Manoj technical Seminar PPT BNMIT(1).pptx

Deals about cnc machine

1. 1 Technical -Seminar TITLE : DESIGN AND FABRICATION OF A PC-BASED 3 AXIS CNC MILLING MACHINE Authors: Abd Rahman Z. , Mohamed S.B , Zulkifli A.R. , Kasim M.S , &W.N.F.Mohamad Publisher: International Journal of Engineering Trends and Technology Publication year: September 2021 Dr .D. Shivalingappa Professor, Dept. of ME BNMIT Under the guidance of Presented by MANOJ R KASHYAP 1BG20ME011

2. Contents Abstract Introduction Literature Survey Materials & Methods Experiments Design/Testing/Simulation Results and Discussion Conclusion References

3. Abstract Objective: Designing and developing a PC-based 3-axis CNC milling machine catering to small-scale and cost-effective manufacturing needs. Current Scenario: CNC-based machine manufacturing technology predominantly monopolized by large-scale industry players. Need for Alternatives: Demand for small-scale, low-cost CNC machines by hobbyists, amateurs, and semi-professionals. Design Approach: Utilized a vertical position with a close frame structure. Constructed using aluminum extrusion profiles for rigidity. Emphasized low cost with off-the-shelf hardware modules to reduce maintenance expense. Software Integration: Employing Mach4 software as a PC-based controller to communicate G-codes for machine control. Testing Results: Successful machining of UHMW-PE samples with varied geometric shapes, demonstrating functionality under specific tool paths. Benefits: Efficient manufacturing capability,Cost-effectiveness,Flexibility for small facilities to reduce capital costs. Limitations: Not suitable for mass production or precise machining, Targeted towards replacing expensive commercial CNC machines for specific applications.

4. Introduction Introduction to CNC Software : Computer Numerical Control (CNC) software utilizes computer-controlled programs to define coordinate systems for manufacturing processes such as milling, turning, drilling, etc. System Configuration of CNC : Consists of interconnected sections and modules comprising mechanical, electrical, and complementary applications. Software Functionality : Leading software translates G-code into coordinate system commands, facilitating parameter storage and guiding the machine for programmable requirements including feed rate, cutting depth, speed, and safety features. Challenges in Acquiring CNC Mac hines: Economic conditions make purchasing large numbers of CNC machines difficult, necessitating the design of small-scale desktop CNC milling machines with a close frame structure and PC-based controller. Need for Cost-effective Solutions : Rising demand in hobbyist and amateur machine tools market underscores the importance of low production costs for small-scale CNC machines. Design and Development Approach : Combining standard PC interface features with open source and promoting off-the-shelf hardware components at low manufacturing costs. Stages Involved in Design and Manufacturing Process : Includes market research, design form, part selection, manufacturing, assembly, and system testing. .

5. Machine Specifications and Components : Frame structure built with aluminum extrusion profiles and plates, main components include high-speed spindle motor, PWM inverter, Nema 23 steppers, Gecko G203V stepper drivers, linear guide, etc. Software Integration: Utilization of Art Soft Mach4 Software for motion control, upgraded to support a USB connector and facilitate control of the machine. Machining Tests and Results : Three profile shapes proposed through machining tests, demonstrating the machine's capability to cut at high speed and fair accuracy fig 1;-Drawing concept of milling machine

6. Literature Survey Piotr Boral (2019): Developed a low-cost, small-scale 3-axis CNC milling unit. Also developed a high-rigidity, high-accuracy 4-axis CNC milling machine with a steel segment design and SmoothStepper control system. Kim et al . (2010): Introduced a compact 3-axis desktop milling machine with a cutting volume of 20 x 20 mm ³ . Darvekar etal. (2013): Explored machine-milling abilities based on Parallel Kinematic Mechanism (PKM) and created regression models to predict surface roughness. Max etal . (2015): Implemented a teaching methodology for designing CNC mills to unify knowledge and facilitate student learning. Mohd Hadzley etal . (2015): Conceptualized a cost-effective CNC 3-axis milling machine with Mach3 software control and high-speed spindle. Basniak&Catapan (2012): Proposed CNC milling machines for printed circuit boards with low production costs for domestic use, utilizing QFD and FMEA methodologies. Key Findings and Innovations : Development of low-cost, small-scale CNC milling units catering to various needs. Integration of advanced control systems like Smooth Stepper and Mach3 for precise control and efficient operation. Utilization of innovative design methodologies such as QFD, FMEA, and CAD/CAM integration to enhance product development processes. Emphasis on rigidity, accuracy, and cost-effectiveness in machine design to meet market demands and user requirements.

7. Materials & Methods

8. TABLE II MACHINE SPECIFICATION

9. METHODS OF CNC MACHINE ASSEMBLY Machine Assembly Process: Four significant elements: x-axis, y-axis, z-axis, and controller systems. Step-by-step installation of components following acquisition of appropriate equipment and accessories. Axis Assembly and Alignment: Each axis assembled and configured separately. Y-axis assembly aligned with the machine table, ensuring proper functionality. Structural Support System: Gantry type chosen for machine pole as structural support. X-axis and Z-axis mounted cross-sectionally, with x-axis positioned horizontally and z-axis vertically. Control System Installation: Connected directly to primary power source and linked to computer via USB communication cable. Components include power supply, DC converter, breakout board, stepper motor with driver motor for all axes, and other necessary components. Spindle and Speed Control: Equipped with high-speed spindle controlled by PWM unit based on instructions received through G-code. Electronics Design: significant steps taken to design electronics, including schematic diagram. .Advantages of Lightweight, PC-based Machine:Reduced weight indirectly decreases energy consumption and improves efficiency, production speed, and environmental impact.

10. X-Axis Y-Axis z-Axis FIG 2;- ASSEMBLY OF THE MACHINE AXIS FIG 3;-TYPE OF THE FRAME STRUCTURE

11. Experiments/ Design/Testing/Simulation Structure Design: Machine structures categorized into open frames, closed frames, and Truss forms. Selection of close frame structure with vertical tool position due to advantages in tooling access and simplicity in configuration. Close frames offer convenient workspace access, compactness, and reduced material costs compared to open frame structures. Design and Development: Product design initiated with SolidWorks software, focusing on machine platform size and axial lengths. Detailed manufacturing process involves mainframe structure, axis components, electronic components, and software integration. Utilization of off-the-shelf components for cost-effectiveness and easy assembly. Milling Machine Components: Key components include breakout board, spindle motor, inverter, stepper motor, and stepper driver. Selection criteria emphasize compatibility with light materials and adequate torque for cutting requirements. Integration of PMDX

12. Machine Fabrication: Custom fabrication of frame structure and machine parts using aluminum extrusion profiles for ease of assembly and corrosion resistance. Emphasis on structural rigidity, weight reduction, and minimization of complexity in component design. Two main frame parts: base platform frame and linear axis traveler, with specific dimensions for working area and travel lengths. Integration and Configuration: Integration of machine platform with linear axis travel system and axial control. Completed axial control and installation illustrated in fig 4

13. FIG 4;-MACHINE DEVELOPMENT AND FRAME STRUCTURE DESIGN

14. TESTING AND VALIDATION Testing Procedure: Evaluation of machine capabilities compared to existing industrial machines. Cutting UHMW-PE sample block (100mm x 100mm x 24mm) with 5 mm four-float end mill. Spindle speed set to S3000, and feed rates set to F500 for machining test. Initial Tests: Ensure movement along three axes: up and down, left and right, and front and back. Calibration and simulation of tool paths using CNC Simulator software before testing with Mach4 Industrial. Mach4 Controller: Controls axes movement and displays tool path during cutting process. G-code encoding via notepad format imported into Mach4 for machining process. G-Code Generation: Integrated Interface System (ISS) used as intermediate platform between CAD and CAM. Generates tool path based on CAD design uploaded in wireframe model, producing G-code for straight lines, circular features, and profile shapes. Accuracy Assessment: Sample G-code imported into Mach4 program controller to assess accuracy of tool path for machining purposes.

15. Results and Discussion FIG 5;-THE 3-AXIS CNC MILLING MACHINE AND CONTROLLER SYSTEM SET FIG 6;-MACHINING TESTING

16. Conclusion CONCLUSION Machine Description: Small-scale three-axis CNC milling machine with close and vertical frame structure. Platform size: 500mm (L) x 600mm (W) x 700mm (H), working area: 240mm (X) x 300mm (Y) x 600mm (Z), maximum spindle speed of 24000 RPM. Manufacturing Process: Selection of main components, procurement of raw materials, and step-by-step installation procedures. Control via ArtSoft Mach4 software using PC-based motion controller. Cost-effectiveness: Integration of standard PC interfaces with open-source CNC Controller and commercially available hardware components. Selection of highest-performing components satisfying rigidity and budget constraints. Testing and Evaluation: Efficiency and stability evaluated through machining of workpieces at specific cutting speed and feed rate. Comparable performance with commercial machines observed in machining UHMW-PE Block material. Feasibility and Applications: Not intended for mass production or precise machining but capable of replacing high-cost machines. Enables manufacturing expansion with greater flexibility and efficiency, lowering capital costs and Requirements.

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