DEVELOPING AND TESTING OF CNC MACHINE ON MARBLE TILES GRINDING

INTO PRECISE THICKNESS

A Thesis
Presented to the
Faculty of the College of Engineering and Technology
Romblon State University
Odiongan, Romblon

In Partial Fulfillment of the Requirements

For the Degree of
BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

By:

Jhon Ciryl Calay

Franz Elleurick Fajiculay
Leo Fred Fernando
Arlan Jay Galos
Joseph Magracia
Jiel Mejares
Joshua Moral

March 2018
 CHAPTER I

INTRODUCTION

This chapter presents the background of the study, objectives of the study,
significance of the study, scope and delimitation of the study.

BACKGROUND OF THE STUDY

The word marble comes from Greek word Mᾴmaros which means shining or
sparkling stone. Marble is a non-foliated, granular metamorphic rock that is formed by
metamorphism of limestone and dolostone. Some marble also form by contact
metamorphism when a hot magma body heats adjacent limestone or dolostone. Before
metamorphism the calcite in the limestone is often in the form of a lithified fossil
materials and biological debris. The term marble is also applied to Serpentine rocks,
originated from the similarity of the texture of the rock to that of the skin of a snake, can
be polished to high shine. These are the natural stones which can be shaped in form of
blocks, slabs, tiles, etc. and are used for monumental and decorative purposes since
antiquity; various civilizations have used dimension stone in many ancient building and
monuments that have survived to the present day. Marble cutting industry produces
large amounts of solid wastes on large areas, which are expected to increase as
construction is continuously increased, owing to the fact that the world production of
marble industry has been increasing annually in the recent years.
By the factors of production we mean all inputs, such as land, labour, machinery,
equipment, capital, and entrepreneurship that produce finished and final products such
as marble slabs, tiles, sculptures, tables, etc.
One of the most important factors of production in marble industry is technology
(i.e. machineries and equipment in use). Due to the nature of business, machinery plays
a big role in the success and productivity firms. By employing standard machineries,
they can increase their productivity, making work easier and faster. In quarrying activity,
blasting is the old method of production, while diamond wire cutting is the new method
of quarrying. With blasting, quarries not only lose 50 to 80 percent of the material, they
can also cause great damage to the entire quarry by enforcing micro-fractures
throughout the entire deposit. Whereas with diamond wire saw cutting, the percentage
of waste can be reduced to 7 percent, while creating no damage to the marble deposit.
During marble processing, 30% of the stone (in case of unprocessed stone) goes to
scrap because of being in smaller size and/or irregular shape.

Marble is a very popular natural stone used for tiles and slabs for floors,
countertops, and walls. It is a metamorphic rock that forms when a sedimentary stone,
such as limestone, that transformed under the heat and pressure into a harder stone
with beautiful color and veined patterns. Marble is sometimes confused with granite but
granite is an igneous rock derived from volcanic magma, not layered sedimentary rock
and typically has a pebbly color pattern, while marble has a veined pattern. Marble has
been very popular building material for millennia, quarried in mountainous regions
around the world. Prized for its beauty, style, and elegance, this material has graced the
palaces of kings and queens for centuries, making it an upscale, luxurious option for
interiors. When used for floors, marble has some undeniable virtues, but it also comes
with some serious drawbacks and concerns that must be understood.

CNC machining is a manufacturing process in which pre-programmed computer

software that dictates the movement of factory tools and machinery through codes and
programs. The process can be used to control a range of complex machinery, from
grinders and lathes to mills and routers. With CNC machining, three-dimensional cutting
tasks can be accomplished in a single set of prompts easily.

Numerical control is a programmable automation in which process is controlled

by Numbers, Letters, and symbols. CNC Machining is a process used in the
manufacturing sector that involves the use of computers to control machine tools like
lathes, mills and grinders.

Early machine tools were designed so that the operator was standing in front of
the machine while operating the controls. This design is no longer necessary, since in
CNC (Computer Numeric Control) the operator no longer controls the machine tool
movements manually but by programming it through CNC. On conventional machine
tools, only about 20 percent of the time was spent removing material. With the addition
of electronic controls, actual time spent removing metal has increased to 80 percent and
even higher. It has also reduced the amount of time required to bring the cutting tool
into each machining position. Almost everything is controlled by the machine just by
only inputting some programs to follow.
 OBJECTIVE OF THE STUDY

The main objective of this study is to develop and test a CNC machine
cutting marble tiles into precise thickness.

Specifically the objectives of this study are:

1. To evaluate the performance of CNC machine.

2. To determine the efficiency and productivity of the machine.

3. To develop a precise cutting marble tiles machine

SIGNIFICANCE OF THE STUDY

The researchers conducted this study to benefit the following:

1. Marble Workers
 This will help the people or labourer to make their work easier and
faster
2. The future researchers
 This will serve as their references as they conduct their own
research.
3. Businessman and entrepreneur
 This study may serve as a merchandise and can be sold to market
and earn profit.

SCOPE AND DELIMITATION OF THE STUDY

The scope and delimitation of this study only refers or circulate on the topic of
developing and testing of the CNC machine for marble tiles planer. The researchers
commissioned a third party who has knowledge in programming and developing the
CNC machine, since the researcher has little knowledge in programming.
To test the machine in cutting/planning selected marble tiles by checking the
thickness or by measuring if it is precisely cut.

CHAPTER II

REVIEW OF RELATED LITERATURE AND STUDIES

This chapter presents the related literature, studies and published paper which
form part of the basis on conceptualization of the present study.

Related Literature

Comparing the Different Types of CNC Machines

Computer numerical control (CNC) machines are used extensively in the

manufacturing industry. Defined as machining system that’s controlled via a computer,
they allow manufacturers to automate many manufacturing processes that would
otherwise have to be performed manually. As a result, CNC driven machines increase
productivity, reduce waste and even reduce or eliminate the risk of human error. But
there are several different types of CNC machines, each of which has their own unique
functions.[ CITATION Mon19 \l 1033 ]

CNC Milling Machine

One of the most common types, milling CNC machines feature built-in tools for
drilling and cutting. Materials are placed inside the milling CNC machine, after which the
computer will guide the tools to drill or cut it. Most milling CNC machines are available in
three- to six-axis configurations.

The Figure 1 shows the CNC Milling Machine

CNC Plasma-Cutting Machine

Like milling CNC machines, plasma-cutting CNC machines are also used to cut
materials. However, they differ from their milling counterparts by performing this
operation using a plasma torch. Plasma-cutting CNC machines feature a high-powered
torch that’s able to cut through rough materials like metal. While electric welding yields
temperatures of up to 10,000 degrees Fahrenheit, plasma torches achieve
temperatures of up to 50,000 degrees Fahrenheit.

The Figure 2 shows the Plasma-Cutting Machine

CNC Lathe Machine

Lathe CNC machines are characterized by their ability to rotate materials while in
operation. They usually have a fewer number of axes than milling CNC machines,
making them smaller and more compact. Lathe CNC machines feature a lathe in the
center that manipulates and moves the material into the position as programmed on the
computer.
The Figure 3 shows the CNC Lathe Machine

CNC Routers
Like most manually operated routers, CNC routers cut materials such as wood,
plastic, steel, aluminium, foam, and composites. But with the CNC routers, you’ll be able
to cut more prototype models and advanced shapes of materials. Like the CNC mill, the
CNC router runs with a numeric computer control, improving productivity as it produces
more items in less time. Normally, industrial CNC routers have 3-axis machines. But
technical and high complex machining operations use 4-axis, 5-axis, and 6-axis

machines.
 The Figure 4 shows the CNC Routers

CNC Electric Discharge Machine

An electric discharge CNC machine, also known as a spark CNC machine, is a

special type of CNC machine that uses electrical sparks to manipulate materials into a
desired shape. Electrical discharge has an erosive effect, meaning it can deform
materials to which it’s exposed. Electric discharge CNC machines take advantage of
this by producing controlled sparks to reshape materials. Materials are placed between
a top and bottom electrode,

Machine Setup

Before the operator runs the CNC program, they must prepare the CNC machine
for operation. These preparations include affixing the workpiece directly into the
machine, onto machinery spindles, or into machine vises or similar workholding devices,
and attaching the required tooling, such as drill bits and end mills, to the proper machine
components.[ CITATION Too17 \l 1033 ]

Once the machine is fully set up, the operator can run the CNC program.

Machining Operation Execution

The CNC program acts as instructions for the CNC machine; it submits machine
commands dictating the tooling’s actions and movements to the machine’s integrated
computer, which operates and manipulates the machine tooling. Initiating the program
prompts the CNC machine to begin the CNC machining process, and the program
guides the machine throughout the process as it executes the necessary machine
operations to produce a custom-designed part or product.

CNC machining processes can be performed in-house if the company invests in

obtaining and maintaining their own CNC equipment or out-sourced to dedicated CNC
machining service providers
CNC Cutting Tools
Since ancient times, cutting tools have existed. They’re one of the oldest
inventions in human history and there has been a dramatic change in the type of cutting
tools we use. Initially, we built them with stones, so these metallic tools are of much
value in the manufacturing world. Although all cutting tools serve one purpose, to cut
through a material, there is a huge difference in their purpose. [ CITATION Too17 \l 1033 ]

Normally, for a cutting tool to be effective, it has to:

 Be 30% to 50% harder than the material it will work on.

 Be easily fabricated.
 Have high thermal conductivity.
 Have low coefficient of friction.
 Be very resistance to wear.
 Be chemically inert and stable.

In practice, different CNC cutting tools perform cutting operations. Before

considering which CNC cutting tools to use for a specific operation, you’ve got to
understand the material that manufacturers used when producing the tool. Based on
that material, we classify cutting tools into:
Carbon Steel Tool
These cutting tools are inexpensive and are mainly for low-speed operations.
They have a carbon composition of 0.6 – 1.5% with a little amount of manganese and
silicon. They’re mainly in twist drills, forming tools, milling cutters, and turning.

High-Speed Steel (HSS)

It‘s composed of high carbon steel with a reasonable amount of element alloys
like chromium, tungsten, and molybdenum. With this combination, it improves hardness,
wear resistance, and toughness. It also offers higher removal rate for metals and other
materials. To improve its property, you’ve got to apply certain surface treatment.
 The Figure 5 shows the HSS core Drills In Various Lengths

Ceramics
These chemically inert tools are corrosion-resistant and 10x faster than high-
speed steel. Usually,aluminum oxide and silicon nitride make up ceramics materials.
Projects that require top-notch finish operations normally use ceramics.
Cemented Carbide
Designed for high-speed operations, these carbide tools are extraordinarily hard
and can withstand temperatures of up to 1000oC. Normally, tantalum, titanium, and
tungsten make them up. Operations that require a high-quality surface finish also use
them. Other classifications include diamond tools, cubic boron nitride (CBN), sialon, and
cermets.

The Figure 6 shows the types of Cemented Carbide

CNC Cutting tools come in various shapes and sizes and you can use them for
various milling and lathe cutting operations.
Some CNC cutting tools are:

1. End Mills

Rotational cutting tools that you can use for the removal of materials. Although
very similar to the drill bit, the end mill is for more versatile machining operations. Unlike
the drill bit that cut axially to the material, end mills are lateral cutting tools that cut in
any direction. Due to their design, some end mills cannot cut materials axially.
Generally, there are different types of tip shapes for an end mill and each end mill
depends on the desired end-product. The various types of end mills are:

The Figure 7 shows the Various Sizes of End Mills

• Ball nose mills: Ideal for 3D contour work, ball nose mills have rounded ends
that produce top-notch curved surfaces.
• V-bit: Depressions that these tools make are V-shaped. V-bit can be 90o or 60o
and each depends on the angle of depression that a material needs. Although they
often use them to engrave signs on materials, they’re ideal for projects that need
excellent sharp edges.
• Straight Flute End Mills: These CNC cutting tools are general purpose tools that
offer top quality edges.
• Down-cut and up-cut end mills: These spiral tools can either produce a smooth-
surface finish by carrying the residue chips down or a rough-surface finish by carrying
the residue up and away from the specified area.
The basic anatomy of an end mill consists of a flute (helical grooves), cutting
edge (teeth), diameter, shank, cut length, and the overall tool length.

2. Twist Drills

These rotary CNC cutting tools have two flutes and two cutting edges. Through
their unique designs, coolants can quickly reach the point of cut action. Manufacturers
usually use these cutting tools to lower production costs and perform operations with
top-notch finishing. The twist drill is comprised of three major parts: The shank, the
body, and the point.
 The Figure 8 shows the Parts of Twist Drill

3. Fly Cutter

These single point cutters are on a mill and general purpose fly cutters provide
excellent surface finishes.
This CNC cutting tool goes across the surface of a material through a clockwise
rotation, making the material surface smooth and flat. The fly cutter is for CNCers who
want to produce an outstanding fine finish.
4. Cutting Fluids and Coolants

Typically not a CNC cutting tool, cutting fluids flush material chips away from the
cutting zone. They also offer additional benefits like:

 Reduction of thermal deformation in a workpiece.

 Improvement of the tool life.
 Surface finish improvement.

Tool holders typically hold CNC cutting tools before fitting them into the CNC
machines. The quality, design, and manufacturer’s specifications about the tool holders
are critical to an overall success of the machining operations.
Why we Should Make The Right Choice with CNC Cutting Tools?
Cutting tools play a vital role in the quality of projects done. Although buying
these items might be pricey, you cannot overlook their importance. In fact, the quality of
your project depends on the kind of cutting tool you use.
The industrial world is highly competitive and, to succeed, manufacturers and
end-users have to build top-notch products through proper planning and precise cutting.
Since cutting tools form the backbone of a professional project, you need to pay special
attention to these little items that can make or mar your projects.
Greater productivity, high precision, accuracy, and efficiency in machining
operations are the driving force needed to craft top-notch products. You can easily
achieve these features by having the right cutting tools and having an in-depth
knowledge about CNC cutting tools is the first step towards success in a competitive
industry.[ CITATION Too17 \l 1033 ]

What is Marble?
Marble is a metamorphic rock composed of recrystallized carbonate minerals,
most commonly calcite or dolomite. Marble is typically not foliated, although there are
exceptions. In geology, the term "marble" refers to metamorphosed limestone, but its
use in stonemasonry more broadly encompasses metamorphosed limestone. Marble is
commonly used for sculpture and as a building material.[ CITATION Hen19 \l 1033 ]

Romblon Marble Quarry

The marble quarry defines the island of Romblon and there are many quarry
sites high in the mountains that seem to have an endless supply of marble. Under the
green lush surroundings and dirt reveals the island’s hidden gem showing the beautiful
marble mountain. Big blocks of the mineral are cut down to smaller pieces. Mining for
marble provides livelihood to many families in the island, especially those living on the
foothills.[CITATION Expll \l 1033 ]
 Figure 9 shows the quarry site in Romblon[ CITATION Expll \l 13321 ]

Romblon Marble

Romblon is a kind of white marble quarried in Philippines. This stone is especially

good for Building stone, countertops, sinks, monuments, pool coping, sills, ornamental
stone, interior, exterior, wall, floor, paving and other design projects. It also called
Romblon White Marble, White Romblon Marble . Romblon Marble can be processed
into Polished, Sawn Cut, Sanded, Rock faced, Sandblasted, Tumbled and so
[ CITATION Pla19 \l 1033 ]

Figure 10 shows the type of marble found in Romblon (Capital)

Data on Romblon Marble

Name: Romblon Marble
Color: White
Country: Philippines ( Romblon Islands )
Recommended Usage: Building stone,countertops, sinks, monuments, pool
coping, sills, ornamental stone, interior, exterrior, wall, floor , paving
Finishing Surface: Polished, Sawn Cut, Sanded, Rockfaced, Sandblasted, Tumbled
Additional Names: Romblon White Marble,White Romblon Marble
According [CITATION Mar06 \l 13321 ] was a circular blade device for cutting flat
marble, granite, glass or similar sheets, including numerical control elements for a
cutting head having a blade addressable within a cutting Volume, which includes
elements for manipulating the sheets within the cutting volume.

(Figure 11 shows the design of Mario Giorgio Prussiani)

According to [ CITATION Mar06 \l 13321 ] the invention relates to a circular blade

device for cutting flat marble, granite and glass sheets, in accordance with the
introduction to the main claim. Sheet cutting devices have been available commercially
for some time, devices provided with a diamond-set circular blade being habitually used
for cutting marble, granite, general Stone, glass and other sheets. The blade is usually
controlled by numerical control means, which guide it during sheet cutting. Such sheets
present virtually standard dimensions, and need to be shaped to form table tops, steps
for stairs, kitchen worktops, etc.
 The sheets are cut by laying them on a cutting area and operating the cutting
device. However, as is well known to the expert of the art, the use of diamond-set
circular blades does not enable a cut to be made without material wastage. In this
respect because of its particular shape, the blade cuts completely only on its diagonal to
the cutting plane while, depending on the blade radius, the material present more or
less distant from the diagonal is only partly cut. In effect the shape of the cut follows the
shape of the blade. When cutting stone sheets, in most cases a first series of
longitudinal cuts are made along the entire length of the sheet. The sheets are then
moved manually and the transverse cuts are made.
This manual movement is done by expert operators such as to exclude the sheet
appendices transverse cut to be made without damaging the previously worked sheets.
However this operation requires the presence of an operator to continuously supervise
the production process. Moreover the idle times due to this movement are extremely
harmful to machine productivity. In this respect, the advantage of a numerically
controlled working centre is not only its working precision but also its high productivity;
the presence of such idle times leads to a halving of the rated productivity of the
machine, plus a reduction in precision due to the manual positioning.
In addition, granite, glass and the like present a considerable resistance to
compression, but a very poor resistance to tension and consequently to bending. This
means that those sheets presenting parts with a small resistant cross-section have to
be reinforced by means of an insert of rigid material (Steel or the like) glued into one or
more longitudinal grooves made in said cross-section. Sheets presenting Small sections
or unconventional shapes also often require reinforcements.
The grooves for housing the reinforcements are evidently made in the lower side
of the sheet given that the upper side, which is the visible and hence finished side, must
not present imperfections. Currently, these grooves are usually made by using
conventional sheet cutting machines; the sheet is turned over, rested on the cutting
Support with its face downwards, and the grooves made by the same circular blade as
used for cutting the sheet. Afterwards, when the reinforcements have been positioned
and glued in, the notches are made which reduce the resistant cross-section.

CONCEPTUAL FRAMEWORK
 The conceptual model of the study utilizes the input, throughput and output which
are shown in Figure
The input of the study is consists of alternative ideas from related literature and
studies.
The throughput covers the different process involved in the development of the
study: Conceptualization, Designing and Fabrication.
The output is the completed CNC Machine on Marble Grinding into Precise
Thickness.

Input Process Output

 Alternative
ideas from
related  Conceptualization
literature  CNC Marble
 Designing
 Supply and Cutting
 Fabrication
Materials Machine
 Finalization
 Tools and
Equipment

FEEDBACK

Figure 12. Conceptual Frame Work

OPERATIONAL DEFINITION OF TERMS

To fully understand this research study, the following terms are defined
technically and operationally.

Stepper Motor - A DC motor that moves in discrete steps. It is use for rotating the belts
to move the blade into X, Y, and Z axis in the CNC Grinding Machine.
Timing Belts – Toothed belt that connects the linear rail shaft guide and the pulley.
Timing Belt Pulley- A specialized pulley that have either teeth or pockets around the
outside diameter of the pulley body.
CNC Shield – An Arduino compatible board that turns your arduino into a CNC
controller.
Linear Bearing - Is a bearing designed to provide free motion in one direction.
Grinding Bit - A material use for removing and surface generation process use to
shape and finish components made of metals and any other materials.
Soldering Lead – A metal or alloy that melts at a low temperature.
Bench Tools – A collection of tools or a toolbox.
Vernier Caliper – is an instrument use to measure thickness accurately.
Level Bar – device use for establishing horizontal line or plane surface by means of
bubble in a liquid and shows the adjustment through the movement of the bubbles
vertically and horizontally.
L Square – Use to measure the table to be use in our CNC machine into the right
angle.

CHAPTER III
 RESEARCH METHODOLOGY

This chapter presents the methods and procedure employed in the study. This
includes the materials used, research locale, time of study and the design and
procedure in constructing the CNC machine.

MATERIALS
Below are list of material to be use in the fabrication of the CNC machine cutting
marble tiles into precise thickness.

Table1: List of materials to be use in the study.

QUANTITY UNIT DESCRIPTION
3 Pcs. Stepper Motor
1 Pc. 12V/DC/30000rpm motor
3 Pcs Timing belt
9 Pcs Timing belt pulley
5.5 Meter Shaft (stainless) /12 mm ø
16 Pcs Linear bearing
1 Pcs. CNC shield
5 Pcs. Grinding bit
10 meter Wire `
24 Pcs. Bolts and Nuts
3 Pcs Screw
3 meter Soldering lead

Tools and Equipment:

1. For Fabrication
 Hacksaw (metal)
 Grinder
 Bench tools
 Electric drill
 Soldering iron

2. For Testing
 Vernier Caliper
 Level Bar
  L Square

3. Safety and Protection

 Eye Goggles
 Hand Gloves

METHODS

Fabrication method:
Assembling Flat form
 Measure and cut pieces to the required dimension.
 Assemble the part by using bolts and nuts
Frame
 Measuring the pieces and cut into its required dimension.
 Assemble the parts using bolts and connect the flat form
Shaft
 As indicated in the drawing design, Measure and cut the stainless steel to the
required dimension.
 Drill the frame to make a hole and insert the shaft.
 Lock the shaft by using the bolts and nuts into the frame.

Connection of other components

 Connect the motor into the frame, then insert the timing belt pulley into the
motor.
 Connect all remaining components into its proper location.
Finishing
 Grind all the rough surfaces using sand paper.
 Use number 1000 sand paper.

Flow Chart of Activity

 CONCEPTUALIZATION OF THE PROJECT

START OF THE PROJECT

PROCUREMENT OF MATERIALS

FABRICATION

FRAME FLATFORM Linear RAIL

Guide

INITIAL TESTING

MODIFICATION

FINAL TESTING

PREPARATION OF PAPERS

PRESENTATION TO PANEL

FINAL EDETING AND PRINTING

References:

Tool holder exchange. (2017, December 03). Retrieved from cnc-cutting-tools-primer:

https://toolholderexchange.com/cnc-cutting-tools-primer/

Explora. (2019). Retrieved 2019, from Explora.ph:

https://explora.ph/attraction/842/marble-quarries

Henry George Liddell, R. S. (2019, October 16). Wikipedia. Retrieved from

en.wikipedia.org: https://en.wikipedia.org/wiki/Marble

Mario Giorgio Prussiani, A. (. (September 28, 2006). Device with CircularBblade for
Cutting flat Marble, Granite and Glass Sheets.

Monroe. (2019, 01 03). blog/comparing-the-different-types-of-cnc-machines/. Retrieved

from https://monroeengineering.com.

Place, International Builders Market. (2019). romblon-marble. Retrieved 2003, from

Stonecontact Web Site: https://www.stonecontact.com