Conversion of Vertical milling machine into CNC

Project Title

Conversion of Vertical milling machine into CNC

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

CNC machining is common in projects that require a high level of precision and repetition. The process can accommodate 3D shapes that—in many cases—are too complex to create via conventional machining. The instructions are written in G-code, which is generated using a form of CAD or CAM software before being fed to computers.

The code is written and revised by programmers, and as such, it can be updated as needed to produce the correct prototype shape and quantity. Upon activating a CNC machining system, the desired cuts and shapes are programmed into the software and relayed to the machinery that will carry out the tasks. The pre-programmed CNC machines feature the exacting, high-speed movements required to customize the prototype.

When the program is loaded, an operator will conduct a test of the code to make sure it’s error-free. This trial run is called “cutting air,” and is meant to protect the CNC machine by reducing the risk of damage. Even the smallest mistakes involving speed or positioning can scrape the CNC machine.

To this end, while the design details are automated in CNC machining—this helps to ensure consistency throughout the production process—a design may require cutters and drills to meet the exact specifications of the prototype. (We’ll go over this in more detail shortly.) A router or spindle will then turn the cutting implement and cut the material

Project Objectives

The objective of CNC machining is to create a prototype by cutting a block of material into a specific shape.

CNC machining boasts both financial and production advantages over manufacturing alternatives like conventional machining and 3D printing. It is more cost-effective, more accurate, and a faster process overall. 

But the appeal of the process doesn’t end there. Rather than relying on live operators to control the manufacturing functions, CNC machining features pre-programmed software and consoles that oversee the movement of the factory tools at play. The process can be deployed to monitor a broad range of machinery—including but not limited to grinders, mills, and routers—through a specific set of prompts.

CNC machining is especially useful because the manufacturing industry tends to use large quantities of materials, which come in complex shapes and a variety of sizes. Many CNC machines include multiple axes that can accommodate different angles and difficult-to-cut materials.

Developed in the 1940s, the first CNC machines used punched-paper technology instead of the digital software we see today. That said, the process has consistently produced large-scale results with great precision, no matter the application. The computerization component of CNC machining guarantees comprehensive, consistent outcomes.

Project Implementation Method

This CNC (Computer Numerical Control) controls have the ability to control the X, Y, Z axes simultaneously, allowing production time to decrease considerably, machine repeatability to be greater and the use of more complex projects to be executed with greater accuracy, where technology was made cheaper by the use of a micro controller from the year 2000, making it possible to be used in microenterprise and hobby media, and in 2009 Simen Svale Skogsrud released the first version of the GRBL (Integration of inverse kinematics), which is a controller for Cartesian axes X, Y and Z, which can be installed on a simple Arduino. Some advantages, which included good cutting precision and repeatability, reduced machining time, and the ability to machine complex geometries. In the milling process, the cutting tool rotates around its axis and meets the part, which performs the forward movements. A great feature is the versatility in the production of different geometries, besides guaranteeing high rates of material removal. In this process, the tool rotates while the piece, attached to the table, is responsible for the longitudinal and transverse feed movements. In some situations, the part may remain static while the cutting tool performs all the movements. End milling, it is used one by a multi-edged cutter, which are wrapped around its axis, in addition to being a precise and very dynamic equipment for moving in several directions at the same time, speeding up the production and the cutting process and also being able to be applied in numerous variations within the industry. It is the result of combined actions of the cutting tool's edges that are at right angles to the face of the part to be machined. The face after machining it is flat without having any relation with the teeth of the tool, among the processes mentioned above it has greater productivity, if it should be chosen as far as possible. Milling in three dimensions the active teeth are located on the periphery (cylindrical surface) of the tool, and the tool axis is parallel to the surface to be machined. The tools used in tangential milling are called cylindrical or tangential milling cutters. The main disadvantage of this process is that the tool tends to have greater vibration, so fixing it with greater precision is necessary, the part to be machined is necessarily fixed because the cutting movement is inconsistent1, soon there will be greater wear of the part and its useful life is reduced. The axis of a CNC refers to the displacement in a direction to its Cartesian plane, since the number of axes that a CNC has is linked to the number of simultaneous machine directions. Bearing in mind that the primary axes of (X, Y, Z) in their linear Cartesian coordinates, aim at the displacement of the machine, however the rotation axes are created 3 new axes called angular, thus the rotation on the X axis becomes axis A , the Y axis becomes the B axis and the Z axis becomes the C axis.

Benefits of the Project

• The accuracy of the CNC machine ensures consistent product quality. The process is more precise than manual machining and can be repeated in exactly the same manner over and over again.
• Increased production speed and increased efficiency. Computers are used to control the machines, the process is automated therefore increasing speed and quality of manufacturing. Considering machines do not tire or need breaks it makes it more efficient than manual machining.
• One of the main advantages for the operators of CNC machines is safety. Using CNC machines are much safer than manually operated machines as they work behind a guard or even a closed, transparent safety door.
• CNC Machining is more cost effective. Traditional machining requires one operator per machine. This type of machining requires fewer machine operators since one skilled operator can run several machines at one time. Since the CNC is so accurate it reduces errors from the manufacturing process and eliminates unnecessary waste.
• CNC machines can automate the jobs that require several cuts. A router or spindle turns the cutting implement, which usually resembles a drill bit. A true drill bit cuts only at the tip, while nearly all of a router bit cuts the material.
• The programming in CNC machines incorporates all the exacting, high-speed movements needed to produce the object, and it enables detailed customization. CNC machining is becoming increasingly popular as a way to fabricate metal parts as well as plastic parts, as it allows the manufacturer to produce complex shapes that would be nearly impossible to create manually. Many industries, especially manufacturers, look to CNC machining advantages for production solutions involving metal and plastic and any number of machining processes they may need.

• Better Safety: Along with an expedient production process and consistent pieces comes a safer environment. While there are operators involved in operating CNC machines, it’s at a distance from the sharp tools, whereas the operators of conventional-manual lathes, drills, punches and other tools come into direct contact with the implement.

  Design Retention: Once a design has been loaded into the CNC machining software and a perfect prototype has been created, the program can easily retrieve the design to run it and create the object again. The master file ensures that regardless of external factors such as machine-operator changes, the CNC machining process produces a spot-on match every time. Additionally, there is no need to keep up with versions of the design that may exist on paper, a flash drive, a disk, other computer or elsewhere.

  Low Maintenance: The G-code-based software will automatically update itself when needed, and CNC machines generally do not require much service other than to change the cutting implements at the proper interval and do some light cleaning. None of the regular maintenance requires professional service, which saves money.

Technical Details of Final Deliverable

The CNC program acts as instructions for the CNC machine; it submits machine commands dictating the tooling’s actions and movements to the machine’s integrated computer, which operates and manipulates the machine tooling. Initiating the program prompts the CNC machine to begin the CNC machining process, and the program guides the machine throughout the process as it executes the necessary machine operations to produce a custom-designed part or product.

CAD File Conversion

The formatted CAD design file runs through a program, typically computer-aided manufacturing (CAM) software, to extract the part geometry and generates the digital programming code which will control the CNC machine and manipulate the tooling to produce the custom-designed part.

CNC machines used several programming languages, including G-code and M-code. The most well-known of the CNC programming languages, general or geometric code, referred to as G-code, controls when, where, and how the machine tools move—e.g., when to turn on or off, how fast to travel to a particular location, what paths to take, etc.—across the workpiece. Miscellaneous function code, referred to as M-code, controls the auxiliary functions of the machine, such as automating the removal and replacement of the machine cover at the start and end of production, respectively.

Once the CNC program is generated, the operator loads it to the CNC machine.

Machine Setup

Before the operator runs the CNC program, they must prepare the CNC machine for operation. These preparations include affixing the workpiece directly into the machine, onto machinery spindles, or into machine vises or similar workholding devices, and attaching the required tooling, such as drill bits and end mills, to the proper machine components.

Once the machine is fully set up, the operator can run the CNC program.

CNC machining operations and their required equipment, and some of the considerations that may be taken into account by manufacturers and machine shops when deciding whether CNC machining is the most optimal solution for their particular manufacturing application.

Final Deliverable of the Project Hardware SystemCore Industry OthersOther Industries Manufacturing Core Technology 3D/4D PrintingOther Technologies OthersSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	79500
CNC Shield	Equipment	1	3000	3000
Stepper Motor	Equipment	4	3200	12800
Stepper Motor Driver	Equipment	4	500	2000
Arduino	Equipment	1	4000	4000
Power Supply	Equipment	1	5000	5000
Jumper	Equipment	1	1000	1000
DC connector	Equipment	2	500	1000
Grinding Machine	Equipment	1	7000	7000
Grinding Cart	Equipment	1	3000	3000
Left bearing support y axis	Equipment	1	1000	1000
Coupler	Equipment	4	4500	18000
Trapezoidal Spindle 610mm	Equipment	1	3500	3500
Trapezoidal Spindle 410mm	Equipment	1	3000	3000
Trapezoidal Spindle 200mm	Equipment	1	2000	2000
metal chest nut	Equipment	4	800	3200
Travelling	Miscellaneous	1	3000	3000
3D Printing	Miscellaneous	1	5000	5000
CNC course learning	Miscellaneous	1	2000	2000