Design and fabrication of three axis CNC laser cutting and engraving machine

Project Title

Design and fabrication of three axis CNC laser cutting and engraving machine

Project Area of Specialization Mechanical EngineeringProject Summary

The interest towards the manufacturing side of mechanical engineering especially towards the fabrication of CNC machines are what made this topic as the final year project. In this project we are intended to design and fabricate the CNC laser cutter and engraving machine. Various kinds of CNC lasers and routers machines are commonly used in industry having specific classifications based on the construction, mechanism and laser specifications. In this project we will design the CNC laser cutting and engraving machine for small commercial scale and use the high intensity electronic laser in it for cutting and engraving of different materials including wood, acrylic sheets, plastic etc. The main problems to be addressed for the design and fabrication of this type of CNC are:

1. Design mechanism of CNC machine that will use less power and give maximum output.

       2. Kind of laser used and compare it with other types of lasers and router and check its efficiency.

As per above given problems, In the design mechanism we have to make the drawings of our CNC machine by calculating the various parameters. Design helps us to make several parts like bed, relay, ball slider etc. that assembles and make good machine. The mechanical systems are the most important part of the CNC laser cutting and engraving machine system that is made up for the optimum working of machine. In mechanical system there are several components including construction bed, stepper motors sliders etc. which are very important to maintain the accuracy in operation. Electronic system in CNC laser machine is used to control the mechanical system to move axis according to the required dimensions. The study reveals that the pulse modulation system is used in it. This system is used to operate the components like Stepper motors, Stepper motors drivers, bread board, limit switches, Power supply etc.

      In this project instead of CO2 laser we will use high intensity electronic laser Sculpfun s9 (90 watt) for cutting and engraving as it is cost effective and has high power. It is one of the most advanced lasers used nowadays.Having completed this project, we will be able to engrave and cut various materials like acrylic sheets, wood and plastic sheets. We will be able to analyze the behavior of high intensity laser and can show its benefit to commercial user. By this, they can improve their work as it is cost effective so they can also earn well.

Project Objectives

The main objectives of the project are given as under:

1. To design the structure of CNC laser cutting and engraving machine by using CAD/CAM software.
2. To fabricate the CNC laser cutting and engraving machine which can cut and engrave variety of materials like acrylic sheets, wood, plywood, and plastic etc. 
3. To compare the efficiency of different lasers and suggest cost effective laser.
4. Analyzing the cutting and engraving processes on different materials.

Project Implementation Method

The project is presented according to the information about hardware structure, design and mechanism, software control and measurement system.

Initially the information about the structure of CNC was collected from different research papers and articles.

Once it was done, we started working on the Design of the CNC laser cutting, and engraving machine.

After it, the fabrication process was started by using various operations of machine shop according to given measurements.

In last, electrical system and computer interfacing processes were added to the system for complete operation.

Using the standard formulae and measurements, the final design was proposed. For the structure of CNC machine, mild steels pipes having different dimensions were used. For making the bed or working space of CNC we selected mild steel sheet having dimension 610mm. we have bent the sheet in such a way that we can get the total working space of 406mm × 457mm.four small bearing were fitted to bed so that the bed can easily slide on the railings in Y-directions. Ball screws, sliders, motor holders, couplings, nut and bolts, steeper motors and drivers and wires were used for the overall assembly of structure. Power supplies including 12-volt power supply for supplying powers to electronic components, 110-volt power supply for motor drivers, and 5-volt power supply for the interface board direct from PC. PC interface board were also used as it is controlling device used for interfacing the software and the CNC machine by using parallel printer ports.

       Having assembled the CNC machine we fit our main part of project which is LASER to it. In this project we have used high intensity laser sculpfun s9 (90 watt) for the cutting and engraving of different materials like wood, plywood, acrylic sheets, stainless steel, rubber, ceramic etc.it is one of the most advanced lasers used nowadays we choose this laser because it has some specifications like thinner beam and longer effective energy range, high energy density, Laser beam shaping technology, 0.8 mm ultra-thin engraving line. This laser can be said as a engraving beast and it is strong enough that it can engrave stainless steel directly.

        During this project, the overall process was carried out according to the measurements and the design was firstly made by using software and then was converted to hardware according to dimensions. Cost  and enviromental aspects were also considered.

• Initially the information about the structure of CNC was collected from different research papers and articles.

• Once it was done, we started working on the Design of the CNC laser cutting, and engraving machine.

• After it, the fabrication process was started by using various operations of machine shop according to given measurements.

• In last, electrical system and computer interfacing processes were added to the system for complete operation.

Benefits of the Project

This project covers a lot of applications in industrial and commercial sector, but some of the main applications of this project based on what the project was chosen to work on are given as under:

This CNC laser cutting, and engraving machine was designed and fabricated for proposing an effective way to reduce production and manufacturing costs. These kinds of machines have the advantage of high production rates as well as the fact that these machines can be easily mechanized, computer controlled and integrated into assembly lines.

In this project laser is used for cutting and engraving processes which is the key benefit of this project because many industries could be revolutionized by the application of laser equipment in their production lines due to their high-quality and low distortion characteristics of cutting and engraving action.

This CNC laser cutter and engraver machine have high accuracy and high precision as compared to other CNC machines because in this CNC machine we have used ball screws instead of lead screws as ball screws have high efficiency, reversibility, and backlash elimination.

The focusing diameter of laser diode is very small i.e., hundredth of millimeter so it can easily produce very sharp edges and corners which cannot be produce by CNC machines like milling and lathes.

There is not any contact surface between the workpiece and the cutting tool, so no material deformation.

Power consumption is also very low as compared to other conventional machines since the motor drives requires 10dc volts and other electronic components requires 12–24-volt dc source.

It also takes up less space as compared to other CNC laser engraving and cutting machines.

It can be made multipurpose CNC machine just by replacing the laser diode by CNC milling router or plotter.

• This CNC laser cutting, and engraving machine was designed and fabricated for proposing an effective way to reduce production and manufacturing costs. These kinds of machines have the advantage of high production rates as well as the fact that these machines can be easily mechanized, computer controlled and integrated into assembly lines.

• In this project laser is used for cutting and engraving processes which is the key benefit of this project because many industries could be revolutionized by the application of laser equipment in their production lines due to their high-quality and low distortion characteristics of cutting and engraving action.

• This CNC laser cutter and engraver machine have high accuracy and high precision as compared to other CNC machines because in this CNC machine we have used ball screws instead of lead screws as ball screws have high efficiency, reversibility, and backlash elimination.

• The focusing diameter of laser diode is very small i.e., hundredth of millimeter so it can easily produce very sharp edges and corners which cannot be produce by CNC machines like milling and lathes.

• There is not any contact surface between the workpiece and the cutting tool, so no material deformation.

• Power consumption is also very low as compared to other conventional machines since the motor drives requires 10dc volts and other electronic components requires 12–24-volt dc source.

• It also takes up less space as compared to other CNC laser engraving and cutting machines.

• It can be made multipurpose CNC machine just by replacing the laser diode by CNC milling router or plotter.

Technical Details of Final Deliverable

In this project, 3-Axis CNC laser cutting, and engraver machine will develop. All three axis are controlled using stepper motor having resolution of 0.05 degree per step. These stepper motors were controlled by its controller. The specific instruction is need to controller the position of stepper motor; however, computer is used to send signals to the controller to operate as per design. The laser intensity will be controlled by using pulse width modulation (PWM) Technique. All these stepper motors are attached with ball screw and ball sliders because ball screws and ball sliders are negligible backlash comparatively other mechanism. All these components are mounted on designed structure which is fabricated locally of mild steel pipe.

This section specifies information necessary for the design and specification for fabrication of the CNC laser cutting and engraving machine components such as frame, bed, and linear slides etc.

Design of CNC machine.

Design mechanism.

Material of frame, bed, linear slides couplings etc.

Casting, milling, boring, facing and bending operation for making CNC parts,

Assembly of parts.

No: of linear slides and their dimensions.

Type of Steeper motor.

Connection of stepper motors with linear slides.

Laser attachment on the CNC machine

So, the final deliverables of the project are:

The frame of CNC machine made up of mild steel.

Bed made from mild steel sheet.

Ball screw was connected to bed, it was used to move bed in desired direction (Y-directions).

Linear slides connected to stepper motor for movement in different axis.

Laser attachment on the CNC machine.

Electrical and electronic components connection with PC through interface board.

Engraving of materials like wood, plywood and acrylic sheets.

cutting process on various material like wood, plywood and plastic.

• Design of CNC machine.

• Design mechanism.

• Material of frame, bed, linear slides couplings etc.

• Casting, milling, boring, facing and bending operation for making CNC parts,

• Assembly of parts.

• No: of linear slides and their dimensions.

• Type of Steeper motor.

• Connection of stepper motors with linear slides.

• Laser attachment on the CNC machine

• The frame of CNC machine made up of mild steel.

• Bed made from mild steel sheet.

• Ball screw was connected to bed, it was used to move bed in desired direction (Y-directions).

• Linear slides connected to stepper motor for movement in different axis.

• Laser attachment on the CNC machine.

• Electrical and electronic components connection with PC through interface board.

• Engraving of materials like wood, plywood and acrylic sheets.

• cutting process on various material like wood, plywood and plastic.

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Education Core Technology Shared EconomyOther Technologies Clean TechSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

This CNC laser cutting, and engraving machine was designed and fabricated for proposing an effective way to reduce production and manufacturing costs. These kinds of machines have the advantage of high production rates as well as the fact that these machines can be easily mechanized, computer controlled and integrated into assembly lines.

In this project laser is used for cutting and engraving processes which is the key benefit of this project because many industries could be revolutionized by the application of laser equipment in their production lines due to their high-quality and low distortion characteristics of cutting and engraving action.

This CNC laser cutter and engraver machine have high accuracy and high precision as compared to other CNC machines because in this CNC machine we have used ball screws instead of lead screws as ball screws have high efficiency, reversibility, and backlash elimination.

The focusing diameter of laser diode is very small i.e., hundredth of millimeter so it can easily produce very sharp edges and corners which cannot be produce by CNC machines like milling and lathes.

There is not any contact surface between the workpiece and the cutting tool, so no material deformation.

Power consumption is also very low as compared to other conventional machines since the motor drives requires 10dc volts and other electronic components requires 12–24-volt dc source.

It also takes up less space as compared to other CNC laser engraving and cutting machines.

It can be made multipurpose CNC machine just by replacing the laser diode by CNC milling router or plotter.