Design & Fabrication of CNC

Engraving Machine
How Design Process Initiated
What is Computer Numeric Control
Different Aspects of Project

 Mechanical
 Electronics
 Software
 Control Aspects
Mechanical

 Mechanical Design
 Mechanical Calculations
Mechanical Specifications

 ISO gantry type

 600mm*400mm Bed area
 560mm*400mm Useful area
 800w water cooled spindle with VFD
 Machine Weight 41.5 Kg
 Box Volume 750*450*550
 Can engrave materials Wood, Aluminum , Cat iron
Mechanical Design

 1st Design
Motors Actuator & Linear Bearing
Shaft Couplings
2nd Design
3rd Design
Mechanical Calculations
 Working Parameters
Table: Recommended Feed per Tooth Table: Milling Machine Cutting Speeds
Slotting
Material High Speed Steel Cutter
Face Mills Helical Mills End Mills
Material Side Mills
ft/min m/min
in. mm. in. mm. in. mm. in. mm.

Machine Steel 70-100 21-30

Aluminum 0.022 0.55 0.18 0.45 0.013 0.33 0.011 0.28

Cast Iron 0.013 0.33 0.01 0.25 0.007 0.18 0.007 0.18
Tool Steel 60-70 18-20
Machine Steel 0.012 0.3 0.01 0.25 0.007 0.18 0.006 0.15
Cast Iron 50-80 15-25
Tool Steel 0.01 0.25 0.008 0.2 0.006 0.15 0.005 0.13
Bronze 65-120 20-35

Stainless Steel 0.006 0.15 0.005 0.13 0.004 0.1 0.003 0.08
Aluminum 500-1000 150-300

Reference: Metal Cutting principles by Milton C. Shaw

Resolved Cutting Forces
 Evaluation of Cutting Forces

 F- principal cutting force in Newton,

 C - material constant at a given cutting speed and rake angle,
 t- uncut chip thickness in mm,
 w- width of cut in mm or length of the cutting edge in engagement
 x- constant for material being machined.

583.35 N 583.35 N 121.86 N 833.93 N

Power = 347.47 watt

Reference: Metal Cutting principles by Milton C. Shaw
 Load on Lead Screw

On X-Axis On Y-Axis On Z-Axis

700 N 703.8 N 345.9 N

Reference: Shigley’s Mechanical Engineering Design by

Richard G. Budyanus and J. Keith Nisbett
Torque Calculations

Reference: Shigley’s Mechanical Engineering Design by

Richard G. Budyanus and J. Keith Nisbett
Nominal Major Diameter Pitch Collar Diameter ώ ώ Torque Power

mm mm mm rad/sec rpm N.m Watt

5 0.8 6.25 23.56193 225 0.992306517 23.38065174

6 1 7.5 18.84954 180 1.196151901 22.5469131

8 1.25 10 15.07963 144 1.583655732 23.88094565

10 1.5 12.5 12.56636 120 1.97117071 24.77044077

12 1.75 15 10.77117 102.8571 2.358691194 25.40585371

14 2 17.5 9.42477 90 2.746214797 25.88244283

16 2 20 9.42477 90 3.10025032 29.21914621

20 2.5 25 7.539816 72 3.875312901 29.21914621

24 3 30 6.28318 60 4.650375481 29.21914621

30 3.5 37.5 5.385583 51.42857 5.77954007 31.12619192

Software development
CNC
Part Programing
• M codes • G Codes
Interpreter

It involves three steps

 Command identification
 Command formation
 Command execution
 Command identification

yes
START Is it G Go to Sub-Prep

no
no
yes
Is it M Go to Sub-Misc
yes
Is it F Go to Sub-Feed
no
no
yes
Is it X Go to Sub-Axes
yes
Is it S Go to Sub-
no Speed
no
yes
Is it Y Go to Sub-Axes yes
Is it T Go to Sub-Tool
no
no
yes
Is it Z Go to Sub-Axes Is it yes Go to next command RETURN
Space
no
no
yes
Is it I Go to Sub-Axes
yes RETURN
Is it CR Go to Next Block
no
no
yes
Is it J Go to Sub-Axes Is it yes
EOF Stop
no
no
yes
Is it K Go to Sub-Axes ERROR
Command Formation
Command execution

G commands
GUI
 Implementation of software
Mach3
Remaining Work

In order to reduce Vibrations

 The X-Axis Guide ways (12mm Diameter) are being replaced with 16mm Diameter SS
rods.
 The connecting Plate of Y-Axis (6mm Thick) is being reinforced with Aluminum Blocks
Remaining Work

 Integrate VFD in Mach 3 by making a circuit to convert PWM signal into High Low