CNC ENGRAVING & MILLING MACHINE

Project Title

CNC ENGRAVING & MILLING MACHINE

Project Area of Specialization 3D/4D PrintingProject Summary

Summary:

An increase in the rapid growth and evaluation of Technology significantly increased the usage and applications of CNC systems in industries for different operations but at considerable expense. CNC is an abbreviation of Computer Numeric Control. This term is used for the devices that are controlled by coded numerical information known as G or M codes. G or M Code CAD/CAM software package runs on a PC and results in a very powerful and economical machine controller. The need for low-cost precise and accurate CNC came forward in the market.

A 3 axes CNC machine works on the X, Y, and Z-axis which means that the raw material block remains fixed in the desired location or on a machine bed whereas Rotating drills or cutting tools are connected to a spindle and move along the X, Y, and Z axes to precisely turn the solid block of raw material into the final or desired shape. 

Whereas SMPS (Switched-mode power supply) is used to control the whole machine. SMPS is an electronic power supply system that transfers electrical power effectively with the help of a switching regulator. SMPS increases the efficiency of machine motors as well as provides us with precise and accurate products.

Project Objectives

Objectives of Project:

• To study what is CNC, its working and its benefits.
• To understand the use of SMPS in a CNC machine.
• To operate a CNC machine on 3 axes. 
• To use G and M codes to make an economical computer control machine
• To fabricate a 3 axes CNC machine with maximum accuracy and precision.
• To fabricate a 3 axes CNC with a low maintenance cost. 
• To decrease the complexity of CNCs and make an easy to operate the machine.
• To increase safety measures in the cutting and milling processes.
• To operate a 3 axes CNC machine on required Current and Voltage ratings.

Project Implementation Method

Project Implementation Method :

• Literature Survey: 

Studied different papers on CNC and specifically 3 axes CNC to understand the basics of CNC machine

• Market Survey:

To search the market for similar products available and understand how to make it more innovative.

• Calculations:

Calculations of all the components that will be used in the project. Names of some important ones are following

1. SMPS 
2. Stepper motors 
3. Mach3 software
4. Mach3 board
5. frames calculations 
6. Spindle motor calculations etc

• Thesis:

Writing the proposal and first chapter of the thesis according to the project.

• Software Learning:

Learning the process of software and understanding how it controls the machine

• Assembling:

1. Integration of motors with software and understanding the function of all axes
2. Fabrication of the mechanical frame and learning how it works electrically with the help of motors as well as current and voltage ratings.

• Testing Phase:

 Testing the machine on different types of materials and shapes.

• Delivery.

Benefits of the Project

Benefits of the Project:

Computer Numeric Control (CNC) machines have been used for a while now however, their popularity is increasing day by day. This is due to the impressive performance of these machines. They can produce a complicated size and shape that would take the skilled worker much longer time. The commercial CNC machines that are used in industries are bulky, larger and so much more expensive to afford by the small industries and to be used at home for hobbist. In the past few years, there have been an increasing number of enthusiast people and businesses invested in these types of systems. Some very common benefits are the following:

• It can reduce the production time and hence produce more products in less time which attracts businessmen.
• The number of labor decreased which results in less labor cost which again attracts businessmen.
• It has high precision and accuracy as compared to a hand-made product. 
• The chances of mistakes are very low because it is a computer-controlled device.
• It is easy to use, one can learn the software in a few days. 
• This type of machine encourages entrepreneurs to start new startups.
• It provides safety to humans from sharp tools in the cutting and milling process.

Technical Details of Final Deliverable

Technical Details of Final Deliverable :

• Stepper motors are used to provide high precision in the movement of axes hence the accuracy of the final product.
• TB6560 driver circuits are used to run stepper motors because of the required current rating of stepper motors. 
• Professional Mach3 software is used to produce G/M codes.
• Mach3 controller board works as a microcontroller for the signal generation for the motors drivers.
• X, Y, and Z axes are used in the machine to move the end mill to turn the solid block of raw material into the desired product.
• Self-designed SMPS is used because of the switching requirements of motors.
• The use of input switches as limit switches that close the machine when it reaches the end of the range.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Medical , Others Core Technology 3D/4D PrintingOther Technologies Robotics, OthersSustainable Development Goals Affordable and Clean Energy, Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	78540
NEMA 23 (Stepper Motor)	Equipment	4	1300	5200
TB6560 (Stepper motor driver)	Equipment	3	1400	4200
MACH3 CNC Controller board	Equipment	1	1500	1500
2040 V-slot Aluminum profile	Equipment	3	7800	23400
2080 T-Slot Aluminum Profile	Equipment	2	3300	6600
Shaft 16mm	Equipment	6	400	2400
Linear bearing 16mm	Equipment	4	480	1920
Leadscrew 10mm	Equipment	3	1700	5100
Shaft Coupler	Equipment	4	150	600
Bearing 10mm	Equipment	12	370	4440
SMPS Components(Transistors, diodes, transformer, resistors, etc)	Equipment	1	2300	2300
PCB SMPS	Equipment	1	2000	2000
CNC router Spindle motor	Equipment	1	7000	7000
Nut Bolts	Equipment	45	10	450
Parallel Port Cable	Equipment	1	230	230
Metal Plates	Equipment	2	600	1200
Stationary(Ballpoints, markers, clippers, assorted pins)	Miscellaneous	5	300	1500
Bindings	Miscellaneous	2	500	1000
Color Prints A3	Miscellaneous	150	20	3000
Color Print A4	Miscellaneous	150	30	4500