MF4212 Advanced Manufacturing Laboratory

MF 4212 Advanced Manufacturing Laboratory Mechanical Engineering 2021– 2022
LABORATORY RECORD
for
MF4212 Advanced Manufacturing Laboratory

of
M.E. MANUFACTURING ENGINEERING
(Anna University Regulation 2021)
For the Batch (2021 to 2023)
II Semester
DEPARTMENT OF MECHANICAL ENGINEERING
KCG COLLEGE OF TECHNOLOGY,
CHENNAI – 600097
KCG College of Technology i ISO 9001:2008

KCG College of Technology ii ISO 9001:2008

KARAPAKKAM, CHENNAI 600 097
REG. No. …………………………….
LABORATORY RECORD
Course Code: ………………….
Name of the Course: ……………………………………………………………….....
It is to certify that this is a bonafide record of the work carried out by
……………………………………………………………………………………………………………… of
………………….semester…………………………………department, during the odd
semester of the academic year 2021-2022.
Faculty In-charge ……………………… HOD………………………………………
Int. Examiner: ………………………… Ext. Examiner ………………..........
Date of the Examination: ……………………
KCG College of Technology iii ISO 9001:2008

KCG College of Technology iv ISO 9001:2008

VISION OF THE COLLEGE

KCG College of Technology aspires to become a globally recognized centre of excellence
for science, technology & engineering education, committed to quality teaching, learning
and research while ensuring for every student a unique educational experience which will
promote leadership, job creation, social commitment and service to nation building.
MISSION OF THE COLLEGE

 Disseminate knowledge in a rigorous and intellectually stimulating environment
 Facilitate socially responsive research, innovation and entrepreneurship
 Foster holistic development and professional competency
 Nurture the virtue of service and an ethical value system in the young minds
VISION OF THE DEPARTMENT
The department aspires to become a globally recognized centre of excellence by
producing competent professionals in Mechanical Engineering to serve as a valuable
resource for industry and society.
MISSION OF THE DEPARTMENT
 Impart intellectually rigorous and holistic education to the students in the field of
Mechanical Engineering.
 Establish state of-the-art facilities for research and consultancy work.
 Enhance the knowledge and skills of the faculty with the latest advancements in the
mechanical engineering domain.
 Mentor the students to develop research and entrepreneurial capabilities.
 Inculcate a high degree of professionalism and contribute to the needs of industry
and society.
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KCG College of Technology vi ISO 9001:2008

PROGRAMME EDUCATIONAL OBJECTIVES:
On completion of the program, the students will achieve the following:
PEO 1 Excel as competent professional or entrepreneur or researcher in related fields

of Mechanical Engineering.
PEO 2 Analyse, design/develop innovative solutions for real world engineering

problems using appropriate modern tools.
PEO 3 Exhibit professionalism, ethical attitude and adapt to the changes in the
industry and society supporting sustainable development.
PEO 4 Lead and manage teams for effective execution of projects.
PROGRAMME OUTCOMES
After successful completion of M.E (Manufacturing Engineering) programme, the students will
be able to:
PO
Description of the PO
No.
Engineering Knowledge: Apply the knowledge of mathematics, science,
PO 1 engineering fundamentals, and an engineering specialization to the solution of
complex engineering problems.
Problem Analysis: Identify, formulate, review research literature, and
PO 2 analyze complex engineering problems reaching substantiated conclusions
using first principles of mathematics, natural sciences, and engineering
Design / Development of Solutions: Design solutions for complex
PO 3 engineering problems and design system components or processes that meet

the specified needs with appropriate consideration for the public health and
safety, and the cultural, societal, and environmental considerations.
Conduct Investigations of Complex Problems: Use research based
PO 4
knowledge and research methods including design of experiments, analysis
and interpretation of data, and synthesis of the information to provide valid
Modern Tool Usage: Create, select, and apply appropriate techniques,
PO 5 resources, and modern engineering and IT tools including prediction and
modeling to complex engineering activities with an understanding of the
limitations.
KCG College of Technology vii ISO 9001:2008

The Engineer and Society: Apply reasoning informed by the contextual

PO 6
knowledge to assess societal, health, safety, legal and cultural issues and the
consequent responsibilities relevant to the professional engineering practice.
Environment and Sustainability: Understand the impact of the professional
PO 7 engineering solutions in societal and environmental contexts, and demonstrate
the knowledge of, and need for sustainable development.
PO 8 Ethics: Apply ethical principles and commit to professional ethics and

responsibilities and norms of the engineering practice.
PO 9 Individual and Teamwork: Function effectively as an individual, and as a
member or leader in diverse teams, and in multidisciplinary settings.
Communication: Communicate effectively on complex engineering
PO 10 activities with the engineering community and with society at large, such as,
being able to comprehend and write effective reports and design
documentation, make effective presentations, and give and receive clear
Project Management and Finance: Demonstrate knowledge and
PO 11 understanding of the engineering and management principles and apply these
to one’s own work, as a member and leader in a team, to manage projects and
PO 12
in multidisciplinary
Lifelong Learning:environments.
Recognize the need for, and have the preparation and
ability to engage in independent and lifelong learning in the broadest context
KCG College of Technology viii ISO 9001:2008

MF 4212 ADVANCED MANUFACTURING LABORATORY

L T P C
0 0 4 2
S. No. List of Experiments as per syllabus

1 Measurement of Cutting Forces in Milling/ Turning Process (Depth of cut
varying)
2 Measurement of Cutting Forces in Milling/ Turning Process (Speed
varying)
3 Determination of maximum and minimum position of links.
4 Verification of transformation (Position and orientation) with respect to
gripper and world coordinate system
5 Estimation of accuracy, repeatability, and resolution.
6 Robot programming and simulation for pick and place
7 Robot programming and simulation for Colour identification
8 Robot programming and simulation for Shape identification
List of Experiments beyond syllabus

1. Robot programming and simulation for machining (cutting, welding)
2 Robot programming and simulation for 3D Printing
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MF 4212 ADVANCED MANUFACTURING LABORATORY

Index
Date
S. Page Date of Staff
of Name of the Experiment Remark
No. No. sub. sign
Exp
Signature of staff in-charge
KCG College of Technology x ISO 9001:2008

MEASUREMENT OF CUTTING FORCES IN MILLING/ TURNING PROCESS

(depth of cut varying)
Exp. No.
Date:
AIM:
To measure the cutting forces for the given cutting conditions
TOOLS AND EQUIPMENTS REQUIRED:

1. Lathe
2. Lathe Tool Dynamometer
PROCEDURE:
1. The Lathe Tool Dynamometer is initially set to zero reading. The speed is kept constant for
the given value
2. The known depth of cut is given and take the readings of Px and Pz force
components from the Lathe Tool Dynamometer.
3. Calculate the resultant cutting force
P= √𝑃𝑥2 + 𝑃𝑧2
4. Repeat the same procedure to get few more readings and calculate the mean cutting
force.
5. Repeat the same procedure for different depth of cuts
DIAGRAM:
NOTE:
1. Pz – the main or tangential component, determines the torque on main drive mechanism,
the deflection of the tool and the required power. This component acts in the direction of the
cutting speed.
2. Px – the axial component, acts in the direction of the tool traverse and it is at right angles
to Pz. It contributes very little to the power consumption.
3. Py – the radial component, acts along the tool shank and perpendicular to the other two
components. It has no share in the power consumption
KCG College of Technology 1 ISO 9001:2008

TABULATION : Speed = rpm
VERTICAL RESULTANT AVERAGE

DEPTH HORIZONTAL
COMPONENT (Kg)
S.NO OF CUT- COMPONENT P= √𝑷𝒙𝟐 + 𝑷𝒛𝟐
PZ(Kg)
(mm) PX(Kg) (Kg)
1. 0.25
2. 0.50
3. 0.75
RESULT:
Thus the cutting forces are measured for different depth of cuts

MEASUREMENT OF CUTTING FORCES IN MILLING/

TURNING PROCESS (speed varying)
Exp. No.
Date:
AIM:
To measure the cutting forces for the given cutting conditions
TOOLS AND EQUIPMENTS REQUIRED:

1. Lathe
2. Lathe Tool Dynamometer
PROCEDURE:
6. The Lathe Tool Dynamometer is initially set to zero reading.
7. The known depth of cut is given and take the readings of Px and Pz
forcecomponents from the Lathe Tool Dynamometer.
8. Calculate the resultant Cutting forceP= √𝑃𝑥2 +Pz 2
9. Repeat the same procedure to get few more readings and calculate the
mean cutting force.
10.Repeat the same procedure for different Speeds
DIAGRAM:
NOTE:
1. Pz – the main or tangential component, determines the torque on main
drive mechanism, the deflection of the tool and the required power. This
component acts in the direction of the cutting speed.
2. Px – the axial component, acts in the direction of the tool traverse and
it is at right angles to Pz. It contributes very little to the power
consumption.
3. Py – the radial component, acts along the tool shank and
perpendicular to the other two components. It has no share in the power
consumption

TABULATION : Depth of Cut = mm.
VERTICAL RESULTANT AVERAGE

Speed HORIZONTAL
COMPONENT (Kg)
S.NO (rpm) COMPONENT
PZ(Kg) P= √𝑷𝒙𝟐 + 𝑷𝒛𝟐
PX(Kg) (Kg)
1.
2.
3.
RESULT:
Thus the cutting forces are measured for different speeds

Study of Robots Configuration and Application

Ex. No.
Date:
AIM
To study about Robots configuration and application
ROBOT ANATOMY
Robot anatomy is concerned with the physical construction of the body, arm
and wrist of the machine. Most robots used in plants today are mounted on a base
which is fastened to the floor. The body is attached to the base and the arm assembly
is attached to the body. At the end of the arm is wrist. The wrist consists of a number
of components that allow it to be oriented in a variety of positions. Relative movements
between the various components of the body arm and wrist are provided by series of
joints. These joint movements usually involving either rotating or sling motions, which
we will describe later in the section. The body armed wrist assembly is some times
called the manipulator.
Attached to the robot’s wrist is a hand. The technical name for the hand is “end
effectors”. The end effector is not considered as part of robot’s anatomy. The arm and
body joints of the manipulator are used to position the end effector, and the wrist joints
of the manipulator are used to orient the end effectors.
Four Common Robot Configurations
Industrial robots are available in a wide variety of sizes, shapes, and physical
configurations. The vast majority of today’s commercially available robots possess
one of four basic configurations:
1. Polar configuration
2. Cylindrical configuration
3. Cartesian coordinate configuration
4. Jointed-arm configuration
The polar configuration is shown in fig(1a). It uses a telescoping arm that can
be raised or lowered about a horizontal pivot. The pivot is mounted on a rotating base.
These various joints provide the robot with the capability to move its arm within a
spherical space, and hence the name “spherical coordinate” robot is some times applied
to this type. A number of commercial robots possess the polar configuration.

1. Polar configuration
2. Cylindrical configuration
The cylindrical configuration is shown in fig(1b). It use a vertical column and

a slide that can be moved up or down along the column. The robot arm is attached to
the slide, so that it can be moved radially with respect to the column. By rotating the
column; the robot is capable of achieving a work space that approximates a cylinder.
3 . Cartesian Coordinate:
The Cartesian coordinate robot is illustrated in fig(1c). Uses three perpendicular slides
to construct the x. y, and z axes. Other names are some times applied to this
configuration, including xyz robot and rectilinear robot. By moving the three slides
relative to one another, the robot is capable of operating within a rectangular work
envelope. An example of this configuration is the IBM RS-1 robot (currently called

the model 7565). The RS-1, because of its appearance and construction, is
occasionally referred to as a “ box” configuration “Gantry” robot is another name used
for Cartesian robots that are generally large and posses the appearance of a gantry –
type crane.
4. Jointed arm configuration:
Its Configuration is similar to that of the human arm. It consists of two straight
components, corresponding to the human fore arm and upper arm, mounted on a
vertical pedestal. These components are connected by two rotary joints corresponding
to the shoulder and elbow. A wrist is attached to the end of the fore arm, thus providing
several additional joints. Several commercially available robots possess the jointed
arm configuration. A special version of the jointed arm robot is the SCARA, whose
shoulder and elbow joints rotate about vertical axis. SCARA Stands for Selective
Compliance Assembly Robot Arm, and this configuration provides substantial rigidity
for the robot in vertical direction, but compliance in the horizontal plane. This makes
it ideal for many assembly tasks.

Inference about Robot Configuration and Application

RESULT :
Thus the Robots configuration and application were studied
Viva Question
1. List out basic components of robot
2. Mention different configurations of robot
3. Define degrees of freedom

4. Discuss about work space of robot
5. Mention some application of robot


Determination of Maximum and Minimum Position of Links

Ex. No:
Date :
AIM
To study and determine the maximum and minimum position of Links in the
Robot.
INTRODUCTION TO MANIPULATOR KINEMATICS.
In order to develop a scheme for controlling the motion of a manipulator it is

necessary to develop technique for representing the position of the arm at points in
time. We will define the robot manipulator using the two basis elements, joints, and
links. Each point represents 1 degree of freedom. Two, the joint may involve either
linear motion (joint-L type) or rotational motion (Joint R, T, and V) between the
adjacent links. Two, the links are assumed to be the rigid structures that connect the
joints.
Joints are labeled in where n begins with 1 at the base of manipulator, and the
links are labeled Lm, again with 1 being the link closet to the base. Figure 6-1
illustrates the labeling system for two different robot arms, each possessing 2 degrees
of freedom. By the joint notation scheme described in chap. Two the manipulator in
FIG (a) has an RR notation and the manipulator in FIG (b) has an LL notation.
We will also use the symbol Ln to indicate the length of the link in some of our
equation. We define the standard notation system used for computing joint link
transformations. This notation system uses the symbol a to denote the length of a
manipulator link.

POSITION REPRESENTATION:
The kinematics of the RR robot are more difficult to analyze than LL robot,
and we will make frequent use of this configurations (and extensions of it) . Figure6.1
illustrates the geometric form of the RR manipulator. For the present discuss, our
analysis will be limited to the two dimensional case. The Position of the end of the arm
may be represented in number of ways. One way is to utilize the two joint angle θ1 and
θ2.This is know as the representation in “joint” space and we may define it as coronet
𝑃 = ( 𝜃 ,𝜃 )
Another way to define the arm position is in ‘world’ space. This involves the
use of a Cartesian coordinate system that is external to the robot. The Origin of the
Cartesian axis system is often located in the robot’s base. The end of the arm position
would be defined in world space as
𝑃 = (𝑥, 𝑦)
This concept of a point definition in the world space can be readily be extended
to three dimensions, that is Pw=(x,y,z).Representing an arm ‘s position in world space
is useful when the robot must communicate with other machines. These other
machines may not have a detailed understanding of the robot’s kinematics and so a
‘neutral’ representation such as the world space must be used. In order to use both
representations we must be able to transform from one to other. Going from joint space
to world space is called the forward transformation and going from world space to
joint space is called the reverse transformation.

FORWARD TRANSMISSION OF A 2 –DEGREE OF FREEDOM ARM
We can determine the position of the end of the arm in world space by
defining a vector for link 1 and another for link2.
𝑟 = (𝐿 𝑐𝑜𝑠 𝜃 , 𝐿 𝑠𝑖𝑛𝜃 ) (2 − 1)
𝑟 = (𝐿 𝑐𝑜𝑠(𝜃 + 𝜃 ), 𝐿 𝑠𝑖𝑛 (𝜃 + 𝜃 )) (2 − 2)
Vector addition of (2-1) and (2-2) yields the coordinates x and y of the end of the
arm (point Pw) in the world space
𝑋 = 𝐿 𝑐𝑜𝑠𝜃 + 𝐿 𝑐𝑜𝑠 (𝜃 + 𝜃 ) (2 − 3)
𝑌 = 𝐿 𝑠𝑖𝑛𝜃 + 𝐿 𝑠𝑖𝑛 (𝜃 + 𝜃 ) (2 − 4)
Reverse Transformation of the 2-degree of Freedom Arm
In many cases it is more important to be able to derive the joints angles given
the end of arm positions in world space. The typical situation is where the robot’s
controller must compute the joint angles required to move its end of arm to a point in
space defined by the point’s coordinates. For the two link manipulator web have
developed, there are two possible configurations for reaching the point(x,y).Some
strategy must be developed to select the appropriate configuration. One approach is
that employed in the control system of the Unimate PUMA robot .In the PUMA’S
control language,VAL,there is a set of commands called ABOVE and BELOW that
determines whether the elbow is to make an angleθ2 that is greater than or less than
zero. For example, let us assume the θ2 is positive. Using the trigonometric identities,
𝐶𝑜𝑠 (𝐴 + 𝐵) = 𝑐𝑜𝑠𝐴 𝑐𝑜𝑠𝐵 − 𝑠𝑖𝑛𝐴 𝑠𝑖𝑛𝐵
𝑆𝑖𝑛 (𝐴 + 𝐵) = 𝑠𝑖𝑛𝐴 𝑐𝑜𝑠𝐵 + 𝑠𝑖𝑛𝐵 𝑐𝑜𝑠𝐴
We can write Esq. (6-3) and

(6-4) as
𝑋 = 𝐿 𝑐𝑜𝑠𝜃 + 𝐿 𝑐𝑜𝑠𝜃 𝑐𝑜𝑠𝜃 − 𝐿 𝑠𝑖𝑛𝜃 𝑠𝑖𝑛𝜃

𝑌 = 𝐿 𝑠𝑖𝑛𝜃 + 𝐿 𝑠𝑖𝑛𝜃 𝑐𝑜𝑠𝜃 + 𝐿 𝑐𝑜𝑠𝜃 𝑠𝑖𝑛𝜃
Squaring both sides and adding the two equations yields
𝑥 +𝑦 −𝐿 −𝐿
𝐶𝑜𝑠𝜃 =
2𝐿 𝐿
defining a and b in fig 2.4 we get
(𝐿 𝑠𝑖𝑛𝜃 )
tan 𝛼 =
𝐿 𝑐𝑜𝑠𝜃 + 𝐿
𝑦
𝑡𝑎𝑛𝛽 =
𝑥
Using the trigonometry identity
𝑡𝑎𝑛𝐴 − 𝑡𝑎𝑛𝐵
tan(𝐴 − 𝐵) =
1 + 𝑡𝑎𝑛𝐴𝑡𝑎𝑛𝐵
We get
[𝑦(𝐿 + 𝐿 𝑐𝑜𝑠𝜃 ) − 𝑥𝐿 𝑆𝑖𝑛𝜃 ]

𝑡𝑎𝑛𝜃 =
[𝑥(𝐿 + 𝐿 𝑐𝑜𝑠𝜃 ) + 𝑦𝐿 𝑆𝑖𝑛𝜃 ]
Knowing the link lengths L1and L2 we are now able to calculate the required joint
angles to place the arm at a position (x, y) in world space.
Inferences about A 3-Degree of freedom Arm in Two Dimensions

RESULT :
Thus the maximum and minimum position of Links in the Robot were determined.
Viva Question
1. What is forward kinematics?

2. What is inverse kinematics?
3. List the parameters used to find the position of end effector
4. Define manipulator


Verification of transformation (Position and orientation) with

respect to gripper and world coordinate system
Ex. No :
Date :
AIM : To verify the mathematical formulation to describe the position and orientation
of a manipulator by using concepts of coordinate transformation.
Matrix operator: Transformations
In addition to performing the vector operations outlined previously, it is

possible to define a class of matrix operators that can be perform simultaneous vector
operation resulting in the translation or rotation of the vector. The matrix H will be
considered such an operator, which transforms a point or vector X in to another point
or vector y.
𝑌 = 𝐻𝑥 → 3.1
Re call that the order of a matrix is defined as the number of rows r by the
number of columns c.Thus the order of a matrix, having r rows and c columns is (rxc).
A(4x1) column matrix for y is obtained by premulating a (4x1) column matrix , X by
a (4x4) H matrix. This follows from the requirement that H and x must be conformable.
That is , the number of columns in His equal to the number of rows in x.
Translational transformations
We define the translational transformation Trans(a,b,c) as the operator that

moves the point defined by the original vector x to a new point y whose location is
given by the vector addition of x and a translation vector defined by the components
a,b, c.This is essentially vector addition. An interesting interpretation can be obtained
by considering moving a point from its current locations for some distance along a
diagonal. The distance is the vector magnitude, while the diagonal is defined by the
direction of the vector. The operator transform the coordinates of the original vector
into the coordinates of a new vector. This matrix operator is defined as follows.
1 0 0 𝑎
0 1 0 𝑏
𝑇𝑟𝑎𝑛𝑠 (𝑎, 𝑏, 𝑐) = → 3.2
0 0 𝑐 𝑐
0 0 0 1
The values a,b,and c represents the components of the vector which are to be
added to those of the operand x of Eq (3.1).From our prior discussion concerning matrix

addition, this matrix will operate properly on any homogeneous representation of a vector,
independent of the value of its scaling factor.
Translational of a point
Suppose that a point p lies at (x,y) =(5,5) in a two dimensional reference frame.
It is desired to move the point along the diagonal corresponding to an angle of 45
degree for a distance of 10 units. What are the coordinates of the final point p1(x2, y2)
.Figure illustrates the initial and final positions
The original points may be represented as a vector in homogeneous

5
5
coordinates. Its value is → 3.3
0
1
Since desired to move the point along the 45 degree radial extension, the unit
vector corresponding this direction is
. 707
. 707
𝑢= → 3.4
0
1
To get a motion of 10 units it is necessary to multiply the components of u by

10, excluding the scaling factor, as mention previously. The new vector u becomes
7.07
7.07
𝑢= → 3.5
0
1

which can be considered a point 10 units from the origin along the radial line
at 45degree.Using the equation(3.1) and (3.2) we can obtain the expression for the
translated point p’ .
1 0 0 7.07 5
0 0 0 7.07 5
𝑝 = → 3.6
0 0 1 0 0
0 0 0 1 1
where we have substituted the components of u for a,b, and c. Carrying out
the multiplication in Eq. (3.6) yields
12.07
12.07
𝑝 = → 3.7
0
1
This simple example points out the two ways that one may view the
translational transformation (i.e., as vector addition or as “motion along a line”) and is
extremely useful in indicating why the scaling factor is important. Consider the
generation of one element of the p’ vector of Eq. (3.7), say the x component. In Eq.
(3.6), the first row of the Trans (a,b,c) matrix selects the x components scale factor of
p. Finally, when the scale component for p’ is computed, it is the original scaling
factor of the input vector p. Thus before adding the vectors, the components of the last
column of Trans (a,b,c) are scaled by the proper constant so that like quantities are
added. Finally, the actual value is generated and the original scaling factor is
preserved.
Rotational Transformations
In addition to moving points along vectors, it is possible to generate new

positions in space by rotating them about an axis. Before investigating the rotational
matrix operator, we will derive the rotation formula for a set of orthogonal axes rotated
in a plane. Our derivation is based on a geometric interpretation. Consider a point P
located at x1, y1 with respect to the x-y reference axis, which we shall call x-ref and y-
ref (see Figure). In addition, assume initially that a second set of axes is lying on top
of the reference axes. This set will be called x-rot and y-rot and the relationship of the
point P with respect to these axes will remain fixed. Now assume that the plane
containing the point P (located in the frame define by x-rot and y-rot) is rotated

Counterclockwise by an angle θ with respect to the reference axes. We would

like to determine the location of the point P with respect to the reference axes (x-ref
and y-ref as shown in Figure. The geometric construction necessary to determine the
coordinates. Line segment PA is the perpendicular from the point P to the x-ref axis.
Line segment PB is the perpendicular from the point P to the x-rot axis. From the
diagram we may write the following relationships
𝑥 = [𝑂𝐴] = [𝑂𝐸] – [𝐴𝐸]

𝑦 = [𝐴𝑃] = [𝐴𝐶] – [𝐶𝑃]
[𝑂𝐸] = [𝑂𝐵] 𝑐𝑜𝑠 𝜃
= 𝑥1 𝑐𝑜𝑠 𝜃
[𝐴𝐶] = [𝐸𝐵] = [𝑂𝐵] 𝑠𝑖𝑛 𝜃
= 𝑥1 𝑠𝑖𝑛 𝜃 [𝐴𝐸] = [𝐶𝐵] = [𝐵𝑃] 𝑠𝑖𝑛 𝜃
= 𝑦1 𝑠𝑖𝑛 𝜃
[𝐶𝑃] = [𝐵𝑃] 𝑐𝑜𝑠 𝜃
= 𝑦1 𝑐𝑜𝑠 𝜃
Combining these equations yields the desired results:
𝑥 = 𝑥 𝑐𝑜𝑠 𝜃 − 𝑦 𝑠𝑖𝑛 𝜃
𝑦 = 𝑥 𝑠𝑖𝑛 𝜃 + 𝑦 𝑐𝑜𝑠 𝜃
The relationship above allows us to determine the location of points affixed to movable
frames of reference in terms of a fixed reference frame. The derivation in the x-y plane
is easily extended to either the y-z or z-x plane. Rotational transformations which
operate on homogeneous coordinates and perform rotations about a given axis of the
reference coordinate system can be shown to be:
1. Rotation θ degrees about the x axis:

1 0 0 0
0 𝐶𝑜𝑠0 −𝑆𝑖𝑛0 0
𝑅𝑜𝑡 (𝑥, 0) = → 3.8
0 𝑆𝑖𝑛0 𝐶𝑜𝑠0 0
0 0 0 1
2. Rotation θ degrees about the y axis:

𝐶𝑜𝑠0 0 𝑆𝑖𝑛0 0
0 1 0 0
𝑅𝑜𝑡 (𝑦, 0) = → 3.9
−𝑆𝑖𝑛0 0 𝐶𝑜𝑠0 0
0 0 0 1
3. Rotation θ degrees about the z axis:
𝐶𝑜𝑠0 −𝑆𝑖𝑛0 0 0
𝑆𝑖𝑛0 𝐶𝑜𝑠0 0 0
𝑅𝑜𝑡 (𝑧, 0) = → 3.10
0 0 1 0
0 0 0 1
POSITIVE ANGLE REFERENCES
___________________________________
Cross product Rotation
___________________________________
x Xy=z Positive rotation about z
y Xz =x Positive rotation about x
z Xx = y Positive rotation about y
__________________________________
Examining the matrices in Eqs. (3.8) through (3.10) shows that the entries of the last
column are all zero except for the scaling factor, which has been set to 1. This
reasonable since we do not wish to do any translation. The first three columns
represent the directions of the x,y, and z axes of the rotated frame. Observe that the
scaling factor is set to zero in each case. For Eqs (3.8) through (3.10) the axis about
which the rotation is performed has unit entry in the appropriate column showing the
direction of that particular axis. For example in Eq. (3.10) the 1 in the third column
shows that rotation is about the z axis. The columns corresponding to the direction of
the axes forming the plane in which rotation takes place contain the transcendental
terms needed to accomplish the rotation. For example, in Eq. (3.8) columns 2 and 3
indicate a movement of the y-z plane.
To visualize the concept of rotating a point about an axis, the reader should
imagine a perpendicular drawn from the point to the axis about which it will be rotated.
If one were to rotate the initial perpendicular, an angular displacement would result.
The angle of rotation may be positive or negative and is defined by using the right-
hand rule. Rotation is positive if the cross product defined by the initial and final
vectors is in the same direction as the axis about which the rotation was performed.
The cross products of the x,y and z axes are shown in Table.

The following example shows the effects of operating on a point or vector with a
rotational operator.
ROTATION OF A POINT ABOUT A REFERENCE FRAME
It is desired to rotate the point u represented by a column vector about the z axis and
determine the coordinates in terms of the original reference frame. Figure 7.5 shows
this operation. The vector u will be given as
1
2
𝑢=
3
1
One may also think of this problem as the rotation of a plane located at a height of 3
units above the x-y reference plane which contains the point (1,2). The relationship of
the point (1,2) remains the same to the reference frame of the plane in which it is
located but is different from the base or original x-y reference frame located at height
z=0. Using Eq. (3.10) we will consider rotations of 60 deg, 90 deg and 120deg. The
operators corresponding to these angles are given as
0.55 −0.866 0 0
0.866 0.5 0 0
𝑅𝑜𝑡 (𝑧, 60) = → 3.12
0 0 1 0
0 0 0 1
−1.232
1.866
𝑉 =
3.000
1
−2.0
1.0
𝑉 =
3.0
1

−2.232
0.134
𝑉 =
3.000
1
Inferences about Verification of Transformation
RESULT:
Thus, the position and orientation of a manipulator by using concepts of coordinate

transformation were verified.
Viva Question
1. What is meant by verification?

2. What is meant by validation?
3. Define homogeneous transformation of matrix
4. Write the matrix for rotation about x axis


Estimation of accuracy, repeatability and resolution.

Ex. No.
Date:
AIM
To estimate the accuracy, repeatability and resolution of the robot
performance.
THEORY
The preceding discuss of response speed and stability is concerned with the
dynamic performance of robot another measure of performance is precision of the
robot’ movement. We will define precision as a function of three features:
1. Spatial resolution
2. Accuracy
3. Repeatability
These terms will be defined with the following assumptions. First, the
definitions will apply at the robot’s wrist end with no hand attached to the wrist.
Second, the terms apply to the worst case conditions, the conditions under which the
robot’s precision will be at its worst. This generally means that the robot’s arm is fully
extended in the case of a jointed arm or polar configurations. Third our definition will
be developed in the context of a point-point robot. That is we will be concerned with
the robot’s capability to achieve a given position within its work volume. It is easier
to define the various precision features in a static context rather than a dynamic
context. It is considerably more difficult to define, and measure, the robot’ capacity to
achieve a defined motion path in space because it would be complicated by speed and
other factors.
1. Spatial resolution
The spatial resolution of a robot is the smallest increment of movement into which
the robot can divide its work volume. Spatial resolution depends on two factors; the
system’s control resolution and the robot’s mechanical in accuracies. It is easiest to
conceptualist these factors in terms of a robot with 1 degree of freedom.
The control resolution is determine by the robot’s position control system and
its feedback measurement system. It is the controller’s ability to divide the total; range
of movement for the particular joint into individual increments that can be addressed
in the controller. The increments some times referred to as addressable points. The
ability to divide the joint range into increments depends on the bit storage capacity in
the control memory. The ability to divide the joint range into increments depends on

the bit storage capacity in the control memory. The number of separate, identifiable
increments for a particular axis is given by
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑛𝑐𝑟𝑒𝑚𝑒𝑛𝑡𝑠 = 2’
Where n=the number of bits in the control memory.
For example, a robot with 8 bits of storage can divide the range into 256 discrete
positions. The control resolution would be defined as the total motion range divided
by the number of increments equal. A robot with several degrees of freedom would
have a control resolution for each joint would have to be summed vector ally. The total
control resolution would depend on the wrist motions as well as the arm and body
motions. Since some of the joints are likely to be rotary while others are sliding, the
robot’s control resolution can be complicated quantity to determine.
2. ACCURACY
Accuracy refers to a robots ability to position its wrist end at a desired target
point within the work volume. The accuracy of a robot can be defined in terms of
spatial resolution because the ability to achieve a given target point depends on how
closely the robot can be define the control increments for each of its joint motions. In
the worst case, the desired point would lie in the middle between two adjacent control
increments. Ignoring for the moment the mechanical inaccuracies which would reduce
the robot’s accuracy, we could initially define accuracy under the worst case
assumption as one of the control resolution. Infact, the mechanical inaccuracies would
affect the ability to reach the target position. Accordingly, we define the robot’s
accuracy to be one half of its spatial resolution as portrayed.
3. REPEATABILITY
Repeatability is concerned with the robot’s ability to position its wrist or an
end effectors attached to its wrist at a point in space that had previously been taught to
the robot. Repeatability and accuracy refer to two different aspects of the robot’s
precision.. Accuracy relates to the robot’s capacity to be programmed to achieve a
given target point. The actual programmed point will be probably be different from the
target point due to limitations of control resolution. Repeatability refers to the robot’s
ability to return to the programmed point when commanded to do so.
In three dimensional spaces, the repeatability errors will surround the
programmed point P, forming a distribution whose outer boundary can

Inferences about accuracy, repeatability and resolution of the robot
RESULT :
Thus, the accuracy, repeatability and resolution of the robot performance were studied
and estimated.

Viva Question
1. Define accuracy
2. Define repeatability
3. What is mean by Spatial resolution
4. How will you estimate robot accuracy
5. What is the difference between repeatability and reproducibility

Precautions
The Forearm and Rear Arm position

1. Please make the Dobot Magician in the workspace witha 45° angle between the Forearm
and Rear Arm (as shown in Figure above)before starting up. If the LED indicator turns
red after starting up, it indicates that the Dobot Magician is at a limited position. Please
make the Dobot Magician in the workspace.
2. Dobot Magician will move slowly to the specific position when shutdown. DO NOT put
hands into the workspace of the Dobot while running, to avoid bruising or pinching. Only
once the LED indicator completely turns off, the Dobot Magician can be powered down.
3. If the coordinates of the Dobot Magician shown on the Dobot Studio are abnormal, please
press the Reset button on the back of the base to reset Dobot Magician or click Home on
the DobotStudio page to perform homing.
4. During resetting, Dobot Magician will disconnect from the PC automatically and the LED
indicator on the base turns yellow. About 5 seconds later, if the LED indicator turns green,
it indicates that the reset is successful.
5. During homing, Dobot Magician will rotate clockwise to the limited position and then
return to the homing point automatically, and the LED indicator on the base turns blue and
is blinking. After homing, if there is a beep sound and the LED indicator turns green, it
indicates that the homing is successful.
6. Please turn off the Dobot Magician completely first before connecting or disconnecting
external equipment, such as Bluetooth, WIFI, stick controller, infrared sensor, color
sensor, etc. Or, it causes damage to your device.
7. Please wear the lasing protective eyeglass when using the laser module. Please protect
your eyes and skin from the laser.
8. The heating rod will produce high temperature up to 250℃ when using the 3D printing
module, please be careful.
9. Please DO NOT operate or turn off Dobot Magician when burning firmware, to avoid
machine damage.

PROGRAM :

Robot programming and simulation for writing practice

Ex. No.
Date:
AIM: To perform and simulate a writing and drawing task using Dobotstudio software
EQUIPMENT \ COMPONENTS REQUIRED:

1. Dobot Magician Robot
2. Dobotstudio Software
PROCESS CHART

PROCEDURE:
RESULT:
Thus the writing and drawing operation were performed using Dobot Magician
Robot.

Viva-Questions
1. What is meant by robot Programming?
2. What are the methods of robot programming?
3. List out robot languages.
4. What are robot task function?

Precautions

the Dobot Studio page to perform homing.
machine damage.

PROGRAM :

Robot programming and simulation for Pick and Place

Ex. No.
Date:
AIM: To perform and simulate a pick and place task in the Dobot Magician robot
using Dobot studio software

PROCESS CHART

PROCEDURE:
RESULT:
Thus the Pick and Place operation were performed using Dobot Magician Robot.

Viva-Questions
1. What is end effector?
2. List the application of Vaccum gripper.
3. What is meant by pneumatic gripper?
4. List out the type of gripper mechanism.

Precautions

machine damage.

PROGRAM:

Robot programming and simulation for Colour Identification

Ex. No.
Date:
AIM: To perform and simulate a Colour identification task in the Dobot Magician
robot using Dobot studio software

2. Dobot studio Software
PROCESS CHART

PROCEDURE :
RESULT:
Thus, the Color Identification task were performed using Dobot Magician Robot.

Viva-Questions
1. What is sensor?
2. List the various sensor used in robotic system.
3. What is photoelectric sensor?
4. What does optical proximity Sensor?

Precautions

machine damage.

PROGRAM:

Robot programming and simulation for Shape Identification

Ex. No.
Date:
AIM: To perform and simulate a Shape identification task in the Dobot Magician robot

2. Dobot studio Software
PROCESS CHART

PROCEDURE :
RESULT:
Thus the Shape Identification task were performed using Dobot Magician Robot.

Viva-Questions
1. What is tactile Sensor?
2. What is meant by touch Sensor?
3. What is edge detection?
4. What is meant by object recognition?

Precautions for Use

Danger :
 Do not operate the robot if the robot is abnormal. The user may be injured.
 Do not put fingers inside the controller with power supplied. Live cables are
connected, which may lead to electrocution or injury.
 Do not modify the robot. Doosan Robots is not responsible for for any issues
that occur due to unauthorized modification.
 Do not enter the robot’s operation area or touch the robot when it is operating.
This may lead to colliding with the robot, resulting in damage to the robot or
injury to the individual.
Warning
 Make sure to read and understand the manuals for all equipment installed.
 To prevent accidents by getting caught by the robot, do not wear loose clothing
or accessories when operating the robot. Tie long hair to prevent accidents with
hair getting caught by the robot.
 The surfaces of the robot and controller are hot during operation due to the heat
generated, so do not handle or touch these surfaces during or immediately after
operation. Failure to do so may result in burns.
 If excessive heat is generated by the robot, turn off the robot and wait for an
hour.
 Before operating the robot, comprehensive risk assessment must be performed.
 Safety-related parameters must be determined through the comprehensive risk
assessment, and safety parameter settings and the operation of safety functions
must be verified before operating the robot.
 Hand-guiding must only be used if risk assessment approves its use.
 If an error occurs on the controller or the teach pendant, activate the emergency
stop function, identify the cause of the error, find the error code on the log
screen and contact the supplier.
Caution
 Take caution of the robot’s movement when using the teach pendant. Failure
to do so may lead to colliding with the robot, resulting in damage to the robot
or injury to the individual.
 Collision with an object generates considerable kinetic energy, leading to
dangerous situations. This energy is proportionate to the speed and payload.
(Kinetic Energy = 1/2 Mass x Speed2)
 Combining different machines may increase existing risks or create new risks.
When a robot is integrated into a system, perform risk assessment of the entire
system.
 If different safety levels and emergency stop performance levels are required,
always select the higher level.
 If a machine that can cause damage to the robot is integrated, it is recommended
to individually test all functions and robot programs.
 It is recommended to test the robot program by designating temporary
waypoints outside another machine’s workspace. Doosan Robotics is not
responsible for damages that occur due to programming error or robot
malfunctioning, as well as damage to the equipment.
 Do not expose the robot to strong magnetic fields. This may damage the robot
or cause malfunctions.
 If the power plug is disconnected or the power is shut off during robot and
controller operation, robot and controller failure can occur.

PROGRAM:

Robot programming and simulation for machining (Welding)

Ex.No.
Date:
AIM: To perform and simulate a Welding task in the Doosan robot using Doosan
robotics software

1. Doosan Robot
2. Doosan Robotics Software
PROCESS CHART


PROCEDURE
RESULT:
Thus, the Welding task were simulated and performed in the Doosan robot using
Doosan robotics software.

Viva-Questions
1. What is meant by robot teach pendant?
2. What are the methods of defining position in space in lead through

programming?
3. What are the two modes of lead through programming?
4. List out the various types of motion commands

Precautions

machine damage.

PROGRAM:

Robot programming and simulation for 3D Printing

Ex. No.
Date:
AIM: To perform and simulate a 3D printing process in the Dobot Magician robot

PROCESS CHART


PROCEDURE:
RESULT:
Thus, the 3D Printing task were performed using Dobot Magician Robot.

Viva-Questions
1. What is meant by 3D Printing?
2. What are the components of image processing?
3. What is light sensor?
4. What is meant by extruder?

MF4212 Advanced Manufacturing Laboratory

Uploaded by

MF4212 Advanced Manufacturing Laboratory

Uploaded by

MF 4212 Advanced Manufacturing Laboratory Mechanical Engineering 2021– 2022

MF4212 Advanced Manufacturing Laboratory

M.E. MANUFACTURING ENGINEERING

(Anna University Regulation 2021)

For the Batch (2021 to 2023)

DEPARTMENT OF MECHANICAL ENGINEERING

KCG COLLEGE OF TECHNOLOGY,

KCG College of Technology i ISO 9001:2008

KCG College of Technology ii ISO 9001:2008

KARAPAKKAM, CHENNAI 600 097

REG. No. …………………………….

Course Code: ………………….

Name of the Course: ……………………………………………………………….....

It is to certify that this is a bonafide record of the work carried out by

………………….semester…………………………………department, during the odd

semester of the academic year 2021-2022.

Faculty In-charge ……………………… HOD………………………………………

Int. Examiner: ………………………… Ext. Examiner ………………..........

Date of the Examination: ……………………

KCG College of Technology iii ISO 9001:2008

KCG College of Technology iv ISO 9001:2008

VISION OF THE COLLEGE

MISSION OF THE COLLEGE

 Facilitate socially responsive research, innovation and entrepreneurship

 Foster holistic development and professional competency

VISION OF THE DEPARTMENT

The department aspires to become a globally recognized centre of excellence by

producing competent professionals in Mechanical Engineering to serve as a valuable

resource for industry and society.

MISSION OF THE DEPARTMENT

 Establish state of-the-art facilities for research and consultancy work.

mechanical engineering domain.

 Mentor the students to develop research and entrepreneurial capabilities.

 Inculcate a high degree of professionalism and contribute to the needs of industry

KCG College of Technology v ISO 9001:2008

KCG College of Technology vi ISO 9001:2008

PROGRAMME EDUCATIONAL OBJECTIVES:

On completion of the program, the students will achieve the following:

PEO 1 Excel as competent professional or entrepreneur or researcher in related fields

PEO 2 Analyse, design/develop innovative solutions for real world engineering

PEO 4 Lead and manage teams for effective execution of projects.

PO 3 engineering problems and design system components or processes that meet

KCG College of Technology vii ISO 9001:2008

The Engineer and Society: Apply reasoning informed by the contextual

PO 8 Ethics: Apply ethical principles and commit to professional ethics and

KCG College of Technology viii ISO 9001:2008

MF 4212 ADVANCED MANUFACTURING LABORATORY

S. No. List of Experiments as per syllabus

List of Experiments beyond syllabus

2 Robot programming and simulation for 3D Printing

KCG College of Technology ix ISO 9001:2008

MF 4212 ADVANCED MANUFACTURING LABORATORY

Signature of staff in-charge

KCG College of Technology x ISO 9001:2008

MEASUREMENT OF CUTTING FORCES IN MILLING/ TURNING PROCESS

To measure the cutting forces for the given cutting conditions

TOOLS AND EQUIPMENTS REQUIRED:

KCG College of Technology 1 ISO 9001:2008

TABULATION : Speed = rpm

VERTICAL RESULTANT AVERAGE

KCG College of Technology 12 ISO 9001:2008

MEASUREMENT OF CUTTING FORCES IN MILLING/

To measure the cutting forces for the given cutting conditions

TOOLS AND EQUIPMENTS REQUIRED:

KCG College of Technology 13 ISO 9001:2008

TABULATION : Depth of Cut = mm.

VERTICAL RESULTANT AVERAGE

Thus the cutting forces are measured for different speeds

KCG College of Technology 14 ISO 9001:2008

Study of Robots Configuration and Application

To study about Robots configuration and application

3. Cartesian coordinate configuration

KCG College of Technology 15 ISO 9001:2008

The cylindrical configuration is shown in fig(1b). It use a vertical column and

KCG College of Technology 16 ISO 9001:2008

4. Jointed arm configuration: