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Design and Development of CNC Robotic Machine Integrate-able with Nd-Yag

Laser Device

Article  in  Procedia Engineering · December 2017

DOI: 10.1016/j.proeng.2017.04.079

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Procedia Engineering 184 (2017) 145 – 155

Advances in Material & Processing Technologies Conference

Design and Development of CNC Robotic Machine Integrate-able with

Nd-Yag Laser Device
Nur Hidayanti Binti Ambrizala, Awais Farooqib, Osama I. Alsultanc, Nukman Bin Yusoffd.
a,b,d
Department of Mechanical Engineering, University of Malaya,50603 Kuala Lumpur, Malaysia
c
Technical and Vocational Training Corporation, Department of Mechanical Technology, Buraydah College of Technology, Buraydah, Qassim, Saudi Arabia.

Abstract

The machining technologies and modern intelligent systems are expensive and require easy handling and integrated-able machine with various
devices to perform multiple machining tasks. Computer Numerically Controlled (CNC) machines are accessible by manufacturers to perform
several machining tasks due to effectiveness in handling accuracy. The majority of CNC machines are costly due to it complex but efficient
machine and software design. This project is aimed to develop a cost effective and easily integrate-able CNC Machine System that is accessible
to add-on Nd-Yag Laser Device. The deliberate mechanical design and the path of laser beam entering the machine and exiting the laser-head
with intended electronics control structure controlled by CNC software is developed. The designed CNC Nd-Yag laser Machine is a teaching
tool for workshop and is targeted to perform laser cutting and suitable engraving or welding tasks for small and medium scale industries. By
testing the machine its expected positional accuracy was achieved and the control mechanism for Nd-Yag laser path reflection function was
successfully tested.
© 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
© 2016 The Authors. Published by Elsvier Ltd.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the Institute of Department of Mechanical Engineering, University of Malay.
Peer review under responsibility of the organizing committee of the Advances in Materials & Processing Technologies Conference
Keywords: CNC Robotics; Laser machining; Cost Effective Manufacturing; Software Control System; Workshop Teaching Tool.

Introduction

Computer Numerical Control (CNC) is a versatile system that allow user to control the motion of the tools and parts through
numerical data. Application of CNC machine is to perform various machining tasks by the use of G-codes. G-code are the point-
to-point coordinated programing language used in CNC machine to operate tools in x, y and z directions to achieve rapid
movement, linear interpolation, clockwise or counter clockwise interpolation etc. A CNC system incorporates machine device
and non-machine instrument territories. In the machine processes CNC machines are generally utilized for drill press, processing
machine, crushing unit, laser, sheet-metal press working machine, tube twisting machine and so on. Meanwhile, the non-
machine processes CNC consist of welding machines (bend and resistance), tape lying, and fiber twisting machines for
composites direction measuring machine and electronic get together.

Nowadays CNC machine can be found in any field of manufacturing units that also includes the laser machining process.
Nd-Yag laser device can be used as external laser source to incorporate with any type of laser CNC machine; such example can
be found in University of Malaya machine lab that uses Nd-Yag laser device as external laser source incorporated with its CO2
Laser CNC machine. Perhaps there are limitations in coordination system when external source is forced implemented into a
ready-made system by manufacture also for example when CO2 laser and Nd-Yag laser operations are required by the user to
be used at same time for different purpose. Therefore a substitute cost effective CNC structure can be made to interface Nd-Yag
laser module separately so that the user can perform experiment individually without interrupting the costly CO 2 CNC laser
machine. Therefore with the rapid development of laser technology, new research on laser topic found almost every month
around the world and mostly comes from higher educational institutions. University of Malaya also has no exception. Many on-
going and future projects regarding Nd-Yag laser experiment are planned within mechanical engineering department. However,
due to lack Nd-Yag CNC machine facility many project has to be postponed. Therefore the design and development of this CNC
machine may facilitate Nd-Yag researches. CNC table is suitable for everyone who requires laser cutting, engraving or welding

1877-7058 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer review under responsibility of the organizing committee of the Advances in Materials & Processing Technologies Conference
doi:10.1016/j.proeng.2017.04.079
146 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155

task. Although for certain situation, user can buy a new machine, yet the price is still expensive. Consumer like students or
workers and even university or college may not have full budget to buy these machine. On the other hand, one of the significant
goals of this project is to design and fabricate a low cost and user friendly CNC machine that might be a best solution to
overcome costly CNC machines. This project will focus on the practical design of CNC machine that is able to be used as
workshop tool for educational purpose to small industrial scale.

Methodology

The prototyped built for this project includes the linear direction i.e. in x and y axis movement. The maximum displacement for
the translational motion at x axis is about 50 cm and at y axis is about 40 cm. K-cam software is used to control the machine
parameters. The CNC machine is constructed in three stages; a) to build mechanical frame, b) to assemble electric system and c)
to install control and computing system.

The modelling of the CNC machine frame in 2d and 3d was conducted using SolidWorks. By calculation of the torque for
required task suitable stepper motor was selected and structure material used to build the prototype includes machine aluminum
profile (of 40 x 40 mm, 40 x 60 mm and 30 x 30 mm). The main components used to build the machine are: a) NEMA 23 2-ph
stepper, b) 3-axis stepper motor control board, c) motor shaft couplings, d) limit switches, d) Micro-step drivers and e) acme
leadscrews.

Design and System Implementation

The CNC machine frame with selected size of machine profile is built into a cube-like structure as shown in figure 1.

Figure 1: Isometric view of the CNC machine frame

This structure was chosen as it can provide large work space in the middle of cube-like structure for user to carry out ant
laser cutting etc., experiments, and the Red beam in figure 1 is the laser path selected to utilize Nd-Yag laser device in later
development stage of the system. This design is similar to three aluminum mountings attached together forming H-like shape on
top of cube structural frame. Each mounting consists of 2 cylindrical rods and one linear guide to allow movement in 2-way
linear direction. Linear rail guide is light and rigid plus commonly used in automated machinery such as CNC machine to
achieve fast motion. Currently there are four types of linear rail guides available in the market as i) acme screw, ii) ball screw,
iii) timing belt drive, and iv) linear sliding guides, each of them has their advantage and disadvantage. From the cost point of
view, linear motor is the most expensive among the four types. On the other hand, timing belt has the lowest accuracy due to
back lash and wears which can cause trouble especially for positioning application. After the consideration of cost and accuracy,
ball screw or acme screw fits our design needs. Since we are focused onto the design of low cost and user friendly simple CNC
machine, acme screw linear guides are used in the development of CNC machine.
 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155 147

A brushless DC motor is cheap and capable of providing high torque. However, the lack of feedback and difficulty to control
the shaft position accurately makes it not a good choice. Therefore stepper motors are used to build the CNC.

Mach3 is most advanced and mostly used CNC controller software as it requires a 32-bit working framework. Whereas K-
Cam is also CNC controller software, it is less prominent than Mach3 because of absence of elements and some execution
issues. However K-cam license is much cheaper to buy and it is feasible to be used for simple machining operations for up to 4-
axis and this software is accessible with the CNC control board by utilizing Parallel Port connection with CPU for
communication. K-Cam is also able to convert any image file or CAD software file into G-Codes automatically; also user
is able to edit the converted G-codes or else can write manual G-codes into the software to perform CNC operations.

Applied devices and software

In this project, K-Cam software is used to control CNC machine operations with the use of G-Codes. The basic flow chart of
software and electronic devices of the system used in CNC machine and the flow chart to explain conversions drawing into G-
codes are given in figure 2.

CAD/Drawing
software
(create the parts to be
machined)

CAM software
(convert the part file to
G-code)

CNC control
software
(turns the G-code file into
motion usually by
controlling the parallel port)

Figure 2: Overview of CNC System and Flow chart for conversions drawing to g code

Applied Software: K-Cam Software Configuration Set Up

The CNC control board is interfaced to connect electrical component and the computer through parallel port connection. The
parameters are needed to setup in the software according to machine design specifications. Figure 3 illustrates the flow chart to
setup K-Cam software configurations.

Figure 3: K-Cam Software Configuration Set Up

Basically for table setup in K-Cam software the user has to define the steps per revolution required by the stepper motor
mounted for the each axis. For this project, the step revolution are set up to 5500 steps for both x and y axis. The step revolution
is obtained by calculating the pitch of leadscrew used (i.e. 8 rounds per 1 inch). After testing the step revolution in the machine
the user can define backlash in the control setup as backlash plays important role in accuracy of dimension produced by moving-
end-effector in CNC operation, hence in this project the 3mm backlash was obtained during calibration test run of the machine.
The maximum feed rate for this CNC table was fixed at 60mm per min.
148 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155

Hardware Setup

The block diagram of electronic component and connections are elaborated in figure 4 and figure 5 shows the motor and drivers
connections with software controller.

Figure 4: Block diagram of all electric component electric component connection

Figure 5: Block diagram of (a) motor driver with stepper motor, and (b) driver control connections
 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155 149

Machine specification

The Technical Parameters of the machine are given in table 1. And the final design of CNC machine prototype is illustrates in
figure 6.

Table 1: Technical Parameters

Overall dimension:
Height 30 cm
Width 50 cm
Length 40 cm

Maximum feeding height Range: 10 - 15 cm

Working platform size:
X Axis Distance 44.5 cm
Y Axis Distance 39.5 cm
Rack Body Material Aluminum Machine Profile
Driver Motor Stepping Motor
Slide Unit Type Acme Lead Screw: 8 rounds/inch
Stepping motor 200 steps per revolution
Maximum feed rate 60 mm / min

Figure 6: CNC Machine Frame and Control Box

Testing and Verification

To setup the experimental process the efficiency of CNC table can be evaluated through several testing methods as given by
Calibration test, Positioning test and Accuracy test.
150 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155

Calibration Test

Calibration is the procedure of finding a relationship between two quantities that are obscure (when the quantifiable quantities
are not given a specific quality for the sum considered or found a standard for the quantity).

Calibration test for this experiment is performed by measuring the capability of software to draw path in exact dimension
drawing random shapes in CNC operation. The exact dimensions drawn by the CNC end-effector (Pen/Marker used for testing)
are recorded as shown in figure 7. The feeding dimension of each box is fixed at 2 x 2 cm. The test was carried out 6 times until
the dimension drawn by machine was equal to feeding dimension, by adjusting backlash value in the software.

Figure 7: Calibration Test Results

Parameters are needed to be adjusted in order to obtain dimension drawn by machine equal to feeding dimension which is
commonly achieved by adjusting backlash. Backlash is any non-movement that occurs during axis reversals and
unexpected plays in an axis due to clearance or looseness of mechanical parts. The causes of backlash is various in each
application but mostly in acme screw it occurs between the leadscrew threads and the nut. Meanwhile in ball screw, backlash
occurs may have almost none. Besides that, any affinity for the screw to move axial in the bearings that hold it and precision
angular contact bearings with preload may cause this defect. Backlash can be defined as the delay of drive briefly before
movement began in process when axis is commanded to move. From the experiment it is found that almost 3 mm of backlash
remained in system which was adjusted by putting its value in software controller.

Positional Accuracy Test

It is done by drawing a triangle and circle to test the position accuracy as equal to feed in dimensions inserted into software by
the use of G-codes. The testing results are demonstrated in figure 8 and 9 respectively.
 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155 151

Figure 8: Test 1 Results - Triangle

Total average time = 10.2 minutes; Average response time = 4.766 second;

RT = Response time; TT = Total time; T1, T4, T5 = Time for G01; T2, T3, T6 = Time for G00

Figure 9: Test 2 Results - Circle

Total average time, TT = 6.23 min; Average response time = 13.67 second;

RT=Response Time, TT=Total Time; T=G03/G02; T2=G00

152 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155

Random shape test

By conducting various shapes experiment through K-Cam software process proves that interference between electrical
component and software are successfully connected. Figure 10 is K-Cam software process step.

Figure 10: Flow chart for K-Cam software process step

Accuracy test

[18] Accuracy and repeatability specification can be defined by a few of positioning standards methods. The same machine tool
will give different accuracy and repeatability numbers dependent on the standard used. This gives an option by comparison to
select between various machine tools. For designed CNC machine an experiment is performed to obtain standard deviation (σ)
to calculate the accuracy and repeatability of it. Whiles it is done by running the CNC machine end-effector to draw a ladder
with G00 and G01 (G-codes) dimensions fed into the system to obtained equal dimensions by measuring the ladder drawn,
given in figure 11.

Figure 11: Result of accuracy testing & CNC control and plot window
 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155 153

The results obtained by this experiment are given in table 2.

Table 2: Result of accuracy test

Dimension

G00/cm G01/cm

Design distance Design distance

No Results Error No Results Error
(coordinates) (coordinates)

1. (0,0) Æ(3,0) (3,6) Æ (3,9)

3 ±0 6. 3 ±0
(3mm) (3mm)

(3,0) Æ (3,3) (3,9) Æ (6,9)

2. 2.6 ±0.4 7. 2.9 ±0.1
(3mm) (3mm)

(0,0) Æ (0,1) (6,9) Æ (6,6)

3. 2.9 ±0.1 8. 3 ±0
(3mm) (3mm)

(0,0) Æ (0,1) (6,6) Æ (9,6)

4. 3 ±0 9. 2.9 ±0.1
(3mm) (3mm)

(0,0) Æ (0,1) (9,6) Æ (9,3)

5. 3.1 ±0.1 10. 3 ±0
(3mm) (3mm)

Calculation of accuracy, repeatability and control resolution

Control resolution indicates to regulate system aptitude to divide the total range of the axis movement into closely spaced point
that can be recognized by MCU.

Control resolution is denoted as the distance separating two adjacent addressable points in the axis movement. Addressable
points are location along the axis to which the work table specifically directed to go. This is subject to on several constraints
which are electromechanical component of positioning system and number of bits used by the controller to define the axis
coordinate system such as lead screw pitch, gear ratio in drive system and step angle in motor.

Therefore by calculating the average dimension achieved from figure 11 will lead us to calculate σ, CR and accuracy of the
designed machine.

ሺଷାଶǤ଺ାଶǤଽାଷାଷǤଵାଷାଶǤଽାଷାଶǤଽାଷሻ
‫ݔ‬lj ൌ ൌ ૛Ǥ ૢ૝‫ܕ܋‬
ଵ଴

Σ(x - x̄ ) 2 = Σ ((3 – 2.94) 2 + (2.6 – 2.94) 2 + (2.9 – 2.94) 2 + (3 – 2.94) 2 + (3.1 – 2.94) 2 +(3 – 2.94) 2 + (2.9 – 2.94) 2 + (3 – 2.94) 2
+ (2.9 – 2.94) 2 + (3 – 2.94) 2 )

Σ(x - x̄ ) 2 = 0.1676

ȭሺ‫ ݔ‬െ ‫ݔ‬ljሻʹ

ߪൌඨ
݊
154 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155

ͲǤͳ͸͹͸
ߪൌඨ
ͳͲ

࣌ ൌ 0.1295 cm

For
ଷ௠௠
۱‫܀‬૚ ൌ   ൌ ૚Ǥ ૟૟૟ૠ‫ܕܕ‬
ଵǤ଼

ͶͶͷ݉݉
۱‫܀‬૛ ൌ  ൌ ૙Ǥ ૙૙૟ૡ‫ܕܕ‬
ʹଵ଺ െ ͳ

CR = (1.6667, 0.0068)

¾ Choose CR = 1.6667 mm
¾ σ = 1.295 mm
‫ݎܥ‬ ͳǤ͸͸͸͹
‫ ܡ܋܉ܚܝ܋܋ۯ‬ൌ  ൅ ͵ߪ ൌ ൅ ͵ሺͳǤʹͻͷሻ ൌ ૝Ǥ ૠ૚ૡ૜૞࢓࢓
ʹ ʹ
‫ ܡܜܑܔ܊܉ܜ܉܍ܘ܍܀‬ൌ േ͵ɐ ൌ  േ͵ሺͳǤʹͻͷሻ ൌ ૜Ǥ ૡૡ૞‫ܕܕ‬

Discussion

The mini-CNC machine built by proposed method its cost is about half price of mini-CNC machines available in market
however as compared to other mini-CNC machines available in market, the proposed machine capability and specification is
compatible. Other mini-CNC machines in market may only have one function. Meanwhile, the built mini-CNC project is
multifunctional because the laser head can be change into other tool which can also perform other processes for example, from
laser cutting application, the function can be change into lathe or graving process by changing the laser head into cutting tool.
This CNC machine making project clearly displays the significant advantage for small manufacturing firms and it is a cost
effective solution.

K-Cam software is user friendly and easy to adopt by users new to CNC processes. It has flexibility to change machine
parameters from 2 degree of freedom 4 degree of freedom by changing the functional button available in software. This CNC
machine works at 2.5 degree of freedom (DOF) which are x axis, y axis and the z axis laser beam. Additional 2 DOF can be
added in to this machine are fully functional z axis and its angular motion. This change can improve the design range from 2D
drawing into 3D drawing. Besides there are functional optional button such as coolant for spindle that can ease the laser cutting
process. In the software, there is also a tool list function available, so tool can be change automatically.

Moreover, the conversion of CAD-model to G-code step is simple and easily understandable by the user. The automatic G-
codes can be are generated either by converting cad drawing file to G-codes or by manually writing the G-codes into the
software. Apart from that machine home position can be set at any position, hence proving flexibility for machining of complex
objects. There is also option available for the user to choose scaling and units in the software that automatically dose the
conversion of diagram. Therefore, any drawing with whatever format can be converted into G-code and then produce tool path.
As verified in previous tests, the experiment proved that this CNC machine is able to run smoothly in x and y axis according to
provided dimension and able also to generate tool path according to G-codes.

Conclusion

The mini-CNC machine developed in this study is capable doing some positioning and coordination in laser cutting application.
Nd-Yag laser can be attached by using mirrors and reflector as shown in figure 1 to achieve the laser engraving application.
Besides, this study is also served as a stepping stone toward building an actual industrial CNC machine that is capable to
compete with other competitors in the market.

From this research study, several conclusions can be drawn that the development of CNC machine can be interfaced with
Nd-Yag laser device by using K-Cam software as controller. The internal working area of machine is approximately: Length x
 Nur Hidayanti Binti Ambrizal et al. / Procedia Engineering 184 (2017) 145 – 155 155

Wide x Height = 50 x 50 x 30 cm. The CNC machined developed in this project is capable of doing some positioning and
coordination in laser cutting application.

From the calibration test experiment backlash was observed, which is equal to 3mm. When backlash value is fed into the
software it automatically adjusted to give output dimension equal to actual dimension input. When the error it is small it can be
ignored. That routine involves taking up the slack (or backlash) on the hand wheels before beginning to cut.

Meanwhile, for positioning test carried out to find total average time and average response time. Two test shapes were used;
circle and triangle. For triangle shape test the average total average time is 10.2 minutes and average response time is 4.766
second. The total average time and average response time for circle shape achieved are 6.23 minutes and 13.67 second
respectively.

The accuracy test was performed to obtain standard deviation (σ) in order to calculate the accuracy and repeatability of
designed CNC machine. While σ = 0.1295cm and Control revolution CR1 and CR2 are 1.6667mm and 0.0068mm, respectively.
However control revolution CR1 of 1.6667mm is chosen because the electronic system is the limiting factor that determined
control resolution. The bit storage capacity of a modern computer controller is sufficient to satisfy this criterion except unusual
criterion.

Reference

[1] D. G. Alciatore and M. B. Histand, Introduction to Mechatronics and Measurement Systems, New York: McGraw-Hill, 2012.
[2] M. G. Pawar, B. S. Nandeshwar, V. N. Borikar and S. B. Jaiswal, "Design of Portable Coordinate Measuring Machine," International Journal of Emerging
Engineering Research and Technology , vol. 3, no. 4, pp. 1-9, 2015.
[3] H. Y. Zhenga, Z. Z. Han, Z. D. Chen, W. L. Chena and S. Yeo, "Quality and Cost Comparisons between Laser and Waterjet Cutting," Journal of Materials
Processing Technology, vol. 62, pp. 294-298, 1996.
[4] M. P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, Massachusetts: John Wiley & Sons, Inc, 2010.
[5] Y. Yusof and D.M.Elias, "CNC Machine Controller Using STEP-NC Data Model For Milling Operation," Proceedings of the 2nd International Conference
on Advanced Manufacturing , pp. 23-27, 2013.
[6] S. Krar and A. Gill, Computer Numarical Control Programming Basics, New York: Industrial Press, Inc..
[7] P. Smid, CNC Programming Techniques, New York: Industrial Press, Inc., 2005.

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