USER INSTRUCTIONS

3-AXIS CNC MINI-MILLING MACHINE

This user manual book is made by:

Fatima Tasya Kamila (2020360002)
Rhainna Rheizkhira Reflin (2020360006)

Based on the Final Year Project of:

Muchammad Fachrizal Ali (2018360032)
Muhammad Dzulkifly (2018360026)

Sampoerna University
May 2023
Table of Contents
1 PREFACE ........................................................................................................................................... 3
1.1 .... Description of the user ..................................................................................................................... 3
1.2 .... Explanation of safety warnings........................................................................................................ 3
1.3 .... Retaining instructions ...................................................................................................................... 3
1.4 .... Obtaining documentation and information ..................................................................................... 3
2 Description of the product ............................................................................................................... 4
2.1 .... Purpose of the product..................................................................................................................... 4
2.2 .... Technical data .................................................................................................................................. 4
2.3 .... Product elements ............................................................................................................................. 5
3 Safety instructions ......................................................................................................................... 12
4 Preparation .................................................................................................................................... 13
4.1 .... How to transport the product ........................................................................................................ 13
4.2 .... Storing the product ........................................................................................................................ 13
4.3 .... Conditions for assembling .............................................................................................................. 13
5 Operation/Use ............................................................................................................................... 14
5.1 .... How to use the product .................................................................................................................. 14
5.1.1 CAD (Computer Aided Design) ................................................................................................................... 14
5.1.2 CAM (Computer Aided Manufacturing) ..................................................................................................... 14
5.1.3 GrblGru ....................................................................................................................................................... 18
5.1.4 Machine Operation .................................................................................................................................... 19

5.2 .... What to do in emergency situations .............................................................................................. 21

5.2.1 Error with the Movement of the Machine ................................................................................................. 21
5.2.2 Error with Specific Number ........................................................................................................................ 21
6 Maintenance and cleaning............................................................................................................. 24
6.1 .... How to maintain the product ......................................................................................................... 24
6.2 .... How to clean the product............................................................................................................... 24

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1 PREFACE

1.1 Description of the user

This user manual book is intended for the person who wants to use a 3-axis CNC milling
machine. The person who wants to use this machine needs at least to know a little bit about
how a CNC milling machine will work.

It is better for more than one user to use this machine as the software operator and electricity
operator since the emergency stop button is not provided. The user needs to know how to
install, make, and perform the machine, including the software(s) needed in order to perform
the machine well.

1.2 Explanation of safety warnings

CAUTION! Caution indicates a hazard with a low level of risk which, if not avoided, could result
in minor or moderate injury.

NOTICE Indicates information considered important, but not hazard-related.

1.3 Retaining instructions

Read and understand this manual and its safety instructions before using this product. Failure to
do so can result in serious injury.

Follow all the instructions. This will avoid fire, explosions, electric shocks, or other hazards that
may result in damage to property and/or severe or fatal injuries.

Keep all safety information and instructions for future reference and pass them on to
subsequent users of the product.

1.4 Obtaining documentation and information

For more information regarding the documentation and information related to this machine,
you can ask Sir Ignatius Budi Hadisujoto as the lecturer who is in charge of this machine. He will
give the contact person to let you know more about this machine.

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2 Description of the product

2.1 Purpose of the product

This 3-axis CNC mini-milling machine is a machine that is purposed for milling machining in the
scale of micro and macro. It can be used to cut smaller dimensions of parts and material such as
wood, plastic, and aluminum. It is very beneficial for small-scale production for the purpose of
education, prototyping, or single part production.

This machine contains the stepper motor, spindle motor, motor driver, and Arduino as the
control system of the machine. The spindle motor will work in the XZ-direction while the bed
will work in the Y-direction. The machine needs to use a software called GrblGru that is used to
execute the G-code into a command for milling process.

2.2 Technical data

Parameter Unit

Voltage 48 V
Weight 38 kg
Dimension of Machine 600 𝑚𝑚 × 620 𝑚𝑚 × 520 𝑚𝑚
Dimension of Bed 200 𝑚𝑚 × 200 𝑚𝑚 × 100 𝑚𝑚

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2.3 Product elements

Figure 1 X-axis Design

Figure 2 Y-axis Design

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Figure 3 Z-axis Design

Figure 4 Worktable/Bed Design

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Figures 1 to 4 show the designs of the machine’s frame. Figure 1 until 3 shows the frame of the
machine’s movement in X-, Y-, and Z-axis. Meanwhile Figure 4 shows the design of the bed,
which will be attached to the design of Y-axis frame. Below in Figure 5, the assembly of those
frames without the Z-axis and spindle motor.

Figure 5 Rigid Base Assembly

Figure 6 Cutting Tool (Flat End Mill) along with Collet

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The cutting tool, in here the flat end mill along with its collet, is used to do the milling machining
such as shown in Figure 6. Each type of cutting tool can create different results and time of
machining. Choosing the right type of cutting tool is important as it can make the process easier.

Figure 7 Example of Cutting Tools

Figure 8 Power Supplies and Arduino Mega

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Next, two power supplies with each 24V maximum capacity are needed to turn on and operate
the machine. It also can be used to supply the power to the microcontroller board, in here the
Arduino Mega, that is used to interpret the G-code. Below is the schematic of the wiring and
pinout of it. Make sure it is always connected at the same location before the milling process
started.

Figure 9 Arduino Pinout

Figure 10 Arduino Pinout

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Figure 11 Arduino Pinout

Figure 12 Arduino Pinout

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Figure 13 Stepper Motor Driver

Figure 14 Clamping Kit

Figure 14 shows the clamping kit that can be used to fix the machine to the bed. Other things
can also be used, such as thread if the dimensions of the clamping kit are not suitable.

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3 Safety instructions

The machine still has some problems that need to be fixed manually by the user. Due to that,
please read the instructions below before using the machine.

CAUTION! Automatic tool in a high-speed working process. Can cause injury. Keep out.

• Always use safety equipment such as: shoes, lab coat, gloves, goggles, and mask.
• Always run the machine with supervision from someone who understands how to
operate.
• Keep the cutting tools away from the bed, especially if you want to install the
workpiece.
• Clamp the workpiece tightly before starting the milling process.
• It is better to use a roll cable that can switch each of the plugged cable manually.
• Start the spindle only if you want to start the milling process.
• If an error occurred during the milling process, turn off the machine immediately.
• Watch the wiring before starting the milling process.
• Keep the children away from the machine.

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4 Preparation

4.1 How to transport the product

To transport the product, it is necessary to move it with more than one person since it is quite
heavy. Plywood can be used to help the transport process as it is also tied to the framework of
the machine.

It is better to not much moving the machine since it can cause some noise to the machine,
which can make the milling process disturbed later. Moreover, make sure all the cables are still
in place to reduce the possibility of errors.

4.2 Storing the product

When the machine is not used, it is better to keep it in a clean condition, also in a clean and dry
place to prevent the possibility of rust. Always check how the machine works after a long period
of time not in used by operating the machine manually (without G-code) or do the process with
an easy product first.

If the machine starts to work unsmoothly, some drops of lubricant can be given. Checking the
machine’s appearance and performance regularly is highly recommended.

4.3 Conditions for assembling

Before starting the milling process always check all the parts of the machine and all the safety
instructions. Make sure all the wires are plugged to the correct place. The cutting tools that are
going to be used must be the same as the G-code, so that the result is correct. Following the
safety instructions will make the machine work properly.

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5 Operation/Use

5.1 How to use the product

5.1.1 CAD (Computer Aided Design)

CAD software, such as SolidWorks, AutoCAD, and Catia is needed to make the desired
design product. The design then needs to be saved as a .stl file before converting it into
a G-code in the CAM software.

Figure 15 Example of the Design in SolidWorks

Figure 15 shows an example of the design that is made in SolidWorks, before saving it
into an .stl file. If the .stl file is obtained from the internet or other resources, this step
which using a CAD software can be skipped.

5.1.2 CAM (Computer Aided Manufacturing)

CAM software such as Fusion 360, is used to produce an alphabetical code, or called a
G-code, that later will be processed by the controller. This code is usually expressed as
N, G, X, Y, Z, F, and S which has its own functions. For example, X, Y, Z is for the position
maneuver to x, y, and z axis, respectively. There are many features available in it such as
the machining type. For this machine, the milling process can be used based on the
workpiece set up and specification tools.

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To make a G-code, all the necessary information will be needed such as the specification
of the machine and the cutting tool. Many things can be set based on the product that is
used, and the result that is wanted to be achieved.

Figure 16 Fusion 360 Software

After the .stl file is done, then import it into Fusion 360 by choosing “Mesh”. After
importing the .stl file, determine the scale of the design in order to make the desired
size of the product. Then, “Generate Face Group” and “Convert Mesh” to make it as a
body.

Moreover, other specifications can also be changed according to needs. From that, click
“Design” and change it into “Manufacture” mode.

Figure 17 Manufacture Mode

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In manufacture mode, the type of milling process can be chosen. Usually, “Adaptive
Clearing” is used. However, other types of milling can also be used depending on the
needs. Moreover, choosing the location of zero-points is important.

When the type is chosen, some information is needed to generate the G-code. In
adaptive clearing mode, this will be shown.

Figure 18 Adaptive Clearing

From that, the specification of the cutting tool must be included based on the real
situation. The other specifications can also be determined based on the needs and
capabilities of the machine.

Figure 19 Cutting Tool Specification

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After all of it is done, then the toolpath (the one that you determine specifically) can be
generated. Firstly, choose the right type of machine. Then, the toolpath will be
rendered, before it can be converted into a G-code. Sometimes it will take a long time,
depending on the difficulty of the design. Other than that, some errors might also occur
which can make the rendering process stop.

Figure 20 Choosing the Machine Specification

When all the things are set, the G-code can be made by click “Setup” and choose
“Create NC Program”. Always check the result of the G-code by see the “Simulation” to
make sure it works in a correct way.

Figure 21 Problem While Converting into a G-code

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 Figure 22 The Preview of How the Tool Will Work (G-code Successfully Made)

After the G-code is successfully made, then the G-code can be imported to the GrblGru
software.

5.1.3 GrblGru

Figure 23 GrblGru Software

In executing G-code, it requires CNC machine control software to flash the G-code into
the microcontroller. In here, GrblGru software is used to execute the G-code. By this
software, all the movement of the machine can be controlled.

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5.1.4 Machine Operation

Here is the step-by-step operation on how to use the machine after the G-code is
already generated in Fusion 360 or other CAM software.

1. Connect Arduino Mega to the laptop, open GrblGru software.

2. Place the workpiece to the bed, fix it by using the clamping kit or any other tools.
3. Install the chosen cutting tool to collet and spindle.
4. Plug the movement power supply to the roll cable that has limit switch for each of
the holes.
5. Back to the GrblGru software, do the configuration of the machine.
For type, choose “Mills 3 axes”;
For machine, choose “Cobra”;
For port, click “P” and choose the same COM with Arduino Mega in this machine;
For controller, choose “GRBL-Mega-5x”.

Figure 24 Configuration in GrblGru

6. Next, set the information of the tool.

For type, choose the same cutting tool that is wanted to be used (must be the same
with the one that is set in the CAM software & installed to the spindle);
For L, type depends on the cutting tools that is used, usually 50 or 100;

Figure 25 Determining the Cutting Tool in GrblGru

7. Now, determine the zero-point of each axis based on the location that is set in the
CAM software.
For the z-axis, it can be fixed by touching the tip of the cutting tools to the
workpiece. Click “Set Workpiece Zero Point” to fix it as the zero-point.

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 Figure 26 Setting the Zero-Point

8. Import G-code by clicking “File”, then Import GCode…”.

Figure 27 Import the G-code

9. Click “Start” to start the milling process automatically.

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 Figure 28 Click "Start"

10. Wait until the milling process is done. If an error happens, read the instructions
below.

5.2 What to do in emergency situations

Some emergency situations can happen during the milling process due to many reasons. One of
them is when the program in GrblGru software shows that it is error. Do this process when
those errors occur.

5.2.1 Error with the Movement of the Machine

When determining the zero-point of the machine, the movement needs to be done
manually. Sometimes, the movement cannot be controlled and it moves too much up until it
reaches the maximum allowable positions of the machine. If it happened, then just
immediately stop the machine by turning off the switch of the power supply manually.

5.2.2 Error with Specific Number

Sometimes, some errors with specific numbers can occur in the milling process
without any warning. If it happens, then do:
a) Restarted from Beginning
1. Immediately stop the machine if it is considered dangerous or might damage the cutting
tools and workpiece. You can do it manually by turning off the switch of the power
supply. If it is not, then you can just follow the next steps.
2. If you can, do not move the workpiece from the bed.

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 3. Click “Ok” to the error that is shown. If the problem can be resolved, then resolve the
problem first. If it cannot be resolved, then just follow the next steps.

Figure 29 Error Example

4. Turn on the machine, then click “Start” to redo the milling process from the very
beginning.
It is clear that when an error with a specific number occurs, it might take your time since the
milling process needs to be started again from the beginning. The errors can be varied, and
if it cannot be resolved, then just start again the milling process.
Usually, the error will not occur again in the same location and will happen in different
locations while passing through the previous error.

b) Start From Nearest Place Where the Error Occurred

1. Install “Notepad++” software, then open the last G-code file with that software.
2. Delete the previous G-code (that is already executed), but still spare some line before
the error appears.
3. Make sure the line started by defining the location of x-, y-, and z-axis. Also, do not
forget to include the feed rate of the machine. It is denoted by “F”.

Figure 30 Specify the X-, Y, and Z-axis Before Start

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4. Save the new G-code. It will automatically update the original G-code file.
5. Open GrblGru, then import again the G-code file.
6. Click “Start”, and it will continue the milling process.

This way can be chosen to reduce the time needed when there is an error. However, you
really need to specify all the axes and feed rate to start the process again. Also, you need to
remember the line where the error appears.

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6 Maintenance and cleaning

NOTICE: Clean the area and the machine after using it is a must.

6.1 How to maintain the product

To maintain the product, here is the list of the things that can be done to maintain the
product.

1. Cleaning: Keep the machine clean by regularly removing chips, debris, and coolant from
the work area, tool holders, and other components. Use appropriate cleaning tools and
avoid using excessive force that could damage delicate parts.
2. Lubrication: Apply lubricants to the appropriate points such as ball screws, linear guides,
and spindle bearings to reduce friction and prevent wear. Regularly check lubricant levels
and top up as needed.
3. Regular Inspection: Perform routine inspections to identify any signs of wear, damage, or
misalignment. Check for loose bolts, worn-out belts, damaged cables, and any abnormal
noises during operation. Address these issues promptly to prevent further damage or
accidents.
4. Calibration: Periodically calibrate the machine to ensure accurate positioning and
machining. This includes checking and adjusting the machine's axis alignment, squareness,
and tool height.
5. Tool Maintenance: Properly maintain and store cutting tools. Clean them after use, check
for wear, and replace any damaged or worn-out tools promptly. Use tool holders and
collets that are appropriate for the tool sizes and ensure they are securely tightened.
6. Electrical Safety: Regularly inspect the electrical components, cables, and connections for
any signs of damage or wear. Ensure that all safety features, such as emergency stop
buttons and limit switches, are in proper working condition.

6.2 How to clean the product

No specific things needed to clean the machine. Using a towel, tissue, fabric, or any dry
materials can be used to clean the machine such as spindle, motor, frame, and bed. Small
brushes or brooms can also be used, especially for the area that is harder to reach by
hand.

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