Design and Implementation of three axis CNC machine

Project Title

Design and Implementation of three axis CNC machine

Project Area of Specialization 3D/4D PrintingProject Summary

This project includes the design and fabrication of 3-axis CNC machine for PU foaming of electrical panels. Solid works and Fusion 360 will be used for CAD/CAM design.

The designing phase, which includes the  assembling and welding the various components to lay the foundation of our structure, has been completed. Materials such as metal works and plywood have been used for this purpose. For proper and efficient operation the electronic circuitry i.e. stepper motors, motor drivers, uninterruptable power supply, microcontroller with CNC shield will be used.

Either Fusion 360 or any third party application like Universal G-code sender can be used for the conversion of the CAM design into CNC understandable G-code and its implementation with the maximum possible accuracy and precision.

Project Objectives

• Inexpensivle prototype CNC:

To develop a low-cost, efficient workaable CNC that can be deployed in any industry settings.

• Electrical Panel foaming:

This CNC, after being developed, will to able to perform foaming onto the edges of electrical panels and switchgears.

• Substitute for importing PU stripes:

Currently, the industry uses PolyUrathene (PU) stripes by imports. The CNC will help in substituting the import of these stripes by automation process with more enhanced mechanism.

• Lifelong learning:

The completion of this project takes into account extensive knowledge of CNCs, CAD/CAM design modules, familiarity with SolidWorks and Fusion 360, hands-on experience with circuit desiging and ither miscellanous things. This project allows to learn many different skillsets that are crucial to the modern day advancements. 

Project Implementation Method

• Establish an initial design for milling structure on SolidWorks/Fusion360:

For this we will be learning SolidWorks and Fusion360. First we will design the mechanical structure for our prototype on SolidWorks and then we will simulate the process of additive manufacturing on Fusion360.

• Development of mechanical structure for the prototype:

After the designing phase, we will dive into the practical work by assembling the various components to lay the foundation of our structure. Materials such as metal works or plywood shall be used either independently or in combination for this purpose.

• Proper calibration of the CNC router with respect to the home position:

After mechanical fabrication, for proper accuracy we will be calibrating the dimensions of CNC machine by using limit switches and physical measuring instrument as Vernier caliper. Software used for this purpose will be universal G-code sender with GRBL framework.

• Implementation of tool paths on the work piece via G-code:

Universal G-code sender will be used to send the CAM program or G-code generated by fusion 360 to the CNC shield so that it may implement for further communication with micro-controller (Arduino/STM-32).

• Conventional injection of 3D printing material:

3D printer extruder and filament will be used as a depiction of electrical panel polyurethane foaming and its dispenser. PU is a chemical that dries and sticks to the material right after extrusion. Here, PLA (polylactic acid) replicates such behavior and both operations (PU foaming and 3D printing) are performed with a controlled temperature and pressure flow.

Benefits of the Project

The crucial extent of the undertaking is to save the expense of manufacturing obligation for the industry. Currently, they import PU stripes and paste individually onto their switchgear panels. By the development of this CNC machine they will achieve self-sufficiency and accuracy in this domain.

CNC machines provide better accuracy with less manufacturing time as compared to manual machining. It requires less labor and material resulting in overall improved efficiency of the industry.

3-axis CNC machines are vastly used in rapid prototyping. With slight modifications in design it can be used as a drilling, cutting or wood engraving machine.

Technical Details of Final Deliverable

• Integration of microcontrollers and CNC shield with stepper motors and drivers:

After the completion of mechanical fabrication of the 3-axis based CNC, a proper software integrated system will be required to make it fully functional and operable. By the help of scaling, programming and axes calibration through the use of relevant software, the prototype itself will be able to move according to the required instructions with impeccable efficiency. 

Furthermore, a 12V DC power suplly shall be needed to run the equipments smoothly.

Through this methodology, we will be able to produce our desired outcome through additive manufacturing with precision, accuracy and reliability.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Manufacturing Core Technology 3D/4D PrintingOther Technologies RoboticsSustainable Development Goals 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)	80000
Stepper Motor	Equipment	4	5000	20000
12 V Power Supply	Equipment	1	2000	2000
STM-32 Controller	Equipment	1	7500	7500
CNC Shield	Equipment	1	500	500
Limit Switches	Equipment	10	1000	10000
Motor driver	Equipment	1	5000	5000
Extruder for 3D printer	Equipment	1	5000	5000
Plywood (Structure)	Equipment	1	20000	20000
Display	Miscellaneous	1	5000	5000
Wires, jumpers, cutting and plywood accessories	Miscellaneous	1	5000	5000