cnc milling machine manufaturing first step,i does not include all procedure but just start material ,component,and desighning

1. MGM’s COLLEGE OF ENGINEERING
AND TECHNOLOGY,KAMOTHE
A Seminar On
“ DESIGN & FABRICATION OF CNC
MILLING MACHINE ”
Group members :
Mr. Dinesh V. Awari
Mr. Manoj S. Bhamare
Mr. Akshay S.Ghanwat
Mr. Ketan M. Jadhav
Guided By:-
Prof. Jagdish M. Chahande

2. CNC MILLING MACHINE

3. Introduction
1. Our CNC Machine is a “personal” version of a CNC machine. It is controlled
by your computer and is designed for the hobbyist to create objects within a
relatively compact space and at modest expense.
2. With the help of CNC technology, machine tools today are not limited to
human capabilities and are able to make ultra-precision products down to
nano scales in a much faster manner.
3. The traditional design philosophy of machine tools is multifunctionality and
highest precision possible.

4. Literature Review
Sr. No. Name Of
Research Paper
Author Year Thesis
1. Semiautomatic
Drilling Machine
Controller
Prof. R. N. Panchal,
Prof. J.R. Panchal
2016 Trying to propose
low cost design
using
which similar
functionality as
that of CNC can be
achieved.
2. Design of low Cost
CNC Drilling
Machine
Gautam Jodh ,
Piyush Sirsat.
2014 Machine is
designed with a
view to keep the
cost of the
machine at
minimum.

5. 3. Development of a
Prototype CNC
Machine
Vatsal Suthar,
Dhaval Patel
2015 Brings CNC
technology to a
size and price that
will fit in our
home or office
4. Prototype CNC
Machine Design
Rogério D. S.
Souza
2012 Development of a
machine which
allows future
researches on the
process
performance, on
educational
purposes, the
demonstration of
the parts involved
on the CNC
machine.

6. 5. Effect Of
Machining
Parameters On
Surface Quality
After Face Milling
Of MDF
Abdullah Sütcü 2011 Focused on
machining
parameters
which are related
the surface
roughness of the
pocket milled
MDF routed by a
CNC machine
6. Design And
Implementation
Of 3-axis Linear
Interpolation
Controller In
FPGA For Cnc
Machines And
Robotics
Dr. Usha S.
Mehta
2014 The simulation
results of the
linear motion in
3D space
verify the
effectiveness of
the implemented
algorithm.

7. 7. An Investigation
Effect of
Machining
Parameters on
CNC
Mr.Dhruv H.
Patel,
Prof. V. N. Patni
2014 Study on CNC,
influence of
various
machining
parameters like,
tool speed (rpm
), tool feed
(mm/min), and
depth of cut
(mm)
8. Construction And
Evaluation Of
Low-cost Table
CNC
Milling Machine
Ivo Pahole, Luka
Rataj, Mirko Fick
2013 In the
continuation the
tests and
checking of static
rigidity,
positioning
accuracy and
repeatability are
discussed

8. Problem Definition
 Yet most mills are costly and difficult to use, keeping them out of reach
for individuals and small businesses. High initial cost and requirement of
skilled labour for operating the CNC machine not suitable for use in small
or medium scale industries.
 In many Indian engineering educational institutions the CAD/CAM and
Manufacturing Technology Laboratories are equipped mainly with large
commercial CNC machines which are prohibitively expensive and
moreover are overdesigned considering the pedagogical needs of
undergraduate students. They come with costly annual maintenance
contracts and are time-consuming and expensive to repair in the case of
breakdowns.

9. Objective
 To full fill the demand of CNC machine from small scale to large scale industries
with optimized low cost.
 Using Arduino-based control system is a major new development in computer
technology is the availability of low-cost open source hardware.
 Clear, easy to follow design
 Comprehensive construction and operation manual .
 For the development of low-cost educational models of CNC machines, such tools
may be quite adequate from the viewpoint of machine control.

10. Methodology
Basic CNC Equipments

11. Main Systems
This system can be divided in to three modules :-
1) Mechanical system
2) Electrical system
3) Software system

12. Working

13. PC RUNNING
MACH 3
Parallel port
or USB
Breakout
bord
Power supply
Stepper drive
Stepper drive
Stepper drive
M1
M2
M3

14. Components
MECHANICAL COMPONENT :
1. BALL/ LEAD SCREWS
2. BALL BEARINGS
3. LINEAR RODS
4. LINEAR BALL BEARINGS
5. SHAFT END SUPPORTS
ELECTRICAL COMPONENT :
1. MICROCONTROLLER BOARD
2. STEPPER MOTOR
3. STEPPER MOTOR DRIVER BOARD
4. LIMIT SWITCHES
5. Computer software

15. Ball / Lead Screws
1. A ball screw is a mechanical linear actuator that translates rotational motion to linear
motion with little friction.
2. A threaded shaft provides a helical raceway for ball bearings which act as a precision
screw.
3. As well as being able to apply or withstand high thrust loads, they can do so with
minimum internal friction.

16. Ball Bearings
1. A ball bearing is a type of rolling-element bearing that uses balls to maintain
the separation between the bearing races.
2. The purpose of a ball bearing is to reduce rotational friction and support
radial and axial loads.

17. Linear Rods
1. Linear rods are rigid strong Mild Steel shafts which are used to carry the load
with out affecting the motion and supports linear movement.
2. Linear rods with linear bearing assembly are used to carry the loads and
supports the structures in linear motions the total load of the structure is taken
away by the linear rod bearing assembly and therefore the load on ball screw is
reduced and causes precise smooth linear motion.

18. Linear Bearings
1. A linear bearing is to provide free motion in linear direction. The load is carried
away by the linear bearing and reduces friction slides over linear rods.
2. A linear-motion bearing or linear slide is a bearing designed to provide free
motion in one direction.
3. It features smooth motion, low friction, high rigidity and long life. They are
economical, and easy to maintain and replace.

19. Shaft End Support
1. Shaft supports are used to support linear rods /shafts rigidly without slip.
2. Shaft support blocks are used for end or intermittent support where loads are
light and slight shaft deflection is not a concern.

20. Stepper Motor
1. A stepper motor is a brushless, synchronous electric
motor that converts digital pulses into mechanical
shaft rotation in a number of equal steps.
2. The motor's position can then be commanded to
move and hold at one of these steps without any
feedback sensor (an open-loop controller).
3. A NEMA 23 stepper motor is a stepper motor with a
2.3 x 2.3 inch size is chosen to drive the motion of
the axes.
4. NEMA 23 stepper motors are high torque about
19KG-Cm holding torque .NEMA 23 stepper motors
have 1.8 degree step angle with 2.5A rated current.

21. Stepper Motor Driver Board
1. Driving a stepper motor is a bit more complicated than driving a regular brushed DC
motor. Stepper motors require a stepper controller to energize the phases in a timely
sequence to make the motor turn.
2. RMCS-1102 is micro-stepping drive designed for smooth and quiet operation is chosen
to drive the NEMA 23 stepper motorRMCS-1102 achieves micro-stepping using a
synchronous PWM output drive. Mismatched motors and drivers can result in
disappointing performance. Or worse: damage to the motor and/or controller.

22. Microcontroller Board
1. Atmega 328 p Arduino Development board is used
as the motion control board.
2. Atmega 328 p is a 16 bit 24 pin ARM Architecture
microcontroller. The microcontroller is flashed
with the GCODE interpreter firmware written in
optimized “C” language .
3. Motion control is carried away through output
pins connected to the stepper motor drives
according to the firmware code in microcontroller.
Inputs like RESET, FEED HOLD, CYCLE
START/RESUME and axis Limits are given to the
Inputs of microcontroller

23. Limit Switches
1. A Limit Switch is the simplest type of end stop a simple mechanical switch
positioned to trigger when a axis reaches the end of its motion.
2. Limit switches are used to protect the stepper motor and circuit by shutting
the motors by triggering the switch when the axis reaches its end .
3. The signal pin from limit switches are connected to the microcontroller board
to sense the axes ends.

24. Design
This CNC machine creates objects from wood. CNC stands for computer
numerical control. The CNC works on the Cartesian coordinate system
(X, Y, Z) for 3D motion control. Parts of a project can be designed in the
computer with a CAD/CAM program, and then cut automatically using
cutters to produce a finished part. This CNC machine is ideal for
hobbies, engineering prototyping, product development, art, and
production work.

25. Rough Sketches

26. Z axis assembly and stepper motor connection

28. Auto Cad Design
Isometric view

29. Auto Cad Design
Isometric View

30. Top View
Front View RHS View

31. Diamensions
Base = 3’ x 2.5”
Column = 1’-8” x 1’-5”
Workpice table = 1’-3” x 3’
Z-axis assembly = 1’-1” x 9”

32. Mach 3 Software
Mach3 turns a typical computer into a CNC machine controller. It is very rich in
features, works on most Windows PC's, and is customizable for many applications.
Mach3 is the most intuitive CNC control software available.
Main features include:
I. Allows direct import of DXF, BMP, JPG, and HPGL files through Lazy-Cam
II. Visual G-code display
III. Generates G-code via Lazy-Cam or Wizards
IV. Fully customizable interface
V. Customizable M-Codes

33. Mach 3 Software

34. Application
1. This CNC machine can be used in the production of many different items, such as
door carvings, interior and exterior decorations, wood panels, sign boards,
wooden frames, moldings , musical instruments, furniture, and so on.
2. It is perfect way to create prototypes using aluminum, foam, wood and plastics.
Using the right software and efficiently create prototypes and reproduction parts.
3. There are one of the most versatile tools for any woodworking operation. Cut to
size, rout, chamfer, rabbet, v-groove, dado, pocket, carve and more.
4. With the development of powerful, easy-to-use software and a CNC machine,
just about anyone can carve beautiful parts, even if he is not a world-class hand
carver

35. Market Survey of some parts
Parts Price
Microcontroller (UNO) 500-1000/-
Stepper Motor 1000-2000/-
Drive Board
(ULN 2003 Board)
400-500/-
Flexible connector 300-500/-

36. Future Work
1. It is planned to scale up the CNC machine in terms of size, use
more powerful motors, strengthen the frame and worktable
with materials like aluminum or cast iron, and augment the
CNC control software with software for simulation ahead of
actual run
2. Time requirement
3. Fabrication of parts
4. Assembly
5. Performance testing

37. Conclusion
1. With the increasing demand for small scale high precision parts in various
industries, the market for small scale machine tools has grown substantially.
2. Using small machine tools to fabricate small scale parts can provide both
flexibility and efficiency in manufacturing approaches and reduce capital cost,
which is beneficial for small business owners.
3. In this thesis, a small scale three axis CNC milling machine is designed and
analyzed under very limited budget.

38. Reference
1. www.nplindia.org
2. www.wikipedia.org
3. Yung C. Shin, Henry Chin, Michael J. Brink, ―Characterization of CNC machining
centers, Journal ofManufacturing Systems,1991
4. Heisel, M Gringel, ―Machine Tool Design Requirements for High Speed Machining‖,1999
5. M Kumar, V Puttige, ―low cost automation for CNC machining center‖, IJMET, Vol. 3.
6. I. Pahole, L. Rataj, M. Ficko, S. Klancnik, S.Brezovnik, M. Brezocnik, and J.
Balic,"Construction and evaluation of low-cost tableCNC milling machine",2009
7. V.K. Pabolu and K.N.H. Srinivas, "Design and implementation of a three dimensional
CNC machine",2010.
8. T. Andrei and I. Nae, "Practical applications performed by a stepper motor CNC
router",2010
9. P.A. Sherring da Rocha Jr., R.D.S. Souza, and M.Emilia de Lima Tostes, "Prototype CNC
machinedesign",2012
10. Xu, Y. Li, J. Sun, and S. Wang, "Research and development of open CNC system based on
PC and motion controller",2012.
11. www.fortune.org
12. www.headland.com
13. www.machinetoolhelp.com
14. www.cncezpro.com