End Semester Presentation of B.Tech.

Final
Year Project

Retrofitting of Denford TRIAC CNC Milling Machine

Group: M 28
Members:
Harshvardhan Sharma ( 20163047 )
Divyansh Yadav ( 20163090 )
Under the guidance of: Dr. V.R. Komma
Mechanical Engineering Department
Motilal Nehru National Institute of Technology, Allahabad

Date: 28/11/2019
Introduction:
Features of Denford TRIAC CNC Milling Machine:

• The three axes motor drives(X, Y and Z) makes this CNC Milling Machine capable of
producing different types of part geometries.

• This machine has a mechanical resolution of 0.01 mm and thus, can maintain close
tolerances in dimension of the part being produced.

• It has an Automatic Tool Changer(ATC), which significantly reduces tool changeover time
by automating the process. Therefore, total machining time is also reduced.

• It has Pneumatic Tool Holding and Work Holding mechanism which make gripping of
tool and workpiece easier.
Existing State of Denford TRIAC CNC Milling Machine:

• The inbuilt microcontroller is not functioning. It is not sending the command signals to
operate the Axes Drives and Spindle.

• The inbuilt microcontroller is an outdated type.

• The Lubrication Pump is not working.

• The Pneumatic Systems of Spindle and ATC are not working.

• Pneumatic work holding devices are not setup.

Existing State of Denford TRIAC CNC Milling Machine:

Machine VDU

Automatic Tool Spindle

Changer

Work Table

Machine Keyboard

Image: Denford Triac CNC Milling Machine

Existing State of Denford TRIAC CNC Milling Machine:

Image: Close view of ATC

Existing State of Denford TRIAC CNC Milling Machine:

Image: Close view of Spindle Drive

Objectives:

1. Study of Mach3 Software and setting it up on PC.

2. To restore the axes drives.
3. To restore the spindle drive.
4. Interfacing of axes drives and spindle with PC.
5. Reconditioning of the Lubrication Pump.
6. To repair the pneumatic tool holding mechanism and ATC.
7. Setup of pneumatic work holding devices.

Color Index:

Completed Objectives
Remaining Objectives
 Recap of Work Done Before Mid Semester:

Machine Keyboard Main PCB User’s PC Break-out Board

Axes Driver Cards In-built Controller Axes Driver Cards MOSFET

To Stepper Motors To Stepper Motors

Fig. Command Signal Flow Chart Fig. Command Signal Flow Chart
(Previous) (New)
Recap of Work Done Before Mid Semester(Contd.):
Input and Output signals rerouted through the break-out board:

Image (I) Image (II) Image (III)

I. Connection between PC, break-out board and the MOSFETs.

II. Connection between Break-out Board pins and the Axes Driver
Cards.
III. Overall Setup.
 Recap of Work Done Before Mid Semester(contd.):
To PC

Break
out
board

To DB25 D-
sub Female
Connector

IRF 520 (DB25 D-sub

MOSFET 16w Ribbon Female
(To Axes Driver connector)
Cards)
From DB25 D-sub
(DB25 D-sub Male
Male connector
connector)
Work done after mid-semester:
1. Studied the electrical connections of the main contactor in the manual and found the
requirement of 240V Supply for it’s working.

2. Made a separate connection from AC Mains to the main contactor and tested it for working.

3. It was found to work successfully and now, we do not have to manually override the relay.

  Input Signal from

Main Contactor X, Y and Z axes
User’s PC Driver Cards

(Step & Direction

Signal)

Mains Input
(220V-240V 50Hz AC)
To Stepper Motors

Fig. Line diagram showing the function of main contactor

Steps followed(continued):

4. The Z axis drive was tested for motion by providing command from the PC.

5. We observed that the motor was working.

6. The Z axis motor tried to move the milling head but the mechanism was jammed.

7. Then the entire Head was disassembled to inspect for problems.

 
Steps followed(continued):

8. The Vertical Head was disassembled

with the help of screw jack. This was
done to ensure that the heavy Vertical
Head won’t fall down suddenly which
may break the machine components
and also injure a person.

Image: Disassembling of Milling head with the help of screw jack

Steps followed(continued):
Jib Strip
(Tapered)

Tapered
Guideways

Spindle

Image: Disassembled Milling Head

Steps followed(continued):

Z Axis Lead Screw

Z Axis Motor Mounting

Slot

Image: Z axis ball screw section (top view)

 Details of work done on the drive
mechanism:
9. Guideways were treated with Anti-Rust WD-40 Spray
to remove rust.

• WD-40 Multi-Use Product lubricates moving parts.

• It protects against rust and corrosion on items.
• It penetrates to free stuck corroded parts like nuts,
bolts, valves and locks.
• It quickly removes adhesives, corrosion and paint.
• It displaces moisture to restore water flooded
equipment such as engines, spark plugs and power
tools.
Image: Z axis Guideways (after
treatment with WD 40 Spray)
Details of work done on the drive mechanism(contd.):

10. Z-axis lead screw was removed and it was lubricated with
grease.

• During the disassembling process, some of the balls came out

of the ball nut of the lead screw which are difficult to set back
in.

• We reassembled the mechanism to see if it can be moved

after lubrication and found that it still gets stuck at some
points during rotation.

• Therefore, the ball nut may need replacement.

Image: Z axis lead screw (rear section)
Details of work done on the drive mechanism(contd.):

11. During the disassembling of the head, the projection on the Jib Strip was found
broken.
• The Jib Strip is used for the parallel motion of the slide.
• This strip is also used in the locking mechanism of the vertical head.

Image: Guideways and Jib Strip Image: Jib Strip Adjustment

Screw
Details of work done on the drive mechanism(contd.):

12. The jib strip was repaired by brazing the broken metal piece by Gas Welding.
• This repaired strip was then tested by reassembling the vertical head.
• However, the strip was getting stuck and the projected part broke again.

Image: Brazed part Image: Jib Strip after brazing

Details of work done on the drive mechanism(contd.):

13. To ensure that the part can sustain the load, a stronger joint had to be made.
• The jib strip was repaired by depositing stainless steel on the strip with TIG Welding.
• Cutting, grinding and filing operations were carried out to remove the excess material.

Image: TIG Welded Image: Jib Strip after welding

Stainless Steel part
Reconditioning the Lubrication Pump:

• The lubrication pump sends oil to all moving

mechanical components.

• It is activated by spindle rotation which starts the

motor-gearbox assembly.

• The BIJUR C-2894 lubricator includes a spring

return piston pump. When the T-handle is fully
raised, a predetermined volume of oil fills the
cylinder and the pump spring is compressed.
Releasing the handle forces oil into the
distribution system. Lubricator will deliver 1cc
per stroke of the piston.

• The motor-gearbox assembly determines the Image: Lubrication Pump of the machine
cycle time of the mechanism.
Repairing the Lubrication Pump:

14. The pump assembly was removed from the

machine.

• The gearbox was dipped in kerosene to free the

jammed components and enable motion.

• After a day of kerosene bath, gearbox was cleaned

and assembled with the motor.

• The assembly was tested for operation and found

working.
Image: Lubrication Pump of the machine
Current Problem:

• The jib strip gets stuck when the head tries to move on the guideways.

• The threads on the Jib Strip Adjustment screw are worn out.

• Therefore, our focus of attention is to find a solution to enable the motion and make a new adjustment
screw of required dimensions for the jib strip.

• We have identified two potential solutions for the same:

• Either, we can use marking blue to mark the points at which the jib gets stuck when the head tries
to move. At that point, we can use machining operations to bring it to required dimension. However,
there is the risk of over removal of material because of which the jib strip may fail in its function.

• Or, we can make a new jib strip with a Mild Steel or Brass specimen. This will require hand scraping
the part to measured dimensions of the guideways as per the requirement.
Target for next semester:
• To find a solution for the problem of jib strip getting stuck between the head and
the guideways.

• To repair the spindle drive.

• To repair the pneumatic system of the machine.

• Enable pneumatic tool holding and ATC.

• Setup of pneumatic work holding devices.

Thank You