Institute of Arts, Science and Technology

LEVEL: MODULE: ASSIGNMENT: ISSUE DATE:

M Academic English for Specific Purposes LAN419 Report 2 5th March 2011

SUBMISSION DATE: Wednesday 16th April 2012 LECTURERS:

To be completed by the student Name: Mykhailo Riabtsev Student ID: S11003495 Course: MSc Manufacturing Date submitted: 16th February 2012 Student Signature:

Dr. Tom Rosario

Certification: I certify that the whole of this work is the result of my individual effort and that all quotations from books, periodicals, etc. have been acknowledged. ____________________________________________________________________ To be completed by the lecturer: Comments:

____________ | Grade/Mark | | | Mykhailo Riabtsev

Abstract
The aim of this paper is to introduce the results of design estimation of a model CNC milling machine, built in Sevastopol National Technical University. The purpose of model is to test different engineering solutions for a small-scaled milling machine. Such CNC milling machines are necessary as a school tutorial, which can show the principles of modern manufacturing process. Proper tests were carried out and the results were analyzed and systematized. Conclusions, which include design recommendations, were made.

Mykhailo Riabtsev

Table of Contents
Introduction 4 Comments and discussion.4 Conclusion remarks...5 References.6

Mykhailo Riabtsev

Introduction
Ukrainian schools are insufficiently provided with tutorial equipment. Most of the machine tools were made in USSR-time and now became obsolescent. Modern Ukrainian industry is not manufacturing any training machine tools, that is why there is a necessity of a small-scaled CNC milling machine suitable for school educational process. Such milling machine should meet several requirements, including: simplicity, cheapness, ease-of-operation, and others. The project was implemented by an initiative group of students. To make the final product cheap and simple, the milling machine parts were made from the materials that are easy to get, or from scrap. The parts machining was minimized to make the construction well-replicable. Also the electric part was assembled from available circuitry. The range of suitable software for this milling machine is wide, including free software. The model was tested under VRI-CNC 7.38 software, which has little system requirements and can be used on old computers.

Comments and discussion

The basis of the proposed machine is a welded frame (Figure 1), made of square section steel tubes 20 20 mm and a tubes of rectangular cross section 20 40 mm. The frame shape is a rectangle with sides of 580 540 mm. In the frame back there is a control unit 8 and stepper motors power supply 7. Also there is spindle control unit 6. There are two cylindrical guides on X-axis on each side of the frame. X-axis carriage moves on 8 ball bearings, driven by the longitudinal feed screw 5 with 1.5 mm thread pitch, which is rotated by bipolar stepper motor 3. X-axis screw is fixed in ball bearings 9, one of which is floating. This was done to compensate for manufacturing errors of the X-axis screw. The torque is transmitted to the screw through an elastic sleeve 4, made from a rubber tube. This connection allows you to avoid jamming due to axis misalignment.

Figure 1. Milling machine frame (Riabtsev, Krilov 2011). As an Y-axis the typewriter carriage was used. Its guides have the grooves shape, between which the balls are riding, placed in plastic cages. The Y axis screw is used a stud, M6 400 mm. Bearers and connections are similar to that on X-axis. Mykhailo Riabtsev

There is a steel plate mounted on Y-axis carriage, it serves as the basis for Z-axis. Z-axis guides are cylindrical. The carriage slides on bronze bushings along Z-axis. Bearers and connections are similar to that on X-axis. The basis of the machine spindle is Odwerk Mikromot 200e Pro firms Odwerk (Figure 2), 200 W with adjustable speed from 600 to 30,000 rev / min. The spindle is attached to the Z-axis carriage with a threaded flange.

Figure 2. Milling machine spindle (Riabtsev, Krilov 2011). Y-axis and Z-axis stepper motors are unipolar, X-axis stepper motor is bipolar. The advantage of bipolar stepper motors, compared to unipolar, is increased torque. The advantage of unipolar stepper motors is higher positioning accuracy (the number of steps per revolution ratio), as well as a simplified control scheme. The controller and driver diagrams are shown on the Figure 3.

Figure 3. Controller and driver diagrams (Vetrov 2008). The result is a machine tool working area of 250 350 mm and height of the workpiece up to 45 mm. The model was tested according to GOST 17734-88 requirements. The results of tests are shown on the Figures 4-5.

Mykhailo Riabtsev

Figure 4. Milling machine stiffness testing in vertical direction: a) testing scheme: 1-spindle; 2crossbeam; 3-bench; 4-load; 5-dynamometer; 6-gauge; b) shift to load diagram.

Figure 5. Milling machine stiffness testing in horizontal direction: a) testing scheme: 1- spindle; 2control mandrel; 3- gauge; b) shift to load diagram. The eccentricity of rotation testing showed 0.1 mm radial runout. The machine is designed for the machining of plastics, wood and other soft materials. Spindle clamping tool allows a maximum diameter of 3.5 mm in the corresponding collet.

Conclusion remarks
The testing results showed that the milling machine model does not meet the GOST 17734-88

requirements. It is caused, generally, by using cheap materials and cylindrical guides. Such guide type has the smallest stiffness among all other types. But it is also the simplest guide type for manufacturing. But the model can be used as a tutorial, it is cheap and simple, so the initial objective was achieved. Milling machine stiffness can be increased by using cylindrical guides of bigger diameter. Further development of this project can provide suitable CNC milling machine for school workshops. This can make improvements in engineering training process starting from school age.

Mykhailo Riabtsev

References
GOST 17734-88. Cantilevered milling machines: stiffness and accuracy standards. Place of publication: Publisher [online] < http://standartgost.ru/%2017734-88#page-1> [Accessed 15 April 2012] Riabtsev, M., Krilov, I., 2011 Vertical CNC milling machine for 3-D part machining. International scientific and technical conference for student, postgraduates and young scientists: Progressive trends of development machine-building and instrument-making branches and transport. SevNTU publishing house, Sevastopol. Vetrov, R., 2008 Controller and driver diagrams. [electronic print] Available at: < http://vricnc.ru/modules.php?name=News&file=article&sid=7> [Accessed 15 April 2012]

Mykhailo Riabtsev