSTRAINT
It is use to convert any type of two line in to a Perpendicular line.
Procedure
Choose perpendicular constraint from the constraints box showing above feature
Select first line
Select second line
TANGENT
It is use to convert any type of line in to a tangent line between two entity.
Procedure
Select a line
Select a circle
MIDDLE CONSTRAINT
It is used to fixing the any entities point at the middle point of a line.
Procedure
Choose horizontal constraint from the constraints box showing above
feature
Select a point of the entity
Select a line
COLLINEAR CONSTRAINT
It is use to fixing the entity over any entity
Procedure
Choose collinear constraint from the constraints box showing above feature
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Select entity
Select fixing point of the entity
SYMMETRICAL CONSTRAINT
It is use to drawing a symmetrical line or entity
About a centre line.
Choose symmetrical constraint from the constraints box showing above
feature
Select a center line
Select both corner of the entity
EQUAL CONSTRAINT
It is use to convert any type of two line in to an equal length line.
Choose equal constraint from the constraints box showing above feature
Select first entity
PARALLEL CONSTRAINT
It is use to convert any type of two line in to an parallel line
Choose parallel constraint from the constraints box showing above feature
Select first entity
LINE
It is used to draw a straight line.
Procedure
Click on the line icon.
Pick start point and the end point of the line.
Modify all the dimensions and constraint.
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TANGENT LINE
It is used to draw a tangent line to the two diff rent circles
Procedure
Click on the tangent line icon.
Select first circle.
Select second circle.
CENTER LINE
It is used to draw a center line.
Procedure
Click on the center line icon.
Pick first point of the center line.
Pick second point of the center line.
RECTANGLE
It is used to draw a rectangle.
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Procedure
Click on the center line icon.
Pick first corner of the rectangle.
Pick second corner of the rectangle.
CENTER POINT CIRCLE - It is used to draw a circle.
Procedure
Click on center point circle icon.
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Pick center point of the circle.

Draw any radius of circle.
CONCENTRIC CIRCLE
It is used to draw no of radius circle at a center point.
Procedure
Click on concentric center point circle icon.
Select a circle.
Draw number of circle about a same center point.
THREE POINT CIRCLE

It is used to draw a circle by picking three points.
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Procedure
Click on three point circle icon.
Pick one by one any three points.
TANGENT CIRCLEIt is used to draw three place tangent circles.
Procedure
Click on three point tangent circle icon.
Select any 3 entity
ELLIPSE
It is used to draw an ellipse.
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Procedure
Click on three point tangent circle icon.
Pick center point of the ellipse.
Pick another point.
START END CENTER TYPE ARC -

It is used to draw an arc.
Procedure
Click on start end center type arc icon.
Pick both end of the arc with out center point
Click desired direction of the arc
CENTER START END TYPE ARC

It is used to draw an arc.
Procedure
Click on center point arc icon.
Select center point of the arc.
Draw both corner of the arc.
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FILLET
It is used to create a circular fillet between two entities.
Procedure
Click on fillet icon.
Select first entity.
Select second entity.
SPLINE
It is used to draw a spline.
Procedure
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Click on spline icon.

Pick first point.
Again and again pick point in desired direction.
DIMENSION
It is used to check the length, angle, and distance between to entity.
DIMENSION (linear)
Procedure
Click on dimension icon.
Select first entity.
Select second entity.
Done desired direction or place.
DIMENSION (circular)
Procedure
Click on dimension icon.
Select a circle or a arc.
Apply one time done for shows radius, two times done for diameter.
TEXT
It is used to write text as a part of section

Procedure
Click on text icon.
Draw a line from bottom to top side.
Write the text.
Press ok.
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PALLET
It is used to insert a foreign data from palette in to active object.
Procedure
Click on foreign data icon.
Select desired cross section.
Apply double click on selected cross section.
creo shows a scale rotate dialog box.
Fill both scale and rotate box.
EXTRUDE
This command is used to generate the solid and Surface by stretching the cross
section in normal direction
Steps involved in the command
Select the command
Placement
define
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select plane
Make cross section
Fill the numerical value
OPTIONS OF EXTRUDE
Extrude command having options to create Solid andSurface are mention bellow :
Blind
Symmetric
Through all
To next
Through until
To selected
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Remove material (cut)
BLIND
This option is used directly fill the numerical value of parameter. By flip option we can
change the direction of parameter.
SYMMETRIC
When we want divide profile fifty-fifty from the coordinate System or any plane is called
symmetric.
THROUGH ALL
This option is under the extrude dialog box .This is Mostly used when there is need to remove
the material. It cut the material from compete model.
TO NEXT
This option is under the extrude dialog box. In this Option we do not give the numerical
value, but only specify the next surface of object.
TO SELECTED: --
This option is under the extrude dialog box. In this option there is not need to give
numerical value. In this option we specify the point, line ,surface.
REMOVE MATERIAL:--
As the name suggested this option is used to cut material. To use this command we can
also used the other option Of extrude like through all, to next, to selected, blind etc.
REVOLVE
This command is used to generate solid or surface by Revolve a cross section around a axis
at a required angle.
Steps involve in the command

Select the command.
Placement
Define
Select plane.
Make cross section.(one axis)
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fill the angle

REVOLVE(OPTIONS) :About the Angle of RevolutionIn a revolved feature, a section is
revolved around an axis of revolution to a specified angle. You can define the angle of
revolution by selecting one of the following angle options:
Variable
Revolves a section from the sketching plane by the specified angle value. Type the angle
value in the text box, or select one of predefined angles (90, 180, 270, 360). If you select one
of the predefined angle values, the system creates an angle dimension.
Symmetric
Revolves a section on each side of the sketching plane by half of the specified angle value.
To Selected
Revolves a section up to a selected datum point, vertex, plane, or surface.Note: The
terminating plane or surface must contain the axis of revolution.
FILLET:
THIS command is used to remove the sharp edges from solid or surface model.
PURPOSE OF FILLET:
To convert the point load into uniform load.
For better looks
To make component safe for user.
Give facility during moulding.
Different method of round:--

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(1)constant round
(2) variable round

This round is similar to previous round but in this case at single edge more than one round we
create.
Right click on first round add radius.
Round the complete surface of the block:-- For round the complete surface of the block
creo.This is the best round surface obtained by this method.
RIB
RIB is used to increase the strength of the component.
IT transfer the load to all the surface.
IT convert the point load into uniform load.
PROCEDURE
GO to insert
Rib
Reference ---- define (plane)
Sketch----
Reference------
Make cross section(openloop)
CHAMFER=
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Chamfer is used to remove the edges. It also facilitate during fitment.
Dimension schemebox with types chamfer be drawn

Displays the current dimension scheme for the chamfer set and contains a list of
valid dimension schemes based on trigon metrical context. This box enables you to
change the dimension scheme for the active chamfer set. The following dimension
schemes are available:
D x DCreate a chamfer that is at a distance (D) from the edge along each surface.
Creo selects this by default.
Note: This scheme is available using the Offset Surface creation method only if the
following conditions are met: For Edge chamfers, all members of the edge chain
must be formed by exactly two 90-degree planes or two 90-degree surfaces (for
example, the ends of a cylinder). For Surface to Surface chamfers, constant-angle
planes or constant 90-degree surfaces must be selected.
D1 x D2Create a chamfer at a distance (D1) from the selected edge along one
surface and a distance (D2) from the selected edge along the other surface.
Angle x DCreate a chamfer at a distance (D) from the selected edge along one
adjacent surface at a specified angle (Angle) to that surface.
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45 x DCreate a chamfer that is at an angle of 45 degrees to both surfaces and a
distance (D) from the edge along each surface.
Note: This scheme is available only for chamfers that use 90-degree surfaces and the
Tangent Distance creation method.
SHELL:-
The Shell feature hollows out the inside of the solid, leaving a shell of a specified wall
thickness. It lets you specify a surface or surfaces that you want to remove from the shell. If
you do not select a surface to remove, a "closed" shell is created, with the whole inside of the
part hollowed out and no access to the hollow. In this case, you can later add the necessary
cuts or holes to achieve proper geometry. If you flip the thickness side (for example, by
entering a negative value, or by clicking on the dialog bar), the shell thickness is added to the
outside of the part.
When defining a shell, you can also select surfaces where you want to assign a different
thickness. You can specify independent thickness values for each such surface. However,
you cannot enter negative thickness values, or flip the thickness side, for these surfaces. The
thickness side is determined by the default thickness of the shell.
You can also exclude one or more surfaces from being shelled by specifying the surfaces in
the Exclude Surface collector. This process is called partial shelling. To exclude more than
one surface, hold down the CTRL key while selecting the surfaces. However, creo cannot
shell material that is normal to the surfaces specified in the Exclude Surface collector.
When Creo makes the shell, all the features that were added to the solid before you created
the Shell feature are hollowed out. Therefore, the order of feature creation is very
important when you use Shell.
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PROCEDURE
select the command.
fill the thickness.
remove the face.
DRAFT ANGLE:-
Draft angle is a very important tool. Draft angle give to the component for easy ejection of
component from Core and cavity. Draft angle is the process of tilting the surface of
component.
Two type of draft angle provided in creo
SINGLE DRAFT ANGLE

VARIABLE DRAFT ANGLE
Variable draft angle
This command is used to give the different draft angle at different points with the help
of this tool we can achieve complicated Shape.
SWEEP:-
This command is used to generate solid and surface by moving one cross section on single
path
Condition of sweep tool
The path should be in perpotion to the section.

Avoid the sharp edge on the path.
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Types of sweep
By sketch a path.
By select the path.
This dialog box is open at starting of command
SWEEP (PROTRUSION
This option is under the sweep tool. IT is used to create the solid by moving one cross
section on single path
PROCEDURE:-
Sketch the trajectory.
Make cross section
SWEEP (CUT):-
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This option is under the sweep tool . It is used to cut the material with the help of sweep.
Method of cut a material by sweep:-

Sketch trajectory
Select trajectory
Chose the option from this window
Window is open during using command

PROCEDURE :-
Sketch the trajectory.
Select the trajectory
Make cross section
BLEND:-
Blend is used to generate the solid and surface joining different cross section at different
depth.
location of command:----
BLEND (Protrusion)
THIS option is under the blend command. This command is used to generate the solid and
surface by joining different cross section at different depth.
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OFFSET TOOL
This command is used to create the complicated profile.
This command is also used to write something on the
Surfaces of the model.
OPTIONS OF OFFSET COMMAND :-

STANDRAD OFFSET FEATURE:-
This command is used to take the offset of a surface
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Expand feature:-
This command is used to expand the surface of the model.
REPLACE SURFACE FEATURE

This command is used to create the complicated feature.
We can write something on the any type of surface.
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PATTREN:
Some type of things arranged in particular manner is called pattren. This command is
used make the duplicate of the feature.
The round can also pattern by reference pattern.
Types of pattern:-
Dimension pattern
Direction pattern
Axis pattern
Curve pattern
Fill pattern
For axis pattern
Procedure
Draw the master feature at some pitch circle diameter
Select the feature
Click on pattern tool
Select axis
Fill no of pattern member
Fill angle or divide in to 360 degree option
Done
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VARIABLE SECTION SWEEP

With the Variable Section Sweep feature, you can create a solid or surface feature. You add
or remove material while sweeping a section along one or more selected trajectories by
controlling the sections orientation, rotation, and geometry. You can create a sweep using a
constant section or a variable section
Location of command:-
To access the Variable Section Sweep tool, click in the Feature toolbar or click Insert >
Variable Section Sweep.
Options of command
SolidSweep as solid.
SurfaceSweep as a surface.
Open the internal section sketcher to create or edit sweep section.
Solid or Surface Cut.
Thin Protrusion, Thin Solid or Surface Cut.
Change the direction of the operation to add or remove material

Steps under command:-
SWEEPT BLEND
This command is combination of sweep and blend. This Command have the properties of
both.the sweep comm.-And is definded as the one cross section and single path is required.
And blend command is definded as the joining of different cross section at different depth.
And so According to this command we can generate the solid and By different cross section
with a single trajectory
Limitation of command:---For a closed trajectory profile, one section must be located at
the start point and at least one other section at another location.
Section references at the chain start and end points of the trajectory are dynamic and update
if the trajectory is trimmed.
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Section locations can be referenced to model geometry a curve for example, but modifying
the trajectory may invalidate the references. In this case the swept blend feature will fail.
All sections must contain the same number of entities.
Helical sweep:-
This command is used to create the spring with constant and variable pitch.
Types of helical sweep:-
constant pitch
variable pitch
Boundary blend
With the Boundary Blend tool, you can create a boundary blended feature between
reference entities that defines the surface in one or two directions. The first and last entities
selected in each direction define the surface boundary. Adding more reference entities, such
as control points and boundary conditions, allows you to more fully define the surface shape.
Steps involve in the command:-
select the command .
select the edge of the surface.
Then select the curve.
Different options in the command for making the surface:--

(1)Click Constraints in the dashboard.
(2)The Boundary column lists all surface boundaries. In the Condition column, click the box
adjacent to the boundary for which you want to set the boundary condition.
Select one of the following boundary conditions from the Condition drop-down list box:
FreeNo tangency conditions are set along the boundary.this option join
The surface straight.
TangentThe blended surface is tangent to the reference surface along the boundary the
surface is both side make tangent both side
CurvatureThe blended surface has curvature continuity across the boundary.
NormalThe blended surface is normal to the reference surface or datum plane.
When the boundary conditions are set to Tangent, Curvature, or Normal, if required, click
Display drag handles to control the boundary stretch factor. Alternatively, you can type the
stretch value in the Stretch Value box. The default stretch factor is 1. The value of the
stretch factor influences the direction of the surface.
Set boundary conditions for all the boundaries as required.
Define other optional feature elements or click to complete the feature.
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FILL :-
You can create and redefine flat surface features called Fill features using the Fill tool
(Edit> Fill). A Fill feature is simply a flat surface, closed-loop feature that is defined by its
boundaries and is used to thicken surfaces.
You can create a Fill feature by doing one of the following:
Select an existing Sketch feature (sketched datum curve). You can select a Sketch
feature from the current model or from another model. The resulting Fill feature uses
a dependent section as a reference. This section is fully associative with the parent
Sketch feature.
Create an independent section for the Fill feature by Using Sketcher. You create this
section while the Fill tool remains open.
command:-
>select the command.

>define the face on which you want to create the surface.
>draw the sketch.
THICKEN ;-
Thicken features use predetermined surface features or quilt geometry to either add or
remove thin material sections in your designs. The surface features or quilt geometry provide
you with greater flexibility within your design and enable you to transform that geometry to
better meet your design needs.
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Typically, Thicken features are used to create complex thin geometry that would be more
difficult, if not impossible, to create using regular solid features.
Designing Thicken features requires you to:
(1) Select an open or closed quilt as a reference.
(2) Determine how you want to use the reference geometry: to add or remove thin
sections of material.
(3) Define the thickness direction for the thicken feature geometry

>select the surface.
>select the command.
>fill your requirement.
Option of command:-
Normal to Surface(Default) Offsets the Thickened surface normal to the
original surface. You can select individual or multiple surfaces to exclude from
the Thicken operation. The surfaces to exclude appear in the Exclude list.
Note: The Exclude list is not available for design situations involving quilts made
of unique surfaces and quilts where all but one of the quilt surfaces have been
excluded (You cannot exclude the last remaining quilt surface).
Auto FitScales and translates the thickened surface with respect to an
automatically determined coordinate system.
Control FitCreates a "best fit" scenario by scaling the original surface about a
selected coordinate system and then translating it along a specified axis. The
Control Fit option consists of:
Example:-
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SOLIDIFY ;-
To create solid geometry using quilts, you must first select the quilts before using the
required commands. There are three methods of creating solid geometry by using quilts:
Replace an entire part surface with a quilt. Surface replacement differs from
protrusions and cuts because it can add material in some places and remove it in
others. Surface replacement is a surface deformation feature, and is created using
Offset on the Edit menu.
Create a "patch", a feature that replaces a portion of a solid surface (or surfaces)
with a quilt whose boundaries lie on the surfaces being patched. This feature is
created using Solidify on the Edit menu.
Create a construction feature (protrusion, cut, or slot) by using a quilt as the solid
features boundaries. Geometry will be added or subtracted up to the border of the
quilt used. This is done using Solidifyon the Edit menu.
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Merge tool: - Merge tool is used to join one surface with other and also used for merge
one surface with other. In merge tool two options available first option is joining and
other is intersect.
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Trim tool: - Trim tool is used to cut any surface through another surface.
Apply trim tool
BOUNDARY BLEND TOOL

It is used to draw a surface between two entitles
Before boundary blend
Procedure
Draw the sketch with proper dimension
Apply center click
Click on boundary blend tool
Select all sketch entity using ctrl
Check the preview
Done
(After boundary blend)

Merge:
You can use the Merge tool to merge two quilts by intersecting or joining them. The
resulting quilt is a separate quilt coincident with the two original quilts. If the merged
feature is deleted, the original quilts remain.
There are two methods for merging quilts:
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>Use intersect to create a quilt that consists of the trimmed portions of two intersecting
quilts.
>Use join if the edges of one quilt lie on the surfaces of the other quilt.
Location of the command:----
Options of command:-
Examples :-
FILL TOOL
It is used to close the surface with the help of a new fill surface
Procedure
Go to edit
Select fill tool
Click on reference
Click on define
Select a plane
Select the perpendicular surface or edge using ctrl
Check the preview
Done
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THICKEN TOOL
It is used to convert a surface in to a solid with the help of sum thickness.
Procedure
Select the surface
Click on edit
Choose thicken tool
Fill proper thickness
Check the preview
Done
DRAFTING
In creo we will convert 3 Dimensional models to 2 Dimensional drawing. Its 2 D drafting is
difficult.
Steps for converting 3D model to 2 D model.
a) Go to file New- Drawing module
b) Give name to the file.
c) Select the model and drawing sheet size.
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d) Right click on screen and go to Drawing options and set units to mm and change other
required parameters like text height, arrow size etc.
e) Again right click on the screen and select insert general view and a dialogue box will
open.
f) Now change the required properties like user view, View display, etc
g) Now right click on this view for long time and select
Insert Projection View and draw other views
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Sheet metal ;-
Sheet metal sub types module in creo. And used for
making sheet.
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Tool used in sheet metal

Extrude: -In sheet metal extrude give the thicken value.
Flat: - Create aFlat wall of end side of any sheet.
Flange tool
Twist angle: -
Tool in sheet metal

Blend
Unblend
Deform area
Bend back
Flat pattern
form
Flatten from
Rip
Notch
Punch
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ASSEMBLY MODELING;-
An assembly is defined as a design consisting of two or more components bonded
together at their respective working positions using the assembly constraints.
The assembly designs are created in the assembly mode of creo. To proceed the
assembly mode, choose the create a new object button from the top tool chest .The New dialog
box will be displayed; select the assembly radio button from the type area and then select the
design radio button from the sub-type area and specify the name of the assembly in the name
edit box and choose OK; the assembly mode is activated.
PLACEMENT CONSTRAINTS
The assembly constraints are also called placement constraints
and are available in the Component Placement dashboard. Generaly these constraints are used
in combinations & you can constrain upto six degrees of the freedom of the compdnent.-
DIFFERENT TYPES OF CONSTRAINTS-
AUTOMATIC
When we choose this constraint, creo assumes the constraints and applies it according to the
type of entity
selected. For example, if we select axes of two components to
assemble, creo will assume that we want to apply the align constraint and the align constraint
will be applied to the two components.
MATE
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The Mate placement constraint allows to make two selected planes, datum planes, faces or a
combination of a datum plane and a face coplanar with respect to each other. The faces or
datum selected may or may not be in contact with each other.
The Mate constraint is used in combination with three options: Offset, coincident and oriented.
MATE OFFSET
If we need to keep the two faces or planes at some distance apart, then we can use the mate
constraint with some offset value. The offset distance between the coplanar faces can be a
positive or a negative value.
MATE COINCIDENT
The mate coincident combination of constraints allows to make two selected planes or faces
coplanar to each other.
Mate Oriented
The mate oriented combination of constraints is used when we want to mate two faces or
planes or a combination of the two and at the same time we want to orient some other faces or
planes of the components to face in the same direction.
ALIGN
The align constraint is used to assemble two components by making the selected faces or
planes coplanar such that the aligned faces or planes face in the same direction. Apart from
planes and faces, we can also select datum axes, datum points, edges, or vertices for applying
the align constraint.
The align constraint is used in combination with three options: Offset, Co-incident and
Oriented.
Align Offset
The align offset combination of constraints is used to align two entities with some offset
distance between the aligning entities. The offset value can be positive or negative.
Align Coincident
The align coincident combination of constraints is used to assemble two components by
making the selected faces or planes coplanar such that the aligned faces or planes face in the
same direction.
INSERT;-The Insert constraint is used to assemble the revolved components. Applying
this constraint allows the revolved component, holes, or a combination of both to share the
same orientation of the central axis.
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CO-ORDINATE SYSTEM;-
Co-ord. Sys constraint aligns the coordinate system of the first components with the coordinate
system of the second component.
TANGENT;-
The Tangent constraint is used to make the selected circular face tangent to the other selected
face or plane and at same time make them coplanar.
FIX;-
The Fix constraint is used to packs the two components & displays that the two components are
fully constrained.
Default:-
The default constraint is used to assemble the component in the assembly by
aligning the default co-ordinate system to the component with the default co-ordinate system of
the assembly. Also,the part datum planes are aligned with the assembly datum planes
Assembling Components:-
The components in an assembly can be placed parametrically or non-
parametrically. If the components are placed using the placement constraints,it is called
parametric assembly. On the other hand, if the component are packaged, it is called non-
parametric assembly.
To assemble the components parametrically, choose the Assembly button; the open
dialog box will be displayed. Once you select the part to assemble from the open dialog box,
the component placement dialog box will be displayed.
The component dialog box has multiple function. This dashboard is used for both
constrained & packaged placement of the components,
There are four tab in this dashboard; Placement, Move, Flexibility & Properties.
Placement tab:-
When you choose the Placement tab, the side down panel will be displayed. The option in the
side down panel is as:
Constraint type drop down list:-
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This drop down list displays the placement constraints that are available to assemble the
components. You can select the constraints from this drop down list to assemble components
in an assembly.
Offset drop down list:-
This drop down list is used to specify the offset value for the placement
constraints. This drop down list has three options, offset, oriented, & coincident. All these
options are used in combination with Mate & Align constraints.
New Constraint Option:- This option is used to specify a new set of constraint to the
assembly components.
Change Orientation of constraint button:-

This constraint button is used to change the orientation of the constraint
applied, this button is used only after a constraint has been applied to the components & is
not available initially when the component placement dashboard is invoked.
a) Select component item collector:-
This collector displays the entities of a component that have been chosen to assembly it
with the parent component.
b) Select assembly item collector:-
This collector displays the entities of the parent component that have been chosen to create an
assembly.
Move tab:-
This option in the move tab can be used only if you have chosen the show
component in the assembly window while specifying constraints buttons. This tab is used to
move or rotate a component along a degree of freedom that is not constrained.
1) Motion type drop down list:- The options in the Motion type drop down list are as:-
a) Orient Mode:-
This option if selected, orients the part in the assembly about its spin center.
b) Translate:-
This option if selected, moves the component from its current location in the
assembly. However, remember that the component can be moved only along the degree of
freedom that are not constrained.
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c) Rotate:- This option if selected, rotates the components in the assembly along its
available degree of freedom.
d) Adjust:-
This option is used to pack a component with reference to the assembly. When you
select this option, you will be prompted to select a surface on the packed component to adjust
the reference plane. The component is assembled according to the surface specified.
Assembled Part
CORE CAVITY
First input to engineer-
2D drawing
Engineer cad
3D model Dimenssion and allowance
MFG. module
Core,cavity,slider,insert
1. CAM
2. Assembly or die design
CAM:
1.1. CNC and NC code
1.2. onventional m/c
CNC and NC code;

Assembly
Production department
Mass property & sample peace
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Quality control
These all inputs are used to make core cavity.

Core cavity is used to make die of any component either it is plastic, die steel, al, zinc.
For plastic component mold cavity is used
For another material - cast cavity is used
Steps include to develop core cavity

Create any part in part module
Change units
Save
Now open new-MFG-mold cavity
A diloge box open menu manager
In that box click on mold model locate ref part than change units.
And change its unit.
See its pull direction is upward if not
Then click redefine
Then click PRT_CSYS_DEF
Then click dynamic
Give value
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Now give shrinkage
Steps:-
1. Click on shrinkage
2. By scaling
3. A dialog box open
4. Select CSYS
5. Give shrinkage ratio
6. Then ok
Now make a mold box
It is of two types:-
1. Automatic
2. Manual
In this I create manual
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When we draw mold box after ok it comes in green colour.
Now silhouette curve- It creates automatic parting line

Make sure it is auto define
Click preview
Ok
When click ok it show parting line in blue color
Now click on parting surface it create surface around silhouette curve.
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In creo software parting surface in between mold box.

Now click on vol. split.
When we click on vol. split it ask us to select parting surface. And when we select &
click ok than a dialog box open vol.one & when again we click vol.2 show ok.
In the model tree it show split vol.

Now final step is click on cavity insert
It show dialog box
In which we select both vol. which are shown
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After selection it shows two vol. in model tree.
One is cavity and

Other is core
To see it right click on that in model tree and click open cavity
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core
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RAPID PROTOTYPING TECHNIQUE

GNA UNIVERSITY (PHAGWARA)
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INTRODUCTION
Additive manufacturing or 3D printing is a process of making three dimensional
solid objects from a digital model. 3D printing is achieved using additive processes, where an
object is created by laying down successive layers of material.3D printing is considered
distinct from traditional machining techniques (subtractive processes) which mostly rely on
the removal of material by drilling, cutting etc.
PROCEDURE
PROCEDURE
3D printing is usually performed using a materials printer, and since 2003 there has
been large growth in the sales of these machines. Additionally, the cost of 3D printers has
gone down.The technology also finds use in the fields of jewellery, footwear, industrial
design, architecture, engineering and construction (AEC), automotive, aerospace, dental and
medical industries, education, geographic information systems, civil engineering, and many
others.
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Additive manufacturing (AM) also known as 3D printing is defined by

ASTM as the "process of joining materials to make objects from 3D model data, usually layer
upon layer, as opposed to subtractive manufacturing methodologies, such as traditional
machining. Synonyms include additive fabrication, additive processes, additive techniques,
additive layer manufacturing, layer manufacturing, and freeform fabrication".The term
additive manufacturing describes technologies which can be used anywhere throughout the
product life cycle from pre-production (i.e. rapid prototyping) to full scale production (also
known as rapid manufacturing) and even for tooling applications or post production
customisation.
Industrial uses
Industrial 3D printers have existed since the early 1980s, and have been used
extensively for rapid prototyping and research purposes. These are generally larger machines
that use proprietary powdered metals, casting media (i.e., sand), plastics or cartridges, and are
used for many rapid prototyping uses by universities and commercial companies. Industrial
3D printers are made by companies such as ExOne, Objet Geometries, Stratasys, 3D
Systems, EOS GmbH, and Z Corporation.
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of
a physical part or assembly using three-dimensional computer aided design (CAD) data.
Construction of the part or assembly is usually done using 3D printing technology.
The first techniques for rapid prototyping became available in the late 1980s and were used to
produce models and prototype parts. Today, they are used for a much wider range of
applications and are even used to manufacture production-quality parts in relatively small
numbers. Some sculptors use the technology to produce exhibitions.
A number of competing technologies are available to do 3D printing. Their main
differences are found in the way layers are built to create parts. Some methods use melting or
softening material to produce the layers, e.g. selective laser sintering (SLS) and fused
deposition modeling (FDM), while others lay liquid materials that are cured with different
technologies, i.e. stereolithography (SLA). In the case of laminated object manufacturing
(LOM), thin layers are cut to shape and joined together (i.e. paper, polymer, metal). Each
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method has its advantages and drawbacks, and consequently some companies offer a choice
between powder and polymer as the material from which the object emerges.Generally, the
main considerations are speed, cost of the printed prototype, cost of the 3D printer, choice
and cost of materials and colour capabilities.
About Dimension / Stratasys
Dimension is a brand of 3D printers by Stratasys that
offers CAD (computer-aided-design) users a low-cost,
networked alternative for printing functional 3D models from
the desktop. The printers build models layer-by-layer using
ABS plastic, one of the most widely used thermoplastics in
today's injection-molded products. Dimension 3D printers
allow users to evaluate design concepts and test models for
form, fit and functionality.
Stratasys invented its patented FDM (Fused
Deposition Modeling) technology in 1988 and has led the
development of 3D printing technology ever since. Stratasys
uses its FDM technology in both its Dimension 3D Printers,
as well as its Fortus 3D Production Systems, developed for
direct digital manufacturing and precision rapid prototyping.
The company also operates Redeye On Demand, a digital manufacturing service.
Stratasys holds more than 180 granted or pending additive fabrication patents
globally. Stratasys products are used in the aerospace, defense, automotive, medical, business
& industrial equipment, education, architecture, and consumer-products markets.
RPT PROJECT:
FLANGE MARITOR
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THE VARIOUS STEPS IN VOLVED IN DESIGNING

AND MANUFACTURING OF FLANGE MARITOR
ARE EXPAINED IN DETAIL BELOW:
PREPARING CAD DATA FOR FLANGE MARITOR
Sketch: -
sketch is a combination of entities, which can be a closed figure or a open figure. It is 2D

view of a component, which is used for a protrusion of component.
First by using of line entity, draw a figure. Figure must be close because of the solid object.
Lines are draw by the Line chain command. Fillets are also draw by the Fillet command,
which is placed in the sketching group area as shown in figure.
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Axis of Rotation: -
The axis of rotation is used to revolve the sketch along the axis. axis of rotation is depend
on the direction of the axis. If the axis is placed along the z-axis then sketch will also revolve
in that direction. So dependency of the sketch directly to the axis, where axis can be draw on
the sketch group. As shown in fig.
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Revolve command: -
Revolve command is protrusion command which is used to revolve the sketch around the
axis. Revolve command need two objects: -
a. A sketch
b. A Axis of rotation
Steps: -
1. Open the revolve command
2. Then click on the sketch
3. Then hold the Ctrl key on the keyboard
4. Then select the axis of rotation.
5. Set the angle up to 360 degree.
6. Then click OK option on the dashboard.
As shown in figure.
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Chamfer: -
Chamfer means generating the angular plane on edges.
Uses:-
1. Chamfer command is used to remove the sharp edges from the component.
2. Chamfer is also use for fitment of the two components together.
3. Chamfer is also used for decreasing the stress concentration on edges.
4. Chamfer is also used for saving the material from wastage.
5. Chamfer is also used to decreasing the weight of the component.
As shown in fig.
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Surface Broaching: -
Broaching is done by the extrude command where both sides are removed by the sketch.
Steps: -
1. First select the extrude command.
2. Then select the middle plane of the planes.
3. Then sketch option will pop up on the screen window.
4. Then draw the cross-sectional area of the broach.
5. Click OK from the Dashboard.
6. Then go to option tab on the dashboard and select both sides as "through all".
7. Then select the remove material option on the dashboard.
8. Then click OK from the dashboard.
As Shown in fig.
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Pattern: -
Pattern is used for generating the duplicate copies of feature in any direction and any place
(depends upon the option of pattern you select).
Steps: -
1. First select the feature.
2. Then select the pattern command.
3. Then select the direction type of pattern from the option on left side.
4. Then select the plane in which direction to want to make duplicate copies of feature on
both side.
5. Then Click OK from the dashboard.
Pattern
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Holes: -
Hole is the pick and place type of feature, which is used for generating the Cylindrical holes
on the part.
Steps : -
1. First select the Hole command from the toolbar.
2. Then select the plane at which you want to generate the holes
3. Then edit the dimension of the hole and the hole placement.
4. Then go to the option tab on the dashboard.
5. Then select the second side as the "through all" option.
6. Then click Ok from the dashboard.
As Shown in figure.
Hole
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DATA MIGRATION:
Data migration is done to convert the CAD data into other format for Prototype production
and CNC manufacturing purposes. For data migrarion copy of the cad file is saved as in
some other file format according to required format.
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3D MODEL PRINTING USING RPT ( REPID PROTOTYPE

TECHNIQUE)
3D PRINTER
Additive manufacturing or 3D printing is a process of making three

dimensional solid objects from a digital model. 3D printing is achieved using
additive processes, where an object is created by laying down successive
layers of material.
3D Printer worked on FDM (Fused Deposition Modeling) technology
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FUSED DEPOSITION MODELING (FDM)

Involves melting a thermoplastic polymer and squeezing thin filaments
out of a nozzle, layer by layer, on a building platform. As the material
descends to the platform, it is immediately hardened.
3D printing is considered distinct from traditional machining techniques (subtractive

processes) which mostly rely on the removal of material by drilling, cutting etc.
FDM
A second nozzle supplies soluble support material, if necessary, to the
building platform to prevent certain geometry from deflecting because
of gravity.
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MATERIALS USED
Usually Polyester, ABS Plastic, or Casting Wax.
Acrylonitrile Butadiene Styrene (ABS) as Building Material
(Chemical formula (C8H8)x (C4H6)y(C3H3N)z) is a common
thermoplastic)
Support Material: ABS_S (Styrene Terpolymer)
Polylactic Acid (PLA)
(BASS: Break Away Support Material)
FDM
When the process finishes, the FDM part is immersed in an alkali
chemical ( pH 11.5 ) bath to remove the support material. Depending
on the machine, the nozzle can move across a stationary platform or
the nozzle may remain stationary while the platform moves.
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3D MODEL OF THE PROJECT
3D printer based on FDM technology is controlled by Catalyst software.
Scale used : 0.3

Model Material used : 13.94cm3
Support material used : 3.07 cm3
Total layers formed : 116
Min Machine temprature required : 700 C
Min Model Material Nozzle temprature required : 3000 C
Min Support Material Nozzle tempraturerequired : 3000 C
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CAM
(Computer Aided Manufacturing)
Computer aided Manufacturing(CAM) is assistance of computer in
manufacturing planning and processes like planning different
operations to be done on product, sequencing all the operations and
finally control the machine parameters like Feed, Speed, Depth of
cut etc.
CAM uses CAD data to control automated machinery. CAM systems
are associated with computer numerical control (CNC) or direct
numerical control (DNC) systems. These systems differ from older
forms of numerical control (NC) in that geometrical data is encoded
mechanically. Since both CAD and CAM use computer-based
methods for encoding geometrical data, it is possible for the
processes of design and manufacture to be highly integrated.
Computer-aided design and manufacturing systems are commonly
referred to as CAD/CAM
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Benefits of CAM:
1. Improve productivity.
2. Lead time reduction.
3. Reduce engineering personal requirements.
4. Improve accuracy of product.
5. Fewer errors in NC part programming. .
6. Saves material and machining time by optimizing algorithm.
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Major CAM Softwares
Software Company
NX 8.5 (Unigraphics) Siemens PLM Software
Master cam CNC Software
CATIA Dassault Systmes
Cimatron Cimatron group
Edge cam Planit (Path trace)
Power mill Delcam
T-FLEX Top Systems Ltd.
Solid CAM Solid CAM
Pro/Tool Maker PTC
Tebis Tebis AG
Work NC Sescoi
CAM Works Geometric Tech.
ESPRIT DP Technology
Gibbs CAM Cimatron Group
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Manufacturing processes:-
It is basically classified into 3 types as follows
NC (Numerical Controlled).
CNC (Computer Numerical Controlled).
EDM.
Numerical Controlled machine

The machines that are automatically operated by commands which are
received by their processing unit are called cnc machine. The
commands are given in the form of coded instructions are in letters
and other symbols. The commands are fed through an external
medium such as punch card, punch tape, magnet tape etc.
The program containing the required data for the production of a
component is punched on the tape. The data on the tape is in the form
of binary codes. Tape reader reads the data and is stored into memory
of the control system called buffer memory and is proceeding by the
machine step by step.
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NC machine tool has the following features:

Control using numerical data.
High degree of accuracy.
High material removal capacity.
Increased tool life.
Reduced inspection.
Computer numerical machine:-
In computer numerical system, a dedicate computer is used to perform
all the basic NC functions as per the control program stored in the
memory of a computer. The use of computer makes the system
flexible so that the system can on a different type of machine tool.
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The main function of the cnc system is the control machine tool
which involves convection of the part program instruction into
machine tool motions through the computer interface and servo
system. The term soft-wired system is also used because of the fact
that the control logic for the machine tool is generated by software
program.
Because of memory availability, user can also store in the computer.
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Features of CNC Lathe

The tool or material moves.
Tools can operate in 1-5 axes.
Larger machines have a machine control unit (MCU) which
manages operations.
Movement is controlled by motors.
Tool magazines are used to change tools automatically.
PROGRAM INPUT
MDI : Manual Data Input
PROGRAM PREPARATION WITH CAD CAM
PROGRAM DATA TRANSFER FROM PC TO CNC M/C
EDM (ELECTRODE DISCHARGE MACHINE)
Here the cutter used is in a form of electrode whose shape is 100%
similar to core and cavity but here when scaling is given it is given to
reduce it value because it expands on getting hot or molten.
MATERIAL USED FOR ELECTRODE ARE AS FOLLOWS:-
Copper.
Graphite.
M.S.
While making the cutter i.e. electrode we use high speed milling
machine because copper and graphite is very hard and if HSM is not
used then material may crack. In this process electrode removes the
material from the core or cavity in the form of small particles by
eroding the material so it turn black in color due to burning. It is
mainly done for ribs.
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POLISHING: -
It is the last step of manufacturing here die which turns black due to
EDM is polished by emery paper or diamond polishing is done for
small holes.
SOME OF THE TERMS IMPORTANT FOR CAM:-

Tool magazine: -
In it there are number of tools present depending on the capacity of
CNC machines which may vary up to 80 tools.
Origin:-
Here there are two co-ordinate systems
WCS (Work co-ordinate system).
MCS (Machine co-ordinate system).
Origin should be placed either at the center or at the corner. But

mainly it is useful to set at the center because we have to grind the
sides to make it set at the corners .Z- axis of MCS or WCS should
always be set in upward direction and always at the top of the core or
cavity and somewhat more than the height of component.
TYPES OF CUTTING TOOLS
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Flat end mill cutter.

Bull nose cutter.
Ball mill cutter.
Face end mill cutter.
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Flat End Mill Cutter:-

Bottom surface of this cutter is totally flat and have sharp corners.
They are mainly used where we sharp corners and planer surface. The
nose radius is zero.
Bull Nose Cutter:-

It is a flat end mill cutter but has a nose
radius which depends on ISO standards.
Nose-radius
Some Standards: (In Dia.)

1,2,3,4,6,7,8,10,12,16,20,25,30,32,40,50
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Ball Mill Cutter:-

Its corner radius is equal to the radius of the cutter.
TYPE OF MATERIAL OF CUTTING TOOL:-

HSS:-It has less stress and strain capacity.
Carbide:-It has a mixture of cobalt, chromium, steel.
Solid carbide:-It has a mixture of cobalt, chromium, tungsten
and titanium.
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TYPES OF CNC AND CNC MACHINE CENTRE ACCORDING

TO AXIS:-
2 axes machine:-in it x and y axis moves at same time but z
axes take a separate move and also axes is a separate
attachment so as to rotate the object along an angle.
3 axes machine:-it is used to generate 3-d profile like concave
or convex shapes.
4th axes machines:-Here a horizontal spindle is also present
which is the 4th axes and it helps to make holes or any profile on
the sides of the component.
5th axes machine:-it consists of pallets (they are small beds or
table like structure placed on main bed and below them are
placed parallel and rotary mechanisms so as to obtain angular
tilt along x and y and rotary along z axis.
7th axes machine.
9th axes machine.
ACCORDING TO CONTROL SYSTEM:-

Fanuc:-It is a Japan control system.
Heidenhain:-It is a Switzerland control system.
Sinumeric: - It is a Germany control system.
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Laxmi numeric: - It is India control system.
TYPES OF CNC USED IN INDUSTRIES

Three types of machines used into different Industries.
Conventional m/c (Small scale Industries)
NC m/c (Medium scale Industries)
CNC m/c (Advance Industries)
Conventional M/C
Two Axis m/c such as lath (Z, X).
Three Axis m/c such as Milling m/c (CX,YZ)
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NC Machine (numerical machine)

Program is written on the punch card and tap.
Program editing not possible.
Speed, feed and depth of cut cannot change.
Memory space is not available.
Cutter profile programming not possible.
Generally used for lathe NC m/c.
CNC Machine (Computer Numeric Controlled M/C Computer)
It is fully automatic m/c and has a mini computer and Control
panel board.
Memory space available for store the small programs.
Productivity and accuracy more than NC machine's.
Have an ATC Automatic tool changes.
Can Cewe, Canven and counter profile cutting possible more
accurately?
You can see also animation on the panel board.
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PROGRAMMING
There are two types of programming.
A
1. NC programming.
2. CNC programming.
B.
1. Manual programming.
2. Automatic programming
Program is a meaningful data arranged in a particular sequence,
provided to the CNC machine by CAD designer.
NC programming
GOTO X 150, Y0
GOTO circle RI0
GOTO point 150 it is cutters location language.
How we can write the program?
1. Program Number.
2. Study the drawing.
3. Calculate the X, Y value points.
4. Decide the control system of the CNC mc.
5. Decide cutter size and type dia of cutter.
6. Set the origin point of the Raw material.
7. Write the program.
8. Simulation of the program.
9. To CNC m/c send and give industries of operates.
Words used in program
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1. N stands for No.

2. F stands for feed.
3. R stands for Tool Number.
4. T stands for Tool Number.
5. S stands for Spindle Speed
CNC PROGRAMMING
Program contains number of blocks each block contains number of
lines each line contains number of units each unit contains number of
words each word contains two words is following:-
(a) Numeric word.
(b) Alphabetic word.
Various Codes used for programming:-
Two types of codes used for programming:-
1. G code stands for geometry code of prosperities code.
2. M code stands for m/c code of misllenaus code
G- code profile (Drawing shows)
M- Code shows coolants on/off, spindle speed, feet etc.
G- Codes
Tool movement
1. Positioning movement (Rapid moment)
2. Cutting movement
Tool magazine (Tool holds )
NC milling centre have a single or double magazine
Fanuc have 16 to 20 tool magazine
Deckle have single 40 tools and double magazine 80 tools
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Manual part programming

Machine codes same for every m/c.
G-code different for every CNC m/c according to control
system.
ISO program is standard CNC program
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ISO
G-Codes (Position movement)
Goo Rapid movement
G01 Linear interpolation
G02 Circular interpolation in clock wise
G03 Circular interpolation in counter clock wise
G04 Dwell (little wait)
G17 XY plane (most important)
G18 ZX plane
G19 YZ plane
G30 Minimum corners of raw material
G31 Maximum corners of the W/pc
G40 Compensate condition (Cancel)
G41 Left hand compensate
G42 Right hand compensate
G70 Inch programming
G71 mm programming
G75 Rectangular packet milling CW
G76 Rectangular packet milling Anti CW
G77 Circular packet milling CW
G78 circular packet millings counter clockwise
G79 Cycle call
G83 Drilling cycle
G90 absolute programming
G91 Incremental programming
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G98 Level sat

G99 Tool information
M-Codes:
M02 Program stop but offset is retain
M30 Program stops and reset
M03 Spindle rotation CW
M04 Spindle rotation stop
M06 Tool call
M08 Coolant on
M09 Coolant off
M13 Spindle rotation + Coolant (Clockwise)
M14 Spindle rotation +Coolant (Counter clockwise)
PROGRAM
Note:-Spiral cutting is two types spiral in and spiral out.

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ISO parameters
1. Packet level
2. Packet depth
3. Packet size and width
4. Length
5. Cutter Size
6. Feed of cutter
Rectangular packet milling cycle
Po1 = Set up = (Zo)
Po2= Total depth = (-15)
Po3= depth of cut (-1)
Po4= Z direction feed = (100)
Po5= Length of the pocket = X distance (100)
Po6= Length of the pocket = Y distance (50)
Po7= X,Y feed = (700)
Circular packet milling parameters:-
G77 Cw
G78 CCw
Po1 Set up
Po2 Total depth
Po3 Depth of cut
Po4 Z direction feed
P05 Radius of packet
Po6 XY feed
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HEIDENHAIN CONTROL SYSTEM PROGRAMMING

It is only alphabetic programming other control system used both
alphabetic and numeric programming.
1. Began PGM1MM (program start new), PLP=Plain language
programming (Dialog version programming)
2. BLK form 0.1 X -1- Y -10 Z -10
3. BLK form 0.2 X - Y- Z
4. Tool DEF T 1 L O R 10 (Fool definition)
5. Tool call (t) 1 (plain) Z S 2000 Mo3
6. L (Linear movement) X 0 Y 0 Z 0 F manual (if enter
without value)
7. L X - Y - Z - 0 F 100
8. Lbl Set 1 (label set)
9. Lbl z -1 (more mental programming)
10. CR X - Y- R - Dr (Direction CW or CCW)
11. LBL Set 0
12. LBL Call 1 Rep - 9 (Repeat)
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COMPUTER AIDED MANUFACTURING

1. CAM Terminology programming
a) Manual part programming is base of automatic programming.
b) Cam knowledge is constant.
2. Origin point-
MCS Machine co ordinate system
WCS W/pc co ordinate system
MCS is placed with respect to WCS
3. Stock top & Appear limit always Z 0
4. Stock bottom - lower limit Z - (value) -60
5. Work piece
Work piece is raw material which is machined by CNC
machine
Auto block:-For automatically deciding the w/pc size itself.
Cutting method (Cut method) is following:
Zig cutting Uni direction cutting
Zig - Y direction cutting
Spiral in & Spiral out
Spiral in :-From out to inward cutting.
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Spiral out :-From in to outward cutting.

Follow periphery used in UG.
Follow part.
5. Stock-
a. Part stock varies form 1 to 0.8 mm.
b. Flow stock .8 to .5 mm .
c. It may both same > part stock same as flow stock.
6. Blank stock- (Not-Required for UG)
7.Trim stock-
Not required because advance use to clamp side.
OPERATIONS PROCESS PLANNING
1. Roughing operation or volume clears operation -
To achieve the rough shop of the die.
2. Semi finishing operation -
This operation is called profile milling operation and in VG
called IPW operation.
3. Finishing operation or copy milling operation.
1. Depth of cut:-
a For En 30, E31, P20, H11------- HSS----.5 to .7.
b Carbide cutters------.5 to .9 some time 1mm.
c If Material is Aluminum, MS or En-1 to 1.5 for solid
carbide cutters.
d For Die steel or H11-------blow .9 for carbide or solid
carbide.
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2. Feed Rate :-
3.1 Rapid feed- From tool magazine to top of the w/pc Give
minimum.
3.2 Approach feed -More them 1200 to 2000 mm/m upto Z 5.
3.3 Cutting feed- Depend upon Raw material and cutter
material
3.4 Cutting feed proportional to the speed of spindle.
3.3 Engage feed- From positioning of tool Z 5 to first touch of
cutters Z 0.
3.6 Entry feed called in VG.
3.7 Exit feed - Is equal to Approach feed.
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3. Speed and Feed:-

Tool Diameters Speed
Feed
T1 40 1200 - 1800 1000 - 1500
T2 20 1500 - 2000 800-
1000 T3 16 2200 - 3000
700 - 900
T4 12 2500 - 3500 600 - 800
T5 10 " " " "
T6 80 2500 - 4500 500 - 700
T7 60 3000 - 4000 300 - 700
T8 30 3500 - 5000 200 - 600
T9 20 4000 - 5000 100 - 200
T10 10 5000 - 100 -
150
Note:- (Cutting tool chart available form tool industry
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BASIC STEPS TO BE FOLLOWED IN ANY PROGRAMMING

ARE AS FOLLOWS
(1) Volume clear operation mainly known as cavity milling:-
It is a roughing operation. In it maximum amount of material is
to be removed sp cutter size to be taken here is maximum but
we should keep in consideration the size of the block.
(2) IPW operation (In Process Work):- It is also a roughing
operation but here tool cuts materials on small features only
where volume clear cutter cannot go and so tool used here is
smaller than cavity milling.
(3)Finishing operation :-It is of two types
1. Area milling.
2. Z-profile operation.(It is of 3 types)
With steep angle.
Non-steep.
None.
Steep angle means cutter will cut the surfaces more than the angle
specified and Non steep angle is just the opposite of steep angle.
Basic difference between area milling and z-profile operation is that
in area milling cutter enters the amount of material to be removed
once and then completes the whole operation of cutting.
In z-profile cutter moves in steps to remove the material.
Flow cut operation: - it is done to make corners and fillets being left
out. They are of three types as follows:-
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Single line:- Here the fillet made does not matches to the side
surfaces and so we have to use emery paper to smoothen it.
Multiple line:- Here the cutter matches the fillet with end surfaces
but does it by using passes from centerline.
Reference tool:- Here also the fillet matches but here the cutter
makes a circle of diameter more than the fillet radius so while cutting
it takes the circle as the reference circle and so matches the fillet t to
its side surfaces.
Localize or section operation.
Planner milling
Face milling
CLAMPING: - Although not used now a days mainly but they are
mainly used to hold the raw material from which core or cavity would
be made.
TRANSFORMATION OF DATA FROM ONE SOFTWARE TO
ANOTHER
Firstly make the step file by saving the data, if in pro/e save it as
.prk then directly open in UG
Now part in UG
1. Rotate:-Middle button
2. Ctrl + Middle button:-Zoom in & Out
3. Shift + Middle button:-Pan
WCS Format click Editing in centre
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MCS Change applications to manufacturing locks operation

navigator Right click and pick geometry view edit MCS
WORK PIECE:-
edit w/pc
dialogue box is open
pick part > select all > ok
pick block> Auto block> ok
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Now part is ready to start operator.

First operation:-
(1) Cavity Milling
Right click on W/pc
Pick insert
dialogue box is open
pick volume clear and ok
Now:-Cavity mill dialogue box is open
1.Main :-
Select cut method'.
Give stop over distance in percentage.
Give global depth value.
Pick 'Cutting' on cavity mill dialogue box cutting parameter
dialogue box is open.
eg.2 Feed put the values of different feeds:-
1. Rapid feed
2. Approach feed
3. Step over feed
4. Cut
5. Engage feed
6. Transverse feed
7. Exit feed
2.Groups:- A Select new milling cutter
Put diameter of cutter
Put lower radius value
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Put number of fluts

3. Click on generate icon for generate the tool path:-
After generate tool path see dynamic verification.
Right click on operation
Pick verification one dialogue box is open
Click on 2D and play
After see verification always click on, ok.
Second operation is semi finishing operation
IPW Operation> Insert > Cavity mill dialogue box open.
1. Main: Select cut method-> Follow part

Global depth per cut 0.5 to .6
a. Cutting 1. Strategy
2. Stock use floor stock same as part stock
3. Connection a open passes
4. Containment (a) in process W/pc Use 3D
b. Feeds and speed put values
2. More:- Trim boundary Select boundary
Side turned out side
Geometry type trim
Mode curve or edges
Chaining
Pick boundary and create next boundary, ok
3. Groups Select tool
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Third operation is finishing operation Area Milling:-
Insert operation > fined contour, ok

Now one dialogue box is open
First of all change body to area milling
1. Feed Rates Put speeds and feeds

2. Trim boundary Select boundary
3. Step over distance
For plastic mold .2to.
For costing mold .3to.5 mm
For sheet mold .4to.7 mm standard
SUPER FINISHING BY EDM MACHINE

After CNC machining of work piece for small feature where CNC
tool reachable EDM machine is used.
In this machine
* Cutting is elected
* Cutting process is current
* Cutting material is die.
POLISHING: Polish the die for to achieve super fin shined die
surface
1. Grinder (Surface grinder, proto type grinder diamond
grinder)
2. Emery paper or sand paper.
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3. Files.
EDM(electric discharge machine)
Electrode Cutter port
Die Cutting port
Electric power cutting process
Material of Electrode
1. Graphite
2. Copper (Auto port and large ports)
3. Mild steel (Home allowance)
4. Depth cut - 0.1 mm
Note: EDM electrode machined on high speed milling centre, speed is
5000 to 50,000.
DNC CONCEPT
Direct numerical control
Distributor numerical control
CL file > Cutter location file have a NC programming which not used
in CNC machine.
CL file convert into PPR file (Post process file) according to
control system of the CNC machine. TP file sent to CNC
machine for machining the work piece.
Three DNC software available in the market

1. PCIN
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2. U24
3. Win DNC (Automatic pause the program)
DNC software setting terminology

1. Baud rate 4800 (Standard) 9600
2. Two port
a Cam 1 - Sent
b Cam2 - Receiver
3. Parity
Send program into odd no and even no.
4. Step bet (data bet)
5. Bytes Program sending in bytes 7 bytes and 8 bytes
NOTE: - Data transfer process in continue send program to CNC

machine according to machine's capacity.
If DNC software open
Continue flow process by DNC software
In deckle machine we can set no. of origin
Output CLSF
Port process (Output file Nam) ok.
Pick 'Build' section and make section on the wise frame shown
in fig.
Pick revolve command pick section and pick axes (Showing fig)
Revolve dialogue box is open put the angle 360 degree and ok.
GETTING STARTED WITH MANUFACTURING MODULE
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A few preparatory steps need to be performed on every CAD model

before moving it into the CAM environment. We are going to work
with one of the models that were given in the exercise problems. For a
change, all the units are followed in millimeters in this model and
manufacturing of the component.
Setting Machining Environment

Now we are set to get into the Manufacturing module.
Select START MANUFACTURING.
A window will pop up asking for the Machining Environment Setup.
There are many different customized CAM sessions available for
different machining operations. Here, we are only interested in the
Milling operation.
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Machine Coordinate System (MCS)

Click on the Geometry View icon in the toolbar to initiate setup
for programming or Right click in operation Navigator Window
> Dialog Box Open> Select Geometry view.
On the Operation Navigator window, double-click on

MCS_MILL
A pop-up window will allow you to set the MCS however,
you want. NX7.5 will also allow you to set WCS however,
you want.
But the z axis must be set upward.
Click on the dynamic button shown.
Click OK to select it as the MCS
Click OK when you are done orienting and positioning
the MCS
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Geometry Definition
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Double-click on WORKPIECE in the Operation Navigator. If

you dont see it, click on the plus sign next to MCS_MILL
The pop up window MILL_GEOM appears. This is where you
can assign the part geometry,blank geometry, and check
geometry if any
Click on the Part icon
Select the design part and click OK
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Click the Blank icon

This will open the Blank Geometry Window. As mentioned
earlier there are many ways to assign the blank.
You can use a solid geometry as the Blank or can allow the
software to assign a prismatic block with desired offsets in the
X, Y, and Z directions.
As we have already created a Rectangular Solid Geometry, we
can use that as the Blank geometry. Remember that our block is
hidden.
Retrieve the block by pressing <Ctrl> + <Shift> + B
In the Blank Geometry window, make sure the
Geometry radio button is selected.

Select the block and click OK
Bring the part geometry back by pressing <Ctrl> +<Shift> + B
once again
Click OK on the MILL_GEOM dialog box
Now we are finished assigning the Part and Blank geometries.
Sometimes it may be required to assign Check geometry. This
option is more useful for shapes that are more complex or 5-
Axes.
Milling operations where the Tool cutters have a higher chance of

dashing with the fixtures. In our case, it is not very important to
assign a Check Geometry
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CREATING OPERATION AND PARAMETER SETTING
1. cavity mill :-
The Manufacturing setup is now ready for us to work further with

Programming Strategies.
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There are many different strategies involved in programming and it

takes practice to know which one is the most efficient. Here, the basic
guidelines are given for the most widely and frequently used
strategies. The chapter will also cover important parameters that are to
be set for the programs to function properly.
Click on the Create Operation icon in the toolbar as shown or

right click on work piece>insert>operation.
The Create Operation window will pop up.
Make sure the Type of Operation is mill_contour
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There are many different subtypes under Mill-Contour, namely Cavity

Mill, Z-Level, Follow Cavity, Follow Core, Fixed Contour, and so on.
These different subtypes are used for different situations and profiles
of the design part. As mentioned before, how you select a strategy for
any situation depends on your experience.
Click on the CAVITY_MILL icon at the top left as shown in

the figure.
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Change the Program from NC_PROGRAM toPROGRAM

Change the Use Geometry to WORKPIECE
The program takes the default name CAVITY_MILL
Click OK
The program parameters window with CAVITY_MILL in the title bar

will pop up. On this window, you can set all the parameters for the
program. A brief introduction on every important parameter and
terminology will be given as we go through the sequence.
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2. z-level:-
Right click on the cavity mill ,click on the insert , then go to

operation.
Then click on the mill contour in the operation type.
Then select the z-level, which are in the 5th position of the 1st
row.
Then click ok.
This operation is used for finishing the vertical faces of the
component. It is project the tool-path from z direction.
Specify cut area:- select the specify cut area option, shown in
fig. Then
Select the surfaces ,which are to be finished.
In this operation, the yellow surfaces are selected, which are shown
in fig.
Then select the cutting tool, fill the parameters.

Then fill the cutting parameters.
Then fill the values of feed speed.
Then generate it.
AFTER GENERATING AND VERIFICATION:-
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Only vertical surfaces are finished, but the horizontal surfaces are not
finished, which are shown.
3.Fixed contour:-
Right click on the z-level, then click on insert, then go to

operation.
The operation type is mill contour.
Then select the fixed contour, which are in the first position of
the second row.
Then click ok on it.
This operation is more useful to finishing the horizontal faces of the

component.
In this operation, the tool-path is project on x-y direction.
Specify cut area
After it select the tool, fill its parameters.
After it select the cutter parameters, fill the parameters.
Then select the feed speed, fill its values.
Then generate it.
AFTER GENERATING AND VARIFICATION:-
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In this figure, all surfaces of the component are finished. The tool
path is generate only horizontal surfaces. So, with the help of these
both operations
the complete finishing of the component is make.
4.Flow cut ref.tool:-
Right click on the fixed contour, then go to insert, then go to
operation.
The opn type is mill_contour.
Then select flow cut from the dialog box.
Then click on ok.
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This operation is used to finishing the fillets, convex and concave

shapes. In this the ref. tool value is giving twice to the tool dia.
After generating and verification:-

2.TOOL CREATION AND SELECTION:
One of the most important decisions to make is selecting the right

shape and size of the tool to use. Before starting with the Tool
parameter settings, we must first know about the types of Tool cutters.
The Milling tool cutters are categorized into three main forms of
cutters. When selecting a cutter, it is important to take into
consideration the size, shape, and profiles of the design parts.
For example, if the corner radius of a pocket is 5 mm, the pocket

should be finished by a cutter with diameter less than or equal to 10
mm. Otherwise it will leave material at the corners. There are other
special forms of cutters available in markets that are manufactured to
suit this need.
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In the CAVITY_MILL pop-up menu click on the

Create New button in the TOOL, dialog box Click NEW
On the New Tool window, select the Mill icon
Type in BUEM12X1 as the Name and click OK
This will open another window to enter the cutter dimensions and
parameters. You can also customize the list of tools that you would
normally use and call the cutters from the library.
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Enter the values as shown in the figure below
Click OK
In the CAVITY_MILL menu click on the Path Settings option
3. TOOL PATH SETTINGS

There are different options in which the tool can move. The following
is a description of each.
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ZIG ZAG: This tool takes a zigzag path at every level of

depth. It saves time by reducing amount of air cutting time (idle
running). The climb and conventional cuts alternate
ZIG: This takes a linear path in only one direction of flow.
ZIG WITH CONTOUR: This takes the path in one
direction either climb or conventional. The unique thing is that it
moves along the contour shape nonlinearly.
FOLLOW PERIPHERRY: This takes the path
depending upon the periphery profile. For example, the outer
periphery of our part is rectangular. So the tool path will be
generated such that it gradually cuts the material from outside to
inside with the Stepover value. This option is mostly used for
projections and cores rather than cavities.
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FOLLOW PART: This is the most optimal strategy where

the tool path is manipulated depending on the part geometry. If
there are cores and cavities in the part, the computer
intelligently considers them to remove the materials in an
optimal way. This is widely used for roughing operations.
PROFILE: This takes the cut only along the profile of the
part geometry. It is used for semi finishing or finishing
operations.
4. CUTTING PARAMETRES
On the parameters window, click CUTTING PARAMETERS
This pops up another dialog box.

Under the Strategy tab button, change the Cut Order from
Level First to DEPTH FIRST

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Changing the cut order to Depth First orders the software to

generate the tool path such that it will mill one island
completely up to the bottom-most depth before jumping to
another level. The Depth First strategy reduces the non-cutting
time of the program due to unnecessary retracts and engages at
every depth of cut.
5.SPEED AND FEED
Choose FEEDS AND SPEEDS to enter the feed and speed

parameters
Speed:
Speed normally specifies the rpm of the spindle (spindle speed).

However, technically the speed refers to the cutting speed of the tool
(surface speed). It is the linear velocity of the cutting tip of the cutter.
The relative parameters affecting this linear speed are rpm of the
spindle and the diameter of the cutter (effective diameter).
Enter the Spindle Speed value as 3500 rpm
For the Surface Speed and the Feed per Tooth, you should enter the
recommended values given by the manufacturers of the cutter. By
entering these values, the software will automatically calculate the
cutting feed rate and spindle speed. You can also enter your own
values for feed rates and spindle speeds
Feeds:
There are many feeds involved in a single program. The most

important is the Cutting feed. This is the feed at which, the tool will
be in engagement with the raw work-piece and actually cutting the
material off the work-piece. It is the relative linear velocity, at which
the cutter moves with respect to the job.
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The other feeds are optional. Some machine control systems use their
default retracts and traverse feed. In those cases, even if you do not
enter the values of other feeds, there would not be any problems.
Some control systems may look for these feed rates from the program.
It can be slightly less than the machines maximum feed rate.
For this exercise, enter the values as shown in the figure. Make
sure to enter the Cut value as 500 mmpm
Click OK
OPERATION METHODS
1. Roughing
Any milling operation should be rough milled before finishing the
job. This practice is strictly followed in industry. The main purpose of
roughing is to remove bulk material at a faster rate, without affecting
the accuracy and finish of the job. Stock allowances are given to
provide enough material for the finishing operation to get an accurate
and good finish job. What we did in the previous chapter is generate a
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roughing program. Now we have to moderately remove all the uneven

material left over from the previous program.
2. Semi-Finishing
Semi-Finishing programs are intended to remove the uneven material
and keep even part stock allowance for the Finishing operations. Once
we are done with the first roughing program, semi-finishing is always
easier and simpler to perform.
Now we will copy and paste the first program in the Operation
Navigator. In the new program, you only have to change a few
parameters and cutting tool dimensions and just regenerate the
program.
Right-click CAVITY_MILL program in the Operation
Navigator and click COPY
Right-click CAVITY_MILL again and choose PASTE
Right-click the second CAVITY_MILL_COPY you just made
and click RENAME.
Rename the second program CAVITY_MILL_1
You can see that next to the newly created CAVITY_MILL_1
is a red mark, which indicates that the program is not generated.
Cutter Selection:
Let us now set the parameters that need to be changed for the second
program. Before we even start, we should analyze the part Geometry
to figure out the minimum corner radius for the cutter diameter. In our
model, it is 5 mm and at the floor edges, it is 1 mm. Therefore, the
cutter diameter can be anything less than 10 mm. For optimal output
and rigidity, we will choose a Bull Nose Cutter with a diameter of 10
and a lower radius of 1.
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Double-click CAVITY_MILL_1 on Operation Navigator to

open the parameters window Just as we did in the previous
program, we have to create a new cutter. In the TOOL tab, you
will see the cutter you first chose.
It will show BUEM12X1 as the current tool.
Create a new cutter and name it BUEM10X1. It should have a

diameter of 10 and a lower radius of 1
Click the Global Depth per Cut as 0.25 in the Path Settings
tab. Then click on CUTTING PARAMETERS tab
Click on the STOCK tab button
Uncheck the box next to Use Floor Same As Side
Enter .5 for Part Side Stock
Enter 1 for Part Floor Stock
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Click on the CONTAINMENT tab button

In the drop-down menu next to In Process Workpiece, choose
USE 3D
In-Process Work piece is a very useful option in NX6. The software

considers the previous program and generates the current program
such that there is no unnecessary cutting motion in the No-material
zone. This strategy reduces the cutting time and air cutting motion
drastically. The algorithm will make the cutter only remove the
material left in the previous program and maintain the current part
stock allowance.
Choose OK to return to the parameters window
Click FEEDS AND SPEEDS
Enter the Speed and Feed values as shown in the following
figures-Then click OK
The parameters and settings are finished for the semi-finishing
program.
Regenerate the program by clicking on the Generate icon

After the software finishes generating click OK
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Then replay the Tool Path visualization. The overall Tool Path
generated in the second program will look like the following figure.
3. Finishing Profile
So far, we are done with the roughing and semi-finishing programs

for the part. There is a sufficient amount of material left in the
Workpiece to be removed in the finishing programs to obtain the
accurate part geometry as intended in the design. The finishing
programs should be generated such that every surface in the part
should be properly machined. Therefore, it is better to create more
than one program to uniquely machine sets of surfaces with relevant
cutting parameters and strategies rather than make one program for all
the surfaces. The following
illustrates how to group the profiles and surfaces and create the
finishing programs.
Outer Profile:
This program is intended to finish the outer inclined walls onto the
bottom of the floor. Because the program should not touch the
contour surface on the top, we have to give Check and Trim
boundaries in the program.
Repeat the same procedure as before to copy and paste
CAVITY_MILL_1 on Operation Navigator
Rename the program CAVITY_MILL_2
Double click CAVITY_MILL_2 to make parameter changes
In the pop-up parameters window, change the Cut Pattern to

Profile and the Stepover percentage to 40 as shown in the
figure
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Click on the Specify Trim Boundaries tab The Trim Boundary

window will pop up. Make sure to carry out the following
procedure in the right sequence. Keep the default setting of
TRIM SIDE to outside. This tells the software that the cutter
should not cut material anywhere inside the boundary. Trim
allows you to specify boundaries that will further constrain the
cut regions at each cut level.
Uncheck the Ignore Holes and check the box in front of Ignore
Islands
Change Filter Type to CURVES.
Then create the boundary and press ok
4. Finishing Contour Surface
Now we have to use a different type of strategy to finish

the top freeform surface.
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Click on the Create Operation icon in the Toolbar

Then click on the FIXED_CONTOUR icon as shown in the
figure
Choose PROGRAM for Program
Choose WORKPIECE for Geometry
Keep the default name of program
Click OK
On the parameters window, under Drive Method, select

BOUNDARY even if it is already shown.
Click OK twice to return to the Boundary Drive Method

window
Change the Stopover method to SCALLOP and enter the
height to be 0.001 and click OK
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In the Cutting Parameters window,

Change the Tolerance values so that the Part Intol and Part
Outtol is 0.001
Click on the MORE tab button and enter the value of Max Step
as 1.0
Click OK
Then click on the FEEDS AND SPEEDS icon on the
parameters window
Enter the Speed parameters as shown in the following figure
Click OK
In the main Parameters window,
Create a new tool and name it BEM10
Change the diameter to be 10 mm and the lower radius to be 5
mm.
Click OK
Generate the program.
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The contour surface is now finished and you can view the simulation
by Tool Path verification.
POST PROCESSING
The primary use of the Manufacturing application is to generate tool

paths in order to manufacture parts. Generally, we cannot just send an
unmodified tool path file to a machine and start cutting because there
are many different types of machines. Each type of machine has
unique hardware capabilities, requirements and control systems. For
instance, it can have a vertical or a horizontal spindle; it can cut while
moving several axes simultaneously, etc. The controller accepts a tool
path file and directs tool motion and other machine activity (such as
Turning the coolant or air on and off ).
Naturally, just as each type of machine has unique hardware

characteristics; controllers also differ in software characteristics. For
instance, most controllers require that the instruction for turning the
coolant on be given in a particular code. Some controllers also restrict
the number of M codes that are allowed in one line of output. This
information is not in the initial NX5 NX tool path.
Therefore, the tool path must be modified to suit the unique
parameters of each different machine/controller combination. The
modification is called post processing. The result is a post processed
tool path.
There are two steps involved in generating the final post-

processed tool path.
1. Create the tool path data file, otherwise called CLSF (Cutter
Location Source File).
2. Post process the CLSF into Machine CNC code (Post processed
file). This program reads the tool path data and reformats it for use
with a particular machine and its accompanying controller.
GENRATING PROGRAM FOR DNC
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Project report on creo 2.0

GNa -UNIVERSITY (PHAGWARA)

Submitted to - Faculty Of Design and Innovation

It is my esteem privilege, to express deep sense of gratitude and indebtedness to my major

I am also very thankful to Mr. C R Tripathy{Principal CAD/CAM department}, who

Industrial visit report

RAPID PROTOTYPE TECHNIQUE

INDUSTRIAL VISIT REPORT

PURPOSE OF INDUSTRIAL TRAINING

INTRODUCTION TO THE UNIT

GNA is an Original Equipment supplier to various Automobile Majors besides having a

Quality Management at GNA is a timeless concept wherein, changes in customer

DIVISION PLACE COVERED PRODUCTS INSTALLED

GNA Duraparts Mehtiana 1550 Super, bevel & 100,000 sets

Each of the functions is given below:

The Production Department is submitted the following documents:

GNA Tool Inspection Report

Some Equipments used in Standard room:

DIE DESIGN SHOP

Die operations and types

A Forged metal can result in the following

Increase length, decrease cross-section, called drawing out the metal.

2. Oil Tank For Quenching:

3. Water Storage Tank for Quenching

5. B.H.N Testing Machine

CNC MACHINE SHOP

1. Lathe machine 6. Hobbing machine

WHAT DOES 'CNC' MEAN?

HOW TO USE A TYPICAL CNC MACHINE

1. The design is loaded into the computer which

2. The material to be shaped is taped on to a

3. The block is then placed in the vice, inside the

4. The guard is placed in position. It protects the

5. The CNC is turned on and the shape is cut

VARIOUS CNC MACHINES:

Gear shaper machine

Gear shaving machine

Surface broach machine

Simple broach machine

Spiral gear cutting machine

Rack rolling machine

Common Heat Treatments

Softening: Softening is done to reduce strength or hardness, remove residual stresses,

Material Modification: Heat treatment is used to modify properties of materials in addition

Components Group: Axles and Rods

E is the electric field,

BASIC KNOWLEDGE ABOUT CAD/CAM SOFTWARE

CAD/CAM SOFTWARE ARE CLASSIFIED ON THE BASIS OF TWO CRITERIAS

ON THE BASIS OF DESIGN CAPABILITY.

1. ON THE BASIS OF DESIGN CAPABILITY CAD/CAM SOFTWARE ARE

1. HIGH END SOFTWARE :-(NX, creo, CATIA, SOLID EDGE etc.)

2. LOW END SOFTWARE:- (AUTO-CAD, CADDIAN etc.)

2. ON THE BASIS OF MODIFICATION CAPABILITY CAD/CAM SOFTWARE

1. PARAMETRIC SOFTWARE(NX, creo, CATIA, SOLID EDGE etc.)

2. NON PARAMETRIC SOFTWARE(AUTO-CAD, CADDIAN etc.)

The main purpose of using constraint, in the designing software is following

(7) EQUAL CONSTRAINT

It is use to converting any type of line in to a vertical line.

It is use to drawing a symmetrical line or entity

t is use to converting any type of line in to a vertical line.

CENTER POINT CIRCLE - It is used to draw a circle.

Pick center point of the circle.

THREE POINT CIRCLE