CNC MACHINE

Senior Project

by

Mohammad Ali Al-Masri 81730472

Haidar Toufily 81630047

Submitted to the School of Engineering of the

Lebanese International University

Beirut, Lebanon

in partial fulfillment of the requirements for the degree of

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

Spring 2019

Approved By:

Dr. Nadine Allam

Supervisor Name Date Signature

Dr. Youssef Aboumsallem

Committee Member Name Date Signature

TABLE OF CONTENTS
Table of Contents........................................................................................................................................i

List of Figures...........................................................................................................................................iii

Chapter 1. Introduction, CNC machine..................................................................................................1

1.1. How Cnc WORKS?........................................................................................................................1

1.1.1. Motion Control......................................................................................................................1

1.1.2. Programmable accessories.....................................................................................................2

1.2. The History of Computer Numerical Control (CNC).....................................................................2

1.3. Types of CNC machines.................................................................................................................3

1.3.1. In the metal removal industry:...............................................................................................3

1.3.2. In the metal fabrication industry:...........................................................................................4

1.3.3. In the woodworking industry:................................................................................................4

1.4. Parts:...............................................................................................................................................5

1.4.1. Stepper Motor:.......................................................................................................................5

1.4.2. Driver stepper:.......................................................................................................................6

1.4.3. Bearing:..................................................................................................................................6

1.4.4. Aluminum Rod:.....................................................................................................................7

1.4.5. Bolt Screw:............................................................................................................................7

1.4.6. Mini spindle:..........................................................................................................................8

1.4.7. Drills:.....................................................................................................................................8

- Chamfer Tool (Figure 15): Used to produce a chamfer on a hole or around the

profile of a part [11].................................................................................................9

1.4.8. CNC USB Controller:..........................................................................................................10

1.4.9. Arduino Uno Board:............................................................................................................10

Chapter 2. Design.....................................................................................................................................11
 Cnc machine........................................................................................................................................14

Chapter 3. Fabrication............................................................................................................................15

Chapter 4. Results....................................................................................................................................20

Chapter 5. Conclusion.............................................................................................................................22

References:..........................................................................................................................................23

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 LIST OF FIGURES

Figure 1: CNC Machine [1].........................................................................................................................1

Figure 2: Old CNC Machine [3]..................................................................................................................3

Figure 3: Metal Removal Machine [4]........................................................................................................4

Figure 4: Metal Fabrication Machine [4].....................................................................................................4

Figure 5: Woodworking Machine [4]..........................................................................................................5

Figure 6:Stepper Motor [5]..........................................................................................................................5

Figure 7:Driver Stepper [6].........................................................................................................................6

Figure 8: Bearing [8]...................................................................................................................................6

Figure 9: Aluminum Rod.............................................................................................................................7

Figure 10:Bolt Screw...................................................................................................................................7

Figure 11: Mini spindle [10]........................................................................................................................8

Figure 12: Square End mill [11]..................................................................................................................8

Figure 13: Ball End mill [11].......................................................................................................................9

Figure 14: Twist Drill [11]..........................................................................................................................9

Figure 15: Chamfer Tool [11]......................................................................................................................9

Figure 16: Arduino Uno Board [12]..........................................................................................................10

Figure 17:Wood Base................................................................................................................................11

Figure 18: Base..........................................................................................................................................12

Figure 19:Rod............................................................................................................................................12

Figure 20:Stepper Motor............................................................................................................................13

Figure 21: CNC Machine Design..............................................................................................................14

Figure 22: Base x-axis...............................................................................................................................15

Figure 23:Base of y and z axis...................................................................................................................16

Figure 24:Plexi plates................................................................................................................................16

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Figure 25:Vertical standard base...............................................................................................................17

Figure 26: Horizontal standard base..........................................................................................................17

Figure 27: Lower part of the machine.......................................................................................................18

Figure 28: CNC Machine...........................................................................................................................19

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 DEDICATION

This study is whole heartedly dedicated to our beloved parents, who have been our source of

inspiration and gave us strength when we thought of giving up, who continually provide their moral,

spiritual, emotional, and financial support.

To our brothers, sisters, relatives, mentor, friends, and classmates who shared their words of advice

and encouragement to finish this study.

To our mentor Dr. Nadine Allam, for her kindness and devotion, and for her endless support.

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 ABSTRACT

CNC machines are widely used to manufacture different parts in different types of materials. It is a

highly precise way for manufactures to make sure all their parts are within the set tolerances. CNC is

computer controlled whereas in the past the operator manually controlled it. Some of the first manual

milling machines in the early 1900's used manual dials to make parts to specific measurements.

This project presents the design and the fabrication of a CNC prototype machine used to produce a

3D wood shape. The shape should be drawn first and it will be then drilled using our CNC machine.

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 CHAPTER 1. INTRODUCTION, CNC MACHINE

CNC stands for Computer Numerical Control. While people in most occupations have never heard

of this term, CNC has touched almost every form of manufacturing process in one way or another.

If you will be working in manufacturing, it's likely that you'll be dealing with CNC on a regular

basis (Figure 1).

Figure 1: CNC Machine [1].

1.1. HOW CNC WORKS?

Everything that an operator would be required to do with conventional machine tools is

programmable with CNC machines ( Figure 1). Once the machine is setup and running, a CNC

machine is quite simple to keep running. In fact, CNC operators tend to get quite bored during

lengthy production runs because there is so little to do. With some CNC machines, even the work

piece loading process has been automated [1].

1.1.1. Motion Control

All CNC machine types share this commonality: They all have two or more programmable

directions of motion called axes. An axis of motion can be linear (along a straight line) or rotary

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 (along a circular path). One of the first specifications that implies a CNC machine's complexity is

how many axes it has. The more axes, the more complex the machine is. The axes of any CNC

machine are required for causing the motions needed for the manufacturing process.

1.1.2. Programmable accessories

A CNC machine would not be very helpful if all it could only move the work piece in two or more

axes. Almost all CNC machines are programmable in several other ways. The specific CNC

machine type has a lot to do with its appropriate programmable accessories. And here we are

going to use Arduino.

1.2. THE HISTORY OF COMPUTER NUMERICAL CONTROL (CNC)

The concept of CNC harkens back to the basic idea of NC, or numerical control. The idea of

numerical control started when the automation of machine tools originally incorporated specific

concepts of programmable logic. In the beginning, the first NC machines were built back in the

1940s. Slightly more advanced machines came along in the 1950s. These manufacturing machines

were constructed based on existing tools that were modified with motors designed to move the

controls of the machine [3].

Over the years, as CNC technology gained acceptance (with proven results), manufacturers began to

replace older technologies and manual machining methods with Computer Numerical Control. And

while the United States launched the CNC technology revolution, Germany and Japan became more

successful in enhancing the technologies and bringing down unit costs. In more recent years,

microprocessors have brought down unit costs even more, and have made CNC technology (Figure

2) much more accessible to smaller manufacturing companies, as well as individuals.

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CNC has had a long and interesting history. As technology evolves in the future, there may be even

more incredible elements to add to its history as manufacturing continues to promote the use of

robotic and automated processes in nearly every field [3].

Figure 2: Old CNC Machine [3].

1.3. TYPES OF CNC MACHINES

As stated, CNC has touched almost every facet of manufacturing. Many machining processes have

been improved and enhanced with CNC. Let's look at some of the specific fields and place the

emphasis on the manufacturing processes enhanced by CNC machine usage.

1.3.1. In the metal removal industry:

The metal removing industries remove the metal from the raw material (Figure 3) to give it the

desired as per the requirements. These can be the automotive industries for making the shafts, gears,

3
and many other parts. It can be manufacturing industries for making the various rounded, square,

rectangular, threaded and other jobs [4].

Figure 3: Metal Removal Machine [4].

1.3.2. In the metal fabrication industry:

In many industries, thin plates like steel plates are required for various purposes, in fabrications

industry the machining operations (Figure 4) are performed on such plates. In these industries, the

CNC machines are used for various machining operations like shearing, flame or plasma cutting,

punching, laser cutting, forming, and welding and many other applications.  [4].

Figure 4: Metal Fabrication Machine [4].

1.3.3. In the woodworking industry:

As in the metal removal industry, CNC machines are heavily used in woodworking shops (Figure 5).

Operations include routing (similar to milling) and drilling. Many woodworking machining centers

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are available that can hold several tools and perform several operations on the work piece being

machined [4].

Figure 5: Woodworking Machine [4].

1.4. PARTS:

There are different parts in the CNC machine, these parts are presented below:

1.4.1. Stepper Motor:

Stepper motors (Figure 6) are DC motors that move in discrete steps. They have multiple coils

that are organized in groups called "phases". By energizing each phase in sequence, the motor

will rotate one step at the time. With a computer, controlled stepping you can achieve very

precise positioning and/or speed control. For this reason, stepper motors are the motor of choice

for many precision motion control applications.  Stepper motors come in many different sizes

and styles and electrical characteristics [5].

Figure 6: Stepper Motor [5].

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 1.4.2. Driver stepper:

Stepper motor drivers (Figure 7) are specifically designed to drive stepper motor (Figure 6), which

are capable of continuous rotation with precise position control, even without a feedback system.

Stepper motor drivers offer adjustable current control and multiple step resolutions, and they feature

built-in translators that allow a stepper motor to be controlled with simple step and direction inputs

[6].

Figure 7: Driver Stepper [6].

1.4.3. Bearing:

Bearing (Figure 11) is used to allow the motion of the base on the rods [8].

Figure 8: Bearing [8].

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 1.4.4. Aluminum Rod:

Aluminum rod (Figure 11)  and bar is produced by several different processes namely extrusion,

rolling and coiling, or drawn directly from molten aluminum. These processes elongate

the aluminum into circular or bar-shaped pieces that can be machined into all kinds of applications.

Figure 9: Aluminum Rod.

1.4.5. Bolt Screw:

Bolt screw (Figure 11) is connected to the stepper motor using coupler. It transforms the rotational

motion (Motor) into translation motion (Base).

Figure 10: Bolt Screw

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 1.4.6. Mini spindle:

The spindle (Figure 11) is an extremely important part of the engraving system. This is true for

manual as well as computerized engravers. Spindles are precision manufactured mechanical

components that operate at variable speeds during rotary engraving. They use internal precision

bearings that provide the rotary capability and support the rotating cutter during engraving. All

spindles use some form of bearings and require special care and handling [10].

Figure 11: Mini spindle [10].

1.4.7. Drills:

There are many types of drills:

- Square End mill (Figure 12): The most common tool. Used to make square cuts [11].

Figure 12: Square End mill [11].

- Ball End mill (Figure 13): Used to do 3D milling [11].

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 Figure 13: Ball End mill [11].

- Twist Drill (Figure 14): Used to drill holes [11].

Figure 14: Twist Drill [11].

- Chamfer Tool (Figure 15): Used to produce a chamfer on a hole or around the profile of a

part [11].

Figure 15: Chamfer Tool [11].

1.4.8. CNC USB Controller:

The USB CNC Controller software is a dedicated application, designed to fully exploit the features

of the purpose-built hardware [7].

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 1.4.9. Arduino Uno Board:

The Arduino Uno board (Figure 16) is a microcontroller based on the ATmega328. It has 14 digital

input/output pins in which 6 can be used as PWM outputs, a 16 MHz ceramic resonator, an ICSP

header, a USB connection, 6 analog inputs, a power jack and a reset button. This contains all the

required support needed for microcontroller. In order to get started, they are simply connected to a

computer with a USB cable or with a AC-to-DC adapter or battery [12].

Figure 16: Arduino Uno Board [12].

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 CHAPTER 2. DESIGN

To construct a CNC machine, we need to assemble different parts together. Therefore, here are some

designs of the parts that we need.

-Wood base: The base of the machine for both x and y axis.

Mass = 4700.00 grams

Dimensions in mm are shown in Figure 17

Figure 17: Wood Base.

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-Base: There are three bases (Figure 18), one for each axis (x, y and z). Base of x- axis is used to fix

the sample (wood sample). Base of y-axis is used to fix the base of z-axis. Base of z-axis is used to

fix the spindle.

Mass = 1064.71 grams.

Figure 18: Base.

-Rod: To ease the motion of the three bases (Figure 19).

Mass = 489.85 grams.

Figure 19: Rod.

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-Stepper Motor (Figure 20):

There are different types of stepper motor, and each one has specific properties such as the power

that can generate and the torque the can endure. To know the type of the motor that we need, we

have to calculate the mass of each part that the motor will move (four motors are needed, two for x-

axis, one for y-axis, and one for z-axis)

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 39

14.50 24.30
42.3
5
21.80

25

8.50 11.20 42.3

Figure 20:Stepper Motor

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 - CNC MACHINE

This is the design of the CNC machine using solid works.

Mass = 28.9 kilograms

Figure 21: CNC Machine Design

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 CHAPTER 3. FABRICATION

Fabrication of the bases:

-Connecting the rods to the base using bearings.

- Connecting the bolt screw to the base using nuts.

-Connecting the two rods to two rectangular iron plates at each end.

Figures 22 and 23 show the fabricated x-y-z axis.

Figure 22: Base x-axis

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 Figure 23:Base of y and z axis

Fabrication of standard bases:

-Fix the plexus plate (Perspex) to the both horizontal and vertical wood bases (Figure 24)

Figure 24: Plexus plates

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 Figure 25:Vertical standard base

Figure 26: Horizontal standard base

Assembly:

-Fix both the bases on the horizontal and vertical standard bases using screws (Figure 27).

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 Figure 27: Lower part of the machine

Overall assembly:

Connect the lower and upper part of the machine using two iron bars at both sides. And one iron bar

is connecting the back of the upper part with the lower part.

Figure 28: CNC Machine

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Figure 29: Final prototype

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 CHAPTER 4. RESULTS

The main result of our project is that it works and draw the desired shape with high precision and

reduced time.

We also calculate the different velocities along the three axis, the motor characteristics and the time

needed to accomplish a drawing.

- Calculation for velocity for the three axes:

*X-axis:

For distance=10cm, it needs 4.22 s.

⇒ V=d/t=0.1/4.22=0.0237 m/s.

*Y-axis:

For distance=10cm, it needs 3.7 s.

⇒ V=d/t=0.1/3.7=0.027 m/s

*Z-axis:

For distance=10cm, it needs 3.5 s.

⇒ V=d/t=0.1/3.5=0.028 m/s.

- Stepper Motor Specifications:

Step angle: 1.8° full step 0.9° half-step
Phase/Windings: 4/2
Voltage & Current: 12V at 400 mA
Resistance per Phase: 30 ohms
⇒ P (power)=V*I=12*0.4=4.8 W

- Calculation of angular velocity for the three axes:

Radius=5mm=0.005m

*X-axis:

w=V/R=0.0237/0.005=4.74 rad/s

*Y-axis:

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w=V/R=0.027/0.005=5.4 rad/s

*Z-axis:

w=V/R=0.028/0.005=5.6 rad/s

- Calculation of the torque for the three axes:

*X-axis:

T=P/w=4.8/4.74=1.012 N.m

*Y-axis:

T=P/w=4.8/5.4=0.88 N.m

*Z-axis:

T=P/w=4.8/5.6=0.85 N.m

- Calculation of drawing time:

Each drawing has different dimensions, therefore; the time varies between one drawing and another.

Also the shape of the drawing affects the movement of the axes, which influence the total drawing

time.

CHAPTER 5. CONCLUSION

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CNC is a very popular method of creating parts. These machines offer extreme precision at a fast

rate. CNC machines are very complex and being able to efficiently operate one takes much time and

practice. Although most of the codes are similar, CNC machines are different from model to model.

CNC milling is not easy at first but mastery of it allows you to create a plethora of usable parts in a

very short time frame. CNC machines are widely used to manufacture different parts in different

types of materials. It is a highly precise way for manufactures to make sure all their parts are within

the set tolerances.

In this project, we presented the different parts of a CNC machine and we drown it using SolidWorks

in real dimensions. Then, each part is fabricated and connected together to have the final CNC

prototype machine. The fabricated CNC machine moves along 3 axis (x, y and z), take the input from

the computer: drawn shape, and produce this shape on a wood base.

REFERENCES:

[1] Lynch, M. (2007). What Is CNC? CNC Concepts.

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[2] Cammachine. (2018). The History of CNC Machines : From the Industrial Revolution to the

Present Day. Cam Machine.

[3] Fox, C. (2016). A Little CNC History. TORMACH LABS.

[4] Heidelbereger, M. (2019). Types of CNC Machines. Techwalla.

[5] Earl, B. (2014). What is a Stepper Motor? explore and learn.

[6] Raj, A. (2018). What is Stepper Motor and How it Works. Cicuit digest.

[7] Ellery, M. (2009). USB Controller – Motion Control for Makers. diymachining.

[8] Mikasa. (2019). Bearing. Mikasa Industry.

[9] hiwin. (2017). Linear Guideways. HIWIN, Motion Control and System Technology.

[10] thomas. (2015). What is a CNC spindle? engravingsys.

[11] Thomas, "Types of CNC Drill Bits," thomasnet, 2019.

[12] Rafael, "Arduino CNC shield version 3.0 with GRBL," DIY Projects, 2015.

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