CHAPTER NO.

- 1

INTRODUCTION

In Industry it is not efficient or profitable to make everyday products by hand. On a CNC machine it is possible to make hundreds or even thousands of the same items in a day. First a design is drawn using design software, and then it is processed by the computer and manufactured using the CNC machine. CNC means Computer Numerical Control. This means a computer converts the design produced by Computer Aided Design software (CAD), into numbers. The numbers can be considered to be the coordinates of a graph and they control the movement of the cutter. In this way the computer controls the cutting and shaping of the material. CNC is one in which the functions and motions of a machine tool are controlled by means of a prepared program containing coded alphanumeric data. CNC can control the motions of the workpiece or tool, the input parameters such as feed, depth of cut, speed, and the functions such as turning spindle on/off, turning coolant on/off. This is a small CNC machine and can be used to machine woods, plastics and aluminium. In industry, CNC machines can be extremely large. The Duet is one of the smaller CNCs and is ideal for use in schools. Have a look at the photograph on the right. Can you imagine how long it would take a skilled worker to carve this shape out of wood or a soft material - it would probably take a full day. We will be going through its manufacture, one step at a time using a CNC machine (next page). How long do you think manufacturing this product with a CNC machine will take? CNC was preceded by NC (Numerically Controlled) machines, which were hard wired and their operating parameters could not be changed. NC was developed in the late 1940s and early 1950s by John T. Parsons in collaboration with the MIT Servomechanisms Laboratory.
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The first CNC systems used NC style hardware, and the computer was used for the tool compensation calculations and sometimes for editing. The introduction of CNC machines radically changed the manufacturing industry. Curves are as easy to cut as straight lines, complex 3-D structures are relatively easy to produce, and the number of machining steps that required human action has been dramatically reduced. With the increased automation of manufacturing processes with CNC machining, considerable improvements in consistency and quality have been achieved with no strain on the operator. CNC automation reduced the frequency of errors and provided CNC operators with time to perform additional tasks. CNC automation also allows for more flexibility in the way parts are held in the manufacturing process and the time required to change the machine to produce different components.

CHAPTER NO. - 2

LITERATURE REVIEW
Computer numerical control is a very broad term that encompasses a variety of types of machines all with different sizes, shapes, and functions. But the easiest way to think about CNC is to simply understand that its all about using a computer as a means to control a machine that carves useful objects from solid blocks of material. For example, a CNC machine might begin with a solid block of aluminum, and then carve away just the right material to leave you with a bicycle brake handle.CNC machines can be divided into two groups: turning machines and milling machines. A turning machine is generally made up of a device that spins a workpiece at high speed and a tool (sharp edge) that shaves off the undesired material from the workpiece (where the tool is moved back and forth and in and out until the desired form is achieved). A milling machine is a machine that has a spindle (a device similar to a router) with a special tool that spins and cuts in various directions and moves in three different directions along the x, y, and z axes. 2.1 INDUSTRIAL USES Industrial applications for CNC machines have been chiefly based around the removal of metal to create a desired form. Metal is widely used for producing almost everything we see around us, even though these things may not be made of metal themselves. Some of the most obvious products that are made of metal are cars. The engine block and the parts within the transmission are directly produced from a CNC machine because tight tolerances are necessary (a tolerance is a range in dimensioning to which the machine must adhere). However, most of the parts of a car are not made by a CNC machine, but they have a latent connection to one. For example, how do you make a quarter panel? There is a hydraulic press with a thing called a die to create an impression in a sheet of metal. Most of the parts of the hydraulic press were made from a CNC machine. The die, the part that carries the negative form of the quarter panel and that can be replaced when design changes, was also made by a CNC machine, and then tempered for hardening and heat resistance. Even the plastic parts of a car have some connection to a CNC machine. Many of these parts were made from a mold that was created using a CNC machine. Because CNC machines have very high precision and
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they can provide information back to the computer, they are also used in dimensional testing. If a switch (probe) is fastened to the location of the tool, it can analyze the measurements of a part that was produced. The machine runs this probe all over the part to confirm its desired form and measurements. 2.2 PERSONAL USES There is a large following by various hobbyists and colleges, universities around the globe interested in the concept of CNC machines. Roboticists, craftsmen, handymen, home machinists, small business owners, tech enthusiasts, backyard scientists, and artists have all discovered how a CNC machine can open doors to new designs and more detailed creations. A roboticist, for instance, will use a CNC machine to create the structural components of the robot with very high precision. Making these components by hand would be tedious and very time consuming. Using a CNC machine, the parts come out beautifully and fit together with great precision. For the typical handyman, a great example of using a CNC machine might be designing and making cabinets for around the house. Typically, cabinets share many of the same dimensions and can be cut by a CNC machine over and over. Imagine cutting all of the drawers and cabinet lids by hand. The parts are numerous and the work would be quite tedious. But with a CNC machine, the individual pieces are cut and the cabinets assembled; no driving around looking for the right cabinets, having to special order them, and then waiting for delivery from the home improvement store. 2.3 FOR TRANING PURPOSE CNC can also be used for training purpose in schools, colleges, universities etc. those CNCs are not very big in size but only are used for the training of students of various courses, in which they are learn that how a CNC can work and how it is used in various types of work. With the help these CNC machines students can learn the programming and coding for CNC and they can implement it for their future work. 2.4 MECHANICAL STRUCTURE

Mechanical structure comprises so many components or we can say that it is an assembly of different components which are fit for its own job like some of the basic components in a mechanical structure of a CNC are: 2.4.1 FRAME The base and frame of a CNC is the main structural element of the machine. The base and frame is what holds everything together. This is what will determine the motor placement and lead screw placement along with everything else. The frame and base design will be determined partially by the materials and supplies that we have the number of lead screws, and motors etc. Some considerations are made while choosing the frame those considerations are: Material of the frame must be chosen as the weight of the frame is optimum (not too light and not too heavy) some basic materials are cast iron steel iron etc. Accuracy of the frame is taken into consideration because if the frame is accurate in dimensions then it will make the other components and devices fit properly in the frame and this will make the whole machine strong in strengths as well as good in looks. Frame is made by those materials which must absorb vibrations in the machine. This will make the work easy and improve the efficiency and accuracy of the machine. 2.4.2 BED Bed of CNC is a very essential part of the machine it consists of base part and a table top. Which help us to basically clamp and hold the workpiece on which the milling process is done. There are many types of beds are available in the market we can choose the bed according to our need. Some different types of beds or table top are given below: 2.4.2.1 T-Slot
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The CNC router table top is where the cutting happens. The table top, also called the cutting bed, can make the life of a CNC operator enjoyable or a nightmare. For example, if we are working with all kinds of materials and shapes. This would probably push us towards a T-slot style, which offers numerous clamping options. On the other hand, we might produce the same type of product on a daily basis which would push us towards a different style. On higher end CNC tables now days, we may find a combination of different types of cutting table tops. However, it is best to be knowledgeable about what kind of CNC router table will be best for us. 2.4.2.2 MAGNETIC BED Sometimes magnetic slots in the bed may also be used in CNC machine 2.4.3 SLIDES Whether to guide, support, locate, or accurately move machinery components and products, linear motion systems deliver low friction, smooth and accurate motion for nearly any moment or normal loading condition. The range of basic building blocks includes: lead screw drives and ball guides, lead screw drives and slide guides, ball screw drives and ball guides, ball screw drives and slide guides, belt drives and ball guides, belt drives and slide guides, and belt drives and wheel guides. Selecting the system that best fits the application is critical but it is only one part of the process of designing a linear system.

2.4.4 SCREWS
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Transform rotational motion of the motor into translational motion of the nut attached to the machine table. With the ball screw, balls roll between the screw shaft and nut to achieve high efficiency. It required a driving torque is only one third of the conventional sliding screw. Advantages of ball screw Inexpensive Low Power Use Low Maintenance High Accuracy High Repeatability High Efficiency High Load Capacity Compact Size

2.4.5 TOOL 2.5 ELECTRICAL SUBSYSTEM An electric subsystem comprises all the electrical components which helps the CNC machine to work properly. In electrical subsystem major component is electric motor. An electric motor is an electromechanical device that converts electrical energy to mechanical energy. This mechanical energy is used for, for example, rotating a pump impeller, fan or blower, driving a compressor, lifting materials etc. Electric motors are used at home (mixer, drill, fan) and in industry.

2.5.1 TYPES OF ELECTRIC MOTORS

This section describes the two main types of electric motors: DC and AC motors. Figure shows the most common electric motors. These are categorized based on the input supply, construction, and operation mechanism

2.5.1.1 MOTORS FOR SLIDES We can use various types of motor to run the slides of a CNC. CNC motors are the heart of any CNC machine. The size and type of motor can define a CNC routers precision, speed, and accuracy. There are two primary classes of motors used on CNC machines, stepper motors and servo motors. Within these two classes there are several types. Stepper motors and servo motors both have their advantages and disadvantages which will be discussed in greater detail in next section.

Characteristics Cost

Servo Motor (DC Brushed

Stepper (Hybrid)

The cost for a servo motor and This feature would have to go to servo motor system is higher stepper than that of a stepper motor generally system with equal power rating. rating. motors. cheaper Steppers than are servo

motors that have the same power

Versatility

Servo motors are very versatile Stepper motors are also very in their use for automation and versatile
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in

their

use

for

CNC applications.

automation and CNC applications. Because of their simplicity stepper motors may be found on anything from printers to clocks.

Reliability

This is a toss up because it The stepper takes this category depends on the environment and only because it does not require an how well the motor is protected. encoder which may fail.

Motor Life

The brushes on servo motors The bearing on stepper motors are must be replaced every 2000 the only wearing parts. That gives hours of operation. Also stepper motors a slight edge on life. motors provide most encoders may need replacing.

Low

Speed

High Servo motors will do fine with Stepper friction and the correct gear ratio

Torque

low speed applications given low torque at low speed (RPM).

High Torque

speed

High Servo motors maintain their Stepper motors lose up to 80% of rated torque to about 90% of their maximum torque at 90% of their no load RPM. their maximum RPM.

Overload Safety

Servo motors may malfunction if Stepper motors are unlikely to be overloaded mechanically. damages by mechanical overload.

Power Weight/Size ratio

to Servo motors have an excellent Stepper motors are less efficient power to weight ratio given their than servo motors which usually efficiency. means a smaller power to weight/size ratio.

Efficiency

Servo motors are very efficient. Stepper motors consume a lot of Yielding 80-90% efficiency power given their output, much of which is converted to heat. Stepper motors are usually about 70% efficient but this has some to do with the stepper driver.
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given light loads.

Torque to Inertia Servo motors are very capable of Stepper motors are also capable of Ratio accelerating loads. accelerating loads but not as well as servo motors. Stepper motors may stall and skip steps if the motor is not powerful enough. Noise Servo motors produce very little Stepper motors produce a slight noise. hum due to the control process. However a high quality driver will decrease the noise level. Resonance Vibration and Servo motors do not vibrate or Stepper motors vibrate slightly and have resonance issues. have some resonance issues because of how the stepper motor operates. Motor Simplicity Servo motors are more Stepper motors are very simple in with no designed

mechanically complex due to design external encoders. Power Range Because servo motors

their internal parts and the consumable parts.

are The power availability range for

available in DC and AC servo stepper motors is not that of servo motors have a very wide power motors. availability range. Table 2.1 2.5.2 CHOICE OF TOOL MOTOR Tool motor is choose on the basis of work is defined or need some of tool motors are2.5.2.1 UNIVERSAL MOTOR A series-wound motor is referred to as a universal motor when it has been designed
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to operate on either AC or DC power. It can operate well on AC because the current in both the field and the armature (and hence the resultant magnetic fields) will alternate (reverse polarity) in synchronism, and hence the resulting mechanical force will occur in a constant direction of rotation. Operating at normal power line frequencies, universal motors are often found in a range rarely larger than 1000 watt. Universal motors also form the basis of the traditional railway traction motor in electric railways. In this application, the use of AC to power a motor originally designed to run on DC would lead to efficiency losses due to eddy current heating of their magnetic components, particularly the motor field pole-pieces that, for DC, would have used solid (un-laminated) iron. Although the heating effects are reduced by using laminated pole-pieces, as used for the cores of transformers and by the use of laminations of high permeability electrical steel, one solution available at start of the 20th century was for the motors to be operated from very low frequency AC supplies, with 25 and 16.7 Hz operation being common. Because they used universal motors, locomotives using this design were also commonly capable of operating from a third rail or overhead wire powered by DC. As well, considering that steam engines directly powered many alternators, their relatively low speeds favored low frequencies because comparatively few stator poles were needed. An advantage of the universal motor is that AC supplies may be used on motors which have some characteristics more common in DC motors, specifically high starting torque and very compact design if high running speeds are used. The negative aspect is the maintenance and short life problems caused by the commutator. Such motors are used in devices such as food mixers and power tools which are used only intermittently and often have high startingtorque demands. Continuous speed control of a universal motor running on AC is easily obtained by use of a thyristor circuit, while multiple taps on the field coil provide (imprecise) stepped speed control. Household blenders that advertise many speeds frequently combine a field coil with several taps and a diode that can be inserted in series with the motor (causing the motor to run on half-wave rectified AC). In the past, repulsion-start wound-rotor motors provided high starting torque, but with added complexity. Their rotors were similar to those of universal motors, but their brushes were connected only to each other. Transformer action induced current into the rotor. Brush position relative to field poles meant that starting torque was developed by rotor repulsion
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from the field poles. A centrifugal mechanism, when close to running speed, connected all commutator bars together to create the equivalent of a squirrel-cage rotor. As well, when close to operating speed, better motors lifted the brushes out of contact. Induction motors cannot turn a shaft faster than allowed by the power line frequency. By contrast, universal motors generally run at high speeds, making them useful for appliances such as blenders, vacuum cleaners, and hair dryers where high speed and light weight is desirable. They are also commonly used in portable power tools, such as drills, sanders, circular and jig saws, where the motor's characteristics work well. Many vacuum cleaner and weed trimmer motors exceed 10,000 RPM, while many Dremel and similar miniature grinders exceed30,000 RPM. Universal motors also lend themselves to electronic speed control and, as such, are an ideal choice for domestic washing machines. The motor can be used to agitate the drum (both forwards and in reverse) by switching the field winding with respect to the armature. The motor can also be run up to the high speeds required for the spin cycle. Motor damage may occur from over speeding (running at a rotational speed in excess of design limits) if the unit is operated with no significant load. On larger motors, sudden loss of load is to be avoided, and the possibility of such an occurrence is incorporated into the motor's protection and control schemes. In some smaller applications, a fan blade attached to the shaft often acts as an artificial load to limit the motor speed to a safe level, as well as a means to circulate cooling airflow over the armature and field windings.

2.5.3 POWER SUPPLY UNIT A power supply is a device that supplies electrical energy to one or more electric loads. The term is most commonly applied to devices that convert one form of electrical energy to another, though it may also refer to devices that convert another form of energy (e.g., mechanical, chemical, solar) to electrical energy. A regulated power supply is one that controls the output voltage or current to a specific value; the controlled value is held nearly constant despite variations in either load current or the voltage supplied by the power supply's energy source.

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Every power supply must obtain the energy it supplies to its load, as well as any energy it consumes while performing that task, from an energy source. Depending on its design, a power supply may obtain energy from: Electrical energy transmission systems. Common examples of this include power supplies that convert AC line voltage to DC voltage. Energy storage devices such as batteries and fuel cells. Electromechanical systems such as generators and alternators. FOR CNC There are many electronic aspects of a CNC router that are vital to its function. Things such as limit and proximity switches, motor wiring, correct cable sizing and selection etc. These features are, in my opinion, vital to building a reliable machine. Yet many people neglect these feature because of lack of know how or budget . Many of these add-ons cost only pennies to install and could save either your machine or the piece you are working on. For the most part, adding these components is by no means difficult. There are also some CNC electronic features that are not often required. Such as manual pulse generators, home and e-stop buttons, touch-off tool sensors etc. These things may or may not be essential to the machine, depending on the user, but do increase user friendliness. Not to mention, increasing the overall look and feel of the machine. With a few CNC electronic add-ons and a well constructed user panel, you can make you homemade CNC routers seem like one off the shelf. 2.6 ELECTRONIC SUB SYSTEM CNC electronics are a vital part of any CNC machine. Aside from the motors and CNC controllers , there are many electronic components that assist in the machine operation. In this section we will cover all the electronics involved with a CNC router. Many people feel more threatened by the electrical components than the mechanics of a machine. This doesnt have to be the case. Whether you are building or buying a CNC router , this section will help inform you on the CNC electronic systems found on a CNC router and help you understand how they come together with other components to create a fully working machine.

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2.6.1 MOTOR CONTROLLERS The CNC controller is the brain of a CNC system. A controller completes the all important link between a computer system and the mechanical components of a CNC machine. The controller's primary task is to receive conditioned signals from a computer or indexer and interpret those signals into mechanical motion through motor output. There are several components that make up a controller and each component works in unison to produce the desired motor movement. The word controller is a generic term that may refer to one of several devices, but usually refers to the complete machine control system. This system may include the protection circuitry, stepper or servo motor drivers, power source, limit switch interfaces, power controls, and other peripherals. Owners, operators, designers, and builders of CNC devices should understand the tasks performed by these components and how they affect machine performance.

2.6.2

BREAKOUT

AND

INTERFACE

CIRCUIT Parallel CNC Breakout Boards connect to your PC's parallel port and convert those signals to screw terminals which you may then use in pointto-point wiring to connect up the rest of your system. These are the most commonly used type of breakout board. They're simple, and relatively inexpensive. They have a few drawbacks. First, the parallel port itself is a bit of a throwback to the early days of the PC. There are limitations on its performance, particularly when used with Windows software, such as with Mach 3. You will be limited in how quickly you can send and receive the signals from the board, which may in turn limit the performance of your CNC. For most low end applications, this is not a problem. For better performance, use a Motion Controller

2.6.3 ROUTER FUNCTIONALITY

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Three motors will be used to move the router and allow your CNC machine to do the job you want it to perform. These motors are controlled using some additional electronics, which well talk about shortly. It is these electronics that will connect to your computer and receive instructions from the special software youll be using to tell the machine where to cut, drill, and perform other actions. There are numerous options available for the electronics used in your CNC machine. This means it is simply impossible to cover every type of electronic device and how to incorporate it into your machine. Because of this, we are going to be using a readily available set of electronics that you can purchase directly from one of the authors (Patrick) or from a couple of vendors. Well give you exact part names (and/or numbers) so youll be able to purchase the exact hardware used in the instructions provided in this chapter. If you choose to purchase different electronics for your CNC machine, be sure to read through all the documentation available. You may find that some electronics use different wire colors or different labels for various parts, but with some careful examination of the documentation and schematics, you may be able to figure out how the differences match up to our instructions. The breakout board connects to your computer via the parallel port. The special CNC software installed on your computer sends signals over a standard parallel printer cable to the breakout board. Each stepper motor driver also connects to the breakout board. When wired properly, the computer software will be able to control the individual stepper motors (sending signals to the stepper motor drivers through the breakout board). 2.6.4 WINDOWS BASED PENTIUM IV PC Computer plays a very important role in CNC. It works as a input to the machine with the help of different softwares. Those softwares are: 2.7 COMPUTER SOFTWARES 2.7.1 Computer Aided Design (CAD) Computer Aided Design, often abbreviated in the engineering field as CAD, has become an integral part of machining. CAD technologies allow engineers to accurately create three
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dimensional digital models of parts they are interested in manufacturing. This allows engineers to easily visualize and assemble multiple parts without going through the expensive process of prototyping. Since its invention CAD has become fundamental in design, drafting, and analysis. There are many varieties of CAD software available to engineers and machinists. The simplest programs allow the operator to create a simple two dimensional drawing; essentially no different from a hand drawn engineering drawing. The more complex programs however are able to create and model intricate assemblies as well as perform accurate heat and stress analyses. At Worcester Polytechnic Institute (WPI) students have access to primarily to the Pro Engineer and Solid Works programs (Oberg et al., 2000).

2.7.2 Computer Aided Manufacturing (CAM) Most machines need control systems to operate. There are many kinds of control systems, for example, manual control, automatic control, computer control or remote control. For the convenience of mass production, machines need to repeat precise, speedy and automatic actions continuously. These machines may use mechanical, pneumatic and electrical systems to control. However, some fixed procedures, changing procedures or tools may need a lot of time to restore the whole system. As technology advances, electronic and computer technologies have been applied to a lot of production machines to reduce the production time and increase both the quality and efficiency. So, modern factories usually use numerical control machines, simply called NC machines. And an NC machine that comes along with a computer is called a computer control numerical machine, simply CNC machine. A CNC machine uses digital information to control the movements of tools and parts, for example, the spinning speed, the cutting speed, the moving direction of tools etc. So, we can change quickly the production procedures simply by modifying the information or program in the computer. Computer Aided Machining, or CAM, is used to help machinists and engineers simulate the required tool paths to create a part. CAM is often interfaced with design software and CAD programs so that solid models can easily be transferred between programs. This allows an engineer to create his or her model in CAD and then send it to a CAM program to set up tool paths. The other useful ability that is available with CAM is that it can quickly create tool paths in NC code. Once and engineer or machinist has the tool paths drawn and
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visualized in the CAM program usually he or she is able to directly transfer the information into the CNC machine. CAM allows someone with very limited knowledge of NC code to easily machine very complex parts 2.7.3 How CAD and CAM works? Creating a part on a CNC mill is a three phase process. The part is drawn in a CAD (Computer Aided Design) drawing program such as AutoCAD. Then a CAM (Computer Aided Manufacturing) program is used to convert the CAD drawing to G-Code. Finally, the G-code controls the CNC mill as it makes the part. We will take a look at what is involved in using these three kinds of software by sketching out the creation of a very simple part. 2.7.3.1 Creating a CAD Drawing There are dozens of CAD programs with which you can create a drawing. Costs vary from free to many thousands of dollars. We are not going to get into reviews or recommendations here, but simply describe the CAD program that we know the best; TurboCAD. Lets take a look at the steps required to create a drawing. A new drawing in TurboCAD is based on a template. In this case the template defines an A-size (8.5 x 11) sheet using inches for dimensions and including the title block.

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To move this file to PartMaster CAM, we save it as a DXF (Drawing eXchange File). 2.7.3.2 The CAM Process CAM (Computer Aided Manufacturing) software takes the CAD drawing you created and translates it into G-code. It is an interactive process, because you must tell the software what tools you will use, plus information such as spindle speed, cutting depth and cutting speed. The CAM program we are using is Dolphin PartMaster CAM. Open PartMaster CAM and select Create a new job from a DXF file. Load the Example 1.DXF file we created with TurboCAD.

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In the DXF Import Options dialog choose Import only geometry on layer, and enter Top View.

The top view of the part appears in PartMaster CAM. Here we have used View >Options to show Geometry Names.

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In the bar on the right of the screen, click Area Clearance and Pockets. Then click User Defined. The Pocket: Custom Shape dialog appears.

Here we tell the CAD program how to clear the square at the top of the part. We have defined an end mill that is in diameter and set the spindle speed to 1000 RPM. We will cut to a depth of 0.26 so we go completely through the part in three passes. Use Execute > Run Program to see how the program will run.

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Now click the Command tab on the right side of the window and make the settings for the slot at the bottom of the part.

. Now the machining parameters for both areas are set. Use Execute > Post Process to create the G-code.

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The program trundles for a few seconds, then produces the G-code necessary to run this part. ( CNC File :- Example 1 ) ( Post Processor :- M_MACH3 ) ( Part Number ID :- ) N5G00G20G17G90G40G49G80 N6G00G28Z0.0 N7G49 N8T1M06 ( End mill ) N9G43Z1.9685H1 N10S1000M03 N11G94 9 N12M08 N13X0.375Y2.125 N14Z0.125 N15G01Z-0.0867F1.25 N16X1.125Y2.125F5.0 N17X1.125Y1.375 N18X0.375Y1.375 N19X0.375Y2.125 N20X0.5625Y1.9375 N21X0.9375Y1.9375 N22X0.9375Y1.5625
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N23X0.5625Y1.5625 N24X0.5625Y1.9375 N25X0.6563Y1.8438 N26X0.8438Y1.8438 N27X0.8438Y1.6563 N28X0.6563Y1.6563 N29X0.6563Y1.8438 N30G00Z1.9685 N31X0.375Y2.125 N32Z0.0383 N33G01Z-0.1733F1.25 N34X1.125Y2.125F5.0 N35X1.125Y1.375 N36X0.375Y1.375 N37X0.375Y2.125 N38X0.5625Y1.9375 N39X0.9375Y1.9375 N40X0.9375Y1.5625 N41X0.5625Y1.5625 N42X0.5625Y1.9375 N43X0.6563Y1.8438 N44X0.8438Y1.8438 N45X0.8438Y1.6563 N46X0.6563Y1.6563 N47X0.6563Y1.8438 N48G00Z1.9685 N49X0.375Y2.125 N50Z-0.0483 N51G01Z-0.26F1.25 N52X1.125Y2.125F5.0 N53X1.125Y1.375 N54X0.375Y1.375
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N55X0.375Y2.125 N56X0.5625Y1.9375 N57X0.9375Y1.9375 10 N58X0.9375Y1.5625 N59X0.5625Y1.5625 N60X0.5625Y1.9375 N61X0.6563Y1.8438 N62X0.8438Y1.8438 N63X0.8438Y1.6563 N64X0.6563Y1.6563 N65X0.6563Y1.8438 N66G00Z1.9685 N67M09 N68G00G28Z0.0 N69G49 N70T2M06 (End mill) N71G43Z1.9685H2 N72S1500M03 N73G94 N74M08 N75X0.375Y0.5313 N76Z0.125 N77G01Z-0.0867F1.25 N78G03X0.4063Y0.5I0.375J0.5F5.0 N79X0.375Y0.4688I0.375J0.5 N80G01X1.125Y0.4688 N81G03X1.0938Y0.5I1.125J0.5 N82X1.125Y0.5313I1.125J0.5 N83G01X0.375Y0.5313 N84Z-0.1733F1.25 N85G03X0.4063Y0.5I0.375J0.5F5.0
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N86X0.375Y0.4688I0.375J0.5 N87G01X1.125Y0.4688 N88G03X1.0938Y0.5I1.125J0.5 N89X1.125Y0.5313I1.125J0.5 N90G01X0.375Y0.5313 N91Z-0.26F1.25 N92G03X0.4063Y0.5I0.375J0.5F5.0 N93X0.375Y0.4688I0.375J0.5 N94G01X1.125Y0.4688 N95G03X1.0938Y0.5I1.125J0.5 N96X1.125Y0.5313I1.125J0.5 N97G01X0.375Y0.5313 N98G00Z1.9685 N99M09 N100M30 % 11 Were not going to teach you G-code here, but we will let you know what sort of thing you are looking at by explaining a few of the lines in that G-code. ( CNC File :- Example 1 ) ( Post Processor :- M_MACH3 ) ( Part Number ID :- ) This is information for you, not the CNC Milling machine. Notice that you can read and understand it. N5G00G20G17G90G40G49G80 N6G00G28Z0.0 N7G49 N8T1M06 ( End mill ) N9G43Z1.9685H1 N10S1000M03 N11G94 N12M08
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These are all getting started codes. Notice that all the lines start with N followed by a number. This is simply the line number and is more for you than for the CNC machine. The CNC machine simply executes code in the order in which it is received. Look at line N5. In that line things are being set up. For example, G20 says to use inch units, while G90 says to use absolute distances. Line N8 stops the CNC machine so you can change the tool. Its stopping for a tool change (M06) and asking for tool number 1 (T1). You click Start Cycle to resume the program once you have changed the tool. N15G01Z-0.0867F1.25 N16X1.125Y2.125F5.0 N17X1.125Y1.375 N18X0.375Y1.375 N19X0.375Y2.125 N20X0.5625Y1.9375 N21X0.9375Y1.9375 Now we start making chips. In line N15, G01 starts linear interpolation. The Z axis goes to -1.086 at a 1.25 feed rate (F1.25). The rest of the lines have X and Y coordinates. These are the end point for the cut for this line of code. As you can see, lines something like these make up most of the rest of the program. This is clearly not an exhaustive discussion of G-code. If you want the nittygritty, see Using Mach3Milll on http://www.machsupport.com. Part Master CAM saved the G-code in a file with a PUN extension. Its in the folder in which you saved your drawing. Creating the Part You now have the definition of the part in a language that the CNC milling machine can understand; G-code. If you were using a commercial CNC machine such as a HAAS Vertical Machining Center , the controller would be built into the machine and you would transfer the G-code directly to the machine. Most hobby CNC machines have an external controller; a personal computer that is cabled to the CNC machine. A large percentage of these personal computers are running the Mach 3 machine control program. Lets briefly see how Mach 3 works. Use a USB Flash Drive to move the G-code file to the computer connected to the CNC milling machine. You probably want to put it in C:\Mach3\GCode. Start Mach 3 using the profile that is appropriate to your CNC machine. In our case, we will use the KX3 profile,

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This screen is the Mach 3 machine controller. You can confirm the profile in the lower right corner. Lets load the G-code, and then look at this screen. Click Load G-Code and select the Example 1.pun G-code file.

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Now we can see what those empty rectangles are for on the screen. In the upper-left corner is the G-code file we are working with. In the upper-center is the DRO; the digital read out. This shows the current position of the four axes. In the upper-right corner is the tool path. This window shows the projected path of the tool and shows its current position as it progresses through the program. The lower-left panel incorporates most of the controls you need to load and execute a G-code program. The Reset button is the on-screen E-Stop, or Emergency Stop button. This button (and the hardware E-Stop button on the machine) will stop the machine immediately. You will use these buttons a lot as you learn CNC programming. Cycle Start does what you expect; it starts executing the program. It also restarts execution from the current position after a tool change, Stop or Pause. Feed Hold pauses execution, while Stop stops it. Cycle Start resumes after either one. Be careful when resuming any programs, because changes you have made manually (such as stopping the spindle) are not reversed. The program is simply executed from the current line. The Tool Information provides just the information you would expect; which tool you are using (or which tool is requested if the Change Tool bar is lit), and information about that tool. The
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Feed Rate block shows the current feed rate and allows you to override the program settings. Like wise, the Spindle Speed block shows the current spindle speed settings and allows you to control the spindle speed. If you press the Tab key, the MPG Pendant appears. This is an on-screen representation of an MPG (Manual Pulse Generator) pendant, a hand-held control on some CNC machines. This screen allows you to manually control the four axes and the spindle. For example, to move the Z-axis up, hold the Z+button down with your mouse.

Weve skipped lots of steps to get to this point. For example, we have said nothing about the physical aspects of mounting your work piece and cutting tools in the CNC milling machine. And we havent addressed how to tell the CNC machine where your part blank and the cutting tool are located (hint, see the Offsets screen in Mach 3). But we did take a look at what the three major pieces of software are that are required to make a part on a CNC machine 2.7.3.3 CAD and CAM Softwatres

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Here are short and very incomplete lists of CAD and CAM programs. Prices range from free (A9CAD) to several thousands of dollars. Dont take these lists as recommendations. These are just the programs we found in a short session with Google and Bing. CAD Programs A9CAD www.a9tech.com Alibre www.alibre.com AutoCad usa.autodesk.com BobCAD-CAM www.bobcad.com DeltaCad www.deltacad.com Dolphin Partmaster www.dolphincadcamusa.com Mastercam www.mastercam.com SketchUp Pro sketchup.google.com SolidWorks' www.solidworks.com TurboCad www.turbocad.com VCarve Pro www.vectric.com CAM Programs ArtCAM Insignia www.delcam.com BobCAD-CAM www.bobcad.com Cut2D www.vectric.com D2nc www.d2nc.com Dolphin Partmaster www.dolphincadcamusa.com Edgecam www.edgecam.com FeatureCAM www.featurecam.com GibbsCAM www.gibbscam.com Mastercam www.mastercam.com VCarve Pro www.vectric.com

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CHAPTER-3 PROPOSED WORK

3.1 FRAME OF MACHINE Frame is the backbone of the machine and it contains all the components mounted on it. So as per the requirement frame must be made up of that material which contains all the strength and other properties which is desirable in case of CNC Machine. In my present work I choose the frame, which is made up of mild steel and the dimension of frame are given below.

Fig 3.1 3.2 BED Bed of CNC is the base of machine and it must be made up of that material which contains all the desired properties i.e. Damping property (Vibration Absorption) Provides base of machine Must clamp all the components Must carry whole load of machine It carries the T-Slot bed also.

So for all these desirable properties material of bed is cast iron. Cast iron as having very good damping property.

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3.3 WORK PIECE HOLDER In our machine we are using T-slot plate which is made up of aluminium and is not costly. 3.4 SLIDES Some features of rails/ slides Interchangeability of Rail and Ball Slide Fig 3.2 One important manufacturing feature of the Gothic Arch is the ability to make highly accurate measurements on both the ball slide and rail, allowing for tight tolerance control, resulting in interchangeability. This means that additions and/or replacement of ball slides is easily done. High Load Capacity and Long Life NSK has developed an infinite ball recirculating type linear guide with the largest load capacity available (comparing equal size ball slides). This high load capability helps to ensure long life. Compact Low Profile Type To minimize space, NSK has developed low profile linear guides to handle various applications. Miniature and Miniature Wide Type Stainless Steel If light loads and corrosive conditions are present for your application needs, NSK can supply a miniature and miniature wide type linear guide in stainless steel. NSKs built-in ball retainer system allows for easy installation and removal of ball slides. Wide Type If your application requires low profile combined with high load, NSK offers the wide series linear guides. Shock Resistant Design Another design feature of the Gothic arch is its ability to absorb vertical shock loads from above using four-row groove configuration. This design is favorable in case of unexpected accidents during installation, or the operation of equipment. The ball groove is designed to avoid edge loading under extreme loads, extending the life of the unit.

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Some features and dimensions of the rail Dimensions: For X & Y Axis 15mmx15mmx15inches For Z- Axis 15mmx15mmx10inches Liner Block Linear block is provided to support 3.5 BALL SCREW Fig 3.3 A ball screw is a mechanical linear actuator that translates rotational motion to linear motion with little friction. A threaded shaft provides a helical raceway for ball bearings which act as a precision screw. As well as being able to apply or withstand high thrust loads, they can do so with minimum internal friction. They are made to close tolerances and are therefore suitable for use in situations in which high precision is necessary. The ball assembly acts as the nut while the threaded shaft Fig 3.4 is the screw. In contrast to conventional ball screws tend to be rather bulky, due to the need to have a mechanism to re-circulate the balls. Round rail ball bushing bearing systems or ball screw, on the other hand, accommodate torsional misalignment caused by inaccuracies in carriage or base machining or machine deflection with little increase in stress to the bearing components. This self-aligning-in-all-directions design is forgiving of poor parallelism and variations in rail height. These bearings allow for smooth travel when mounted to widertolerance prepared surfaces. Whether to guide, support, locate, or accurately move machinery components and products, linear motion systems deliver low friction, smooth and accurate motion for nearly any moment or normal loading condition. The range of basic building blocks includes: lead screw drives and ball guides, lead screw drives and slide guides, ball screw drives and ball guides, ball screw drives and slide guides, belt drives and ball guides, belt drives and slide guides, and belt drives and wheel guides. Selecting the system that best
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fits the application is critical but it is only one part of the process of designing a linear system. Dimensions For X & Y Axis 16mm Pitch 5mm Length 14 inches For Z Axis 16mm Pitch 5mm Length 09 inches 3.5.1 BALL SCREW END SUPPORT The bearing balls travel inside the screw and nut thread. If the ball nut did not have a return mechanism the balls would fall out of the end of the ball nut when they reached the end of the nut. For this reason several different recirculation methods have been developed. An external ballnut employs a stamped tube which picks up balls from raceway with use of small pick up finger. Balls travel inside of tube and are then replaced back in thread raceway. An internal button ballnut employs a machined or cast button style return which allows balls to exit raceway track and move one thread and reenter raceway. An endcap return ballnut employs a cap on the end of ball nut. The cap is machined to pick up balls out of the end of nut and direct them down holes which are bored transversely down the ballnut. The compliment cap on the other side of nut directs balls back into raceway.

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Where

= Torque applied to screw or nut, = Linear Force Applied, = Ball screw lead, and = ball screw efficiency.

3.6 ELECTRIC MOTOR FOR SLIDE Stepper motors provide very precise, extremely cost-effective motion control. The 2-phase motors inherently move in small, precise, 1.8 degree increments at 200 steps/revolution and are brushless and maintenance free. Stepping action is simple to control and does not require complicated, expensive feedback devices. National Instruments also offers encoders matched to the motors for applications where position verification is required. Stepper motors are available from NI in three different National Electrical Manufacturers Association (NEMA) frame sizes and with either a single or a dual shaft. The motors provide optimum performance and easy connectivity when matched with the P7000 series stepper drives available from NI. Some specifications of the motor 2.3 Amp 20.3 Kg/cm(holding torque) 20-40 volt operating voltage 3.7 TOOL MOTOR Most small hand held tools have what are called universal or AC/DC motors. The most common failure in these is that the brushes wear out. Symptoms of brush failure are generally failure
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to start, intermittent starting, and more sparking when running than is normal. New brushes are cheap and are usually accessible enough to be replaced by the user. A good rule of thumb is that if the manual for the tool contains info on brush replacement then we can probably do it ourselves. Get the brushes from the tool manufacturer. If we can't figure out how to replace the brushes ourselves, we may want to consider whether or not to send the tool in for repair or just pitch it and replace it. Brush replacement and minor maintenance for a hand held tool will generally take one shop hour. Sometimes motors simply burn out. This is pretty easy to spot in a hand held tool as they usually smoke a lot and get hot when they do. It is usually most cost effective to simply pitch the whole tool if the motor burns out. Some specification of tool motor: Input 230V AC Power 600 watt Speed 30000 rpm 3.8 BREAKOUT BOARD Breakout boards are common electrical components that take a bundled cable and break out each conductor to a terminal that can easily accept a hook-up wire for distribution to another device. They are a common item in electronic projects and enable easy, clean installation of electronic devices. The image at right shows a simple DB25 breakout circuit board from Winford Engineering. The breakout board is positioned between your computer or indexer and the motor drivers and serves two purposes in the CNC control system: circuit protection and signal distribution. Here we will describe the boards function in the CNC control system. Lets say, that we have three
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simple bipolar stepper motors, each with the normal 4 wires. The wiring schematic would look something like the following:

The illustration above shows a block diagram for a stepper motor CNC control system. At right we will see four conductors between the driver and the motor. These wires correspond to the coils inside the motor that are energized to coordinate rotation. Remember, there would be six wires for each stepper if we had unipolar motors and we could have as many as eight wires Inside the controller box, we see a direction signal and a step signal being distributed from the breakout cirrus board to each driver. A common ground line is distributed in the same fashion. A power source also distributes power to each driver. Note that there is no power to the board in this system. At left, there are three signal pairs coming from the computer, one for each stepper, and a ground line for the return as indicated by the small black line under the three pairs of signal wires. For a typical DB-25 cable, the ground is the outer jacket of the connector. Actual image of breakout board 3.9 POWER SUPPLY UNIT When we plug a small flash drive up to our USB port, the computer powers the device through the port. When we plug a larger device, says a printer for example, we have to use an external power source because the computer is not capable of supplying sufficient power.
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This condition means that we have to plug that device into the computer as usual, but we also have to plug a second line to an auxiliary power source, such as the 110V outlet on your wall. The same conditions are true for CNC devices. They require a low-voltage communication line, through which the computer tells the machine what to do, and a power source that provides the power for moving, cutting, and other such operations. A power converter, usually referred to as the power supply unit (PSU), is often used to change the form of the supplied power from alternating current (AC) from the power grid, to direct current (DC) that is more easily used by the machines drive motors. The power supply handles large voltages and currents that could be harmful to the NC circuitry. Therefore, the power source, motor drivers, and motors are often separated from the computer with a circuitry protection system that isolates surges in electrical power. 3.10 CNC CONTROLLER COMPONENTS SETUP The figure below shows the typical setup of the CNC controller components, such as that for a 3 axis CNC router. The system is composed of a computer with NC control software, the controller box, and the drive motors. The controller box includes a breakout board, power source (not shown), and motor drivers. The breakout board provides the circuitry protection and signal distribution inside the controller box.

In the figure below, we can see the computer is connected to the breakout board, usually through the printer port (DB25). As a note, the computer is fully capable of connecting directly to the drivers and driving the motors, but this setup puts your computer at risk. The first figure is an idealized block diagram of your CNC electrical system. A little more detail has been added in the figure below to show the conceptual layout of signal wires (light black) and power wires (heavy black).

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Although your computer will run on 110VAC, the CNC machine may run on 110VAC, or 220VAC, or 480VAC, and may be single phase, three phase, etc. This power enters the controller box and will be distributed by the power supply. For most machines, the power supply will convert the incoming power from alternating current (AC) to direct current (DC). This DC supply will be of a lower voltage, such as 12V, 24V, 36V, or higher. The power supplied depends on you CNC controller components, specifically the motor drivers. 3.11 WORKING OF MACHINE Now the production on machine is done with the help of software called vectric. VCarve Pro is a powerful, flexible industrial strength software package that includes all the design, layout and machining functionality demanded by commercial shops and users, while remaining incredibly easy to use and affordably priced. VCarve Pro is a complete solution For CNC routing, sign making, woodcarving and engraving. As well as world class V-Carving strategies, VCarve Pro offers all the tools you need for 2D CNC machining as well. Features such as True Shape Nesting, Raised Prism machining, Auto-Inlays, Wrapped Rotary 4 axis machining user definable Tabs / Bridges, Ramping, Lead in / out, automated tools for identifying open and duplicate vectors, an advanced toolpath simulation engine and many more, have all been designed to enable you to work more quickly and efficiently. 3.12 TASK
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The task is to write Bhagwant University on a wooden Block We start the work is by opening the software on PC

In the next step we write the desired task on the software i.e. BHAGWANT UNIVERSITY.

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In next step we select the tool for the desired operation.

In next step we generate the tool path by providing the required data.

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In last we give the final command to start the cutting of the workpiece.

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CHAPTER-4 RESULT ANALYSIS

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CHAPTER-5 CONCLUSION
With the help of this project I conclude that if regular work is done on the area of design and development then there are many new methods and techniques are invented for the benefit of an individual or the society. This will create a direct impact on the society. If I individually talk about the higher technical colleges this is hard to say but this is true that day by day as technology advances but the students of those colleges are not even aware about all those. And if some of them are aware so they must be with the help of internet or their own resources. By this project, entry of CNC machine in the education field will become easy because it is cost effective and my machine is not very costly as comparison to other machines which are already available in the market. This project will also help me to understand that how the cost of any machine can minimized or make less by changing the material some electronic and mechanical component according to the need of the work. Te concept of this project was come in my mind when Indian Government introduced AKASH Tablet in the market at a very low cost. As we all aware about this fact that there are so many companies are running in the market which are already manufacturing tabs in the market and those Tabs are doing very good in the market so why the need of making Akash Tab? Akash is made for those students who are not able to afford other tabs which are already available in the market due to their high cost. Akash tab makes the thing easier for those students. The same concept came in my mind that CNCs are also available in the market but due to its high cost some institute and some individuals are not able to afford it. So I tried to make a CNC which is less in Cost and perform all training work on it.

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CHAPTER-6 FUTURE SCOPE

As our economy shifts toward globalization every CNC Mill and Lathe shop must address the issue of offshore competition with confidence and a healthy respect. We must say goodbye to the days where North America had dominance in precision machining. But we must not despair or grow bitter. We must innovate. Machine shops in America must rise to the challenge. Custom machining must be redefined by higher standards and better customer service. One important thing to remember is that companies are looking for CNC mill and lathe shops to supplement the machined parts they are sending over seas. They realize that quick turnaround is often a necessity for them to meet the custom machining needs of their customers. If all their parts are machined in China, they are left vulnerable. The manufacturing sector is exploding. Be creative. Look for niche markets where your machine shop can thrive. The emergence of CNC machines has accomplished new meaning to accuracy in the positioning of specific manufacturing operations. The extremely important part of the process of ensuring that all moving parts match perfectly is played by CNC programming. For intricate or large volume production runs where a high standard of replicated product is required, these computer-controlled machines are of greatest use. The results are as per the specified designs. Operations are carried out at high speed and whole production line is capable of producing repetitive tasks providing high standard of product finish. Machines are enabled to go through a complete machining cycle using various tools at very rapid speeds and with minimal human intervention. Measurements are made down to thousandths of an inch accuracy and the processes have very fine tolerances. The technological advances allow faster performances by CNC types. In worldwide competitive business, this edge is very necessary. Greater profits are created in the process that spells efficiency for a company. The CNC machine applications allow
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streamlining of operations for maximum profit for smart companies. Today's CNC controlled machines allow for unattended production capabilities for manufacturers. Stretching every investment is the lookout of businesses. Business plans today and for years to come means making wise decisions. A constant watch over machining is provided by CNC future technology. The mark of performance will constantly be raised by new technology. Innovation, quality, precision and quick turn-around take the focus. State-of-the-art equipment, years of combined experience, and a relentless commitment to clients bring about longer tool life, minimized downtime and reduced cost. Introducing innovative products and services means surviving for manufacturing companies. Programming is expected to be much easier for machine operators with the kinds of further sophistication in programming CNC future machines. Continued research is conducted on the use of computer programming and robotic applications. The solid future of fabrication industries is the advanced, state-of-the art CNC future technology.

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REFERENCES

Reintjes, J. Francis (1991), Numerical Control: Making a New Technology , Oxford University Press
Web-based manufacturing systems: a review, Int. journal. prod. res., 2003, vol. 41, no. 15,

36013629.
Bureau of Energy Efficiency (BEE), Ministry of Power, India. Components of an Electric Motor. 2005.

Briceno, J., El-Mounayri, H. and Mukhopadhyay, S. Selecting an Artificial Neural Network for Efficient Modeling and Accurate Simulation of the Milling Process, International Journal of Machine Tools and Manufacture, Vol. 42, pp. 663-674, 2002. Abari, F. and Elbestawi, M.A., Closed form formulation of cutting forces for ball and flat end mills, International Journal of Machine Tools and Manufacture, Vol. 37(1), 1997. P.N.Rao, CAD/CAM Principles and Applications Introduction to Computer Numerical Control 9-5/9-13b

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APPENDIX-A

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