MSA

October University for Modern Science & Arts

Faculty of Engineering
Department of Industrial Systems Engineering

Design and Manufacture of a Desktop

CNC-Router

A Graduation Project
Submitted in Partial Fulfillment of B.Sc. Degree
Requirements in Industrial & Systems Engineering
(Part I)

Prepared By
Abdallah Walid Abdelaziz 164191
Amr Hisham Fathi 174699

Supervised By
Prof. Dr. Tarek El Hossainy

Fall 2020

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 Abstract
Computer Numerical Control machines (CNC) have rolled out progressive improvements
within the manufacturing areas. In the past, accomplishing productivity up to the ideal
level was not possible because of number of downsides like inconvenience of shapes and
sizes, absence of skilled workers, heaps of wastages and scraps because of errors, quality
levels and precision. By utilizing CNC, all these downsides can be overcome, and this
will be the objective of the project to show the CNC importance.

The aim of this project is to design and manufacture a Desktop CNC Router machine.
Desktop machine is not a replacement for its full-sized counterpart but it’s less expensive,
easy to use and requires small area.

In this project, designing and manufacturing a prototype CNC router will occur after
reviewing the most famous previously existing models. The design calculations will be
done for choosing the dimensions of different elements of the machine. Then developing
an electrical system which includes control, programming and the interfacing between
the control unit, computer unit and the machine.

KEYWORDS: Machine Design, Materials, CAD CAM, CNC.

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 Acknowledgment

We cannot express enough thanks to our supervisor Prof. Dr. Tarek El Hossainy for his
continued support and encouragement, we offer our sincere appreciation for the learning
opportunities provided by our committee.
Our completion of this project could not have been accomplished without the support of
Prof. Mohamed Hassan, thank you for your support, revising and guidance.
All thanks to our mentor Thank you for your great effort, support and guidance in our
project, your inspiration and support are like footprints that have etched in our hearts and
minds forever.
We would like to express our gratitude to our Dean Prof. Dr. Nahed, thank you for your
absolute and tremendous guidance, effort, time and support.
Many thanks to our families, for the love and support they have provided throughout this
period, for bearing with the long working days and nights in order to come out with this
project.
Last but not least, we are very grateful to our friends for pushing us forward and assisting
us and thereby mainly providing optimum help in many ways; and for all of this, we thank
you.

Finally, we would like to sincerely thank all the T.A’s and lecturers who have given us
the opportunity to undergo such a brilliant experience, and for giving us all the required
information that are needed to produce this report, we are very honored and no words are
enough to thank all of you.

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 Table of contents
Abstract………………………………………………………………………………...i
Acknowledgment……………………………………………………………………...ii
Table of contents……………………………………………………………………..iii
List of Figures………………………………………………………………………...iv
List of Tables……………………………………………………………………….....v
Work effort contribution……………………………………………………………...vi
Report writing contribution………………………………………………………….vii

Chapter I: Introduction ……………………………………………......1

1.1 Background of the study...……………………………………………………..1
1.2 Problem Definition………………………………………………......................1
1.3 Aims and objectives……………………………………………………………2
1.4 Report Organization……………………………………………………………2

Chapter II: Literature review ………………………………………....3

2.1 Historical background……………………………………………………….....3
2.2 CNC mill and CNC router……………………………………………………11
2.3 CAD/CAM……………………………………………………………………15
2.4 CNC system elements………………………………………………………...15
2.5 G-code………………………………………………………………………...16

Chapter III: Preliminary design ……………………………………..17

3.1 Proposed design……………………………………………………………....17
3.2 Main components of CNC-Router machines…………………………………18
3.3 Structural materials for router………………………………………………...22
3.4 Control system………………………………………………………………..40

Chapter IV: Conclusion and Future work…………..…………...…..46

4.1 Conclusion……………………………………………………………………46
4.2 Future work…………………………………………………………………...47

References ……………………………………………………………..48

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 List of Figures
Figure 2.1 Modern milling machine…………………………………………………..4
Figure 2.2 Horizontal and Vertical milling machines…………………………………4
Figure 2.3 Early design of milling machine…………………………………………...6
Figure 2.4 Comparison of conventional and non-conventional machines………….....7
Figure 2.5 Non-traditional machines……………………………………………….....8
Figure 2.6 1958 CNC………………………………………………………………...10
Figure 2.7 Modern day CNC………………………………………………………...10
Figure 2.8 CNC router……………………………………………………………….13
Figure 2.9 CNC mill…………………………………………………………………14
Figure 2.10 CNC system element……………………………………………………15
Figure 3.1 Proposed Model of the CNC-Router……………………………………..17
Figure 3.2 Frame……………………………………………………………………..18
Figure 3.3 Table……………………………………………………………………...18
Figure 3.4 Spindle……………………………………………………………………19
Figure 3.5 Drive system……………………………………………………………...19
Figure 3.6 Axis Drive………………………………………………………………. 20
Figure 3.7 Motion system……………………………………………………………20
Figure 3.8 Drivers……………………………………………………………………21
Figure 3.9 Acme form………………………………………………………………..23
Figure 3.10 Square form……………………………………………………………..23
Figure 3.11 Buttress form……………………………………………………………24
Figure 3.12 Ball screw assembly…………………………………………………….24
Figure 3.13 Mechanism of roller screw……………………………………………...25
Figure 3.14 Acting forces………..…………………………………………………..27
Figure 3.15 Ball Bearing……………………………………………………………..32
Figure 3.16 Types of bearings……………………………………………………….34
Figure 3.17 Linear motion system…………………………………………………...34
Figure 3.18 Linear motion system…………………………………………………...36
Figure 3.19 Round rail bushing bearing……………………………………………..38
Figure 3.20 Selection option…………………………………………………............38
Figure 3.21 Linear bearing accuracy………………………………………………...39
Figure 3.22 Controller system………………………………………………………..40
Figure 3.23 Operation selection in Mach2…………………………………………...42
Figure 3.24 Stepper motor…………………………………………………………...42
Figure 3.25 Stepper motor vs DC motor rotation……………………………………43
Figure 3.26 Open loop…………………………………………………………….....44
Figure 3.27 Closed loop system……………………………………………………...45

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 List of Tables

Table 2.1 MDI G-Code Quick Reference……………………………………………16

Table 3.1: Bearing strength…………………………………………………………..37

Table 4.1: Future plan Gant chart……………………………………………………47

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 Work effort contribution
Part I
Project Title: Design and Manufacturing of a desktop CNC-Router
Advisor Name: Dr. Tarek El Hossainy
Week Defined work Student Name
1 • Abstract Amr Hisham

• Introduction
2 Abdallah Walid
• Problem definition

• Aim and objectives

3 Amr Hisham
• Background check

• Historical analysis
4 • Types of CNC milling machines Abdallah Walid
• Brief research on CNC-router

• CNC-router components
5 • CNC System elements Amr Hisham
• Motion of machine

• CAD/CAM
6 • G-code Amr Hisham
• Preliminary design

7 • Preliminary design Abdallah Walid

• Design of power screws

8 • Preliminary design Amr Hisham

• Selection of bearing

9 • Preliminary design Abdallah Walid

• Design of guide way

10 • Assembly part Amr Hisham

• Control system

13-14 Final exams

15 • Conclusion and Future work Abdallah Walid

16 Final graduation presentation

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 Report writing contribution
Part I
Project Title: Design and Manufacturing of a Desktop CNC-
Router
Advisor Name: Dr. Tarek El Hossainy
Report contents Student Name
Cover sheet/Abstract (English)
Amr Hisham
Cover sheet/Abstract (Arabic)
Acknowledgment/Table of contents
Abdallah Walid
List of Figures

Chapter I Introduction Abdallah Walid

Chapter II Literature Review Amr Hisham

Chapter III Preliminary Design of Proposed Model Amr Hisham

Chapter VII Conclusion& Future Work Abdallah Walid

References Amr Hisham

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 Chapter I
Introduction

1.1 Background of the study

Milling machines normally require a skilled worker to operate the machine and it
wasn’t guaranteed that the required accuracy of dimensions and design will be
achieved , years after inventing the conventional milling machine a Numerically
controlled milling machine then a CNC milling machines were introduced into the
industrial region which was a huge step forward in the production and industrial part
and helped gain and achieve the production goal for its high production rate in types
of it , also helped in manufacturing complex shapes with accurate dimensions ; with
addition to less skilled craftsmen required since its computerized and mainly
automated; However there are still a number of downsides to CNC machines, they
are not that big of a problem but still if there is a chance for improvement then it is
better to improve, the price of CNC milling machines are considerable and highly
expensive also the size of it since it take a big space from the ground of the factory
and this is a big problem for smaller workshops talking about price and size highly
matter to them for the limited budget and the space available to install a machine so
designing and manufacturing a CNC desktop milling machines will solve these
problems since its cheaper than a regular CNC milling machine and even smaller in
size since it will take less than a 1 meter square from the ground and can also be
easily moved from one place to another in the factory “portable” unlike the normal
CNC milling machine that will be very hard to move or adjust position because of
its big size and heavy weight .

1.2 Problem definition

This project will be based on designing and manufacturing a Desktop CNC-Router with
the aim to solve the troubles and downsides that faced the previously existing milling
machines. A Desktop CNC-Router is light in weight, portable, cheap and smaller in size
than most CNC machines in the industry.

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1.3 Aim and Objectives:
The aim of this project is Designing and manufacture of a Desktop CNC-Router that is
light in weight which has high accuracy and precision along with high production speed,
taking into consideration the cost of the machine and the size to be less and smaller than
the typical CNC milling machine, through the following Objectives:

• Reviewing of the literature of the previous work

• Choosing a suitable model to be designed and manufactured.
• Preliminary design of the main components of the chosen model
• Designing a suitable controlling model
• Manufacturing and purchasing the final model and testing its performance.

1.4 Report Organization

This report is split to four chapters. The first chapter consists of a brief introduction
containing some background information about the CNC machines, the problem
definition and finally the aim and the objectives of the current project. The second chapter
is the background history “literature survey” it includes the history of the milling
machines different types of it, and the machining processes it also includes the evolution
of CNC machines how it works alongside an introduction to CAD/CAM and the G-codes;
there is also a brief explanation of the CNC-Router and a comparison between the two
types of machines. The third chapter is the preliminary design with the proposed designed
the components of the machine the power screw, bearing and guide way design and
selection. The fourth and last chapter consists of two parts, first the conclusion of the
study and the second part is the future work to be done for the completion of the project.

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 Chapter II
Literature Review
This chapter presents a literature survey in terms of historical background and literature
review regarding various types of milling machines and how they have been developed,
evolved and improved over the past years.

2.1 Historical Background:

In this section, the history of the milling machines and their evolvement will be
reviewed.
There are many types of milling machines, out there the following five types are the main
ones and the most common in the industry and manufacturing field and some of them will
be illustrated and discussed more in chapter II in the historical background part, those are
the most common types of CNC milling machines:

1. Horizontal Milling Machine.

2. Vertical Milling Machine.
3. Bed mill
4. C-Frame Mill.
5. Double spindle Mill.

2.1.1 Milling Machines

A milling machine is a machine found primary to remove excess material from solid metal
and to shape them with the required design to form a finished product. It is used for a
variety of operations like slotting, cutting, threading.
There are two main types of milling machines the cylindrical milling machine and the end
mill machine they both are type of conventional machines
A milling machine removes metal by rotating a multi-toothed cutter that is fed into the
moving work piece. With milling, the workpiece remains stationary, whereas the cutting
tool rotates. As the rotating cutting tool presses against the workpiece, it removes
material.

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 Figure 2.1: Modern milling machine.[1]

In this section the difference between vertical and milling machines will be illustrated and
explained, figure 2.2, shows the two machines alongside each other.

Figure 2.2: Horizontal and Vertical milling machines.[1]

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What is a vertical milling machine?
It is a major type or model of milling machine, it has a vertical oriented spindle which
holds and spin the cutting tool against a station workpiece, making it the most common
milling machine. To remove material, the spindle moves up and down along the z-axis
while pressing against the workpiece. The two main types of vertical milling machines:

• turret machines
• milling machines for the bed
Because the spindle and table of a turret milling machine moves parallel and
perpendicular to the axis, whereas bed milling machines move the table perpendicular to
the axis, turret milling machines are mostly preferred in the industry.

What is a horizontal milling machine?

The spindle of horizontal milling machine contains a rotating cutting tool that press
against the workpiece to remove excess material. Horizontal milling machines differs
from vertical milling machines in many ways, the most notable of which is the spindle
orientation. The spindle on vertical machines has a vertical orientation. The spindle on
horizontal machines is horizontal, whereas the spindle on vertical machines is vertical. In
other words, horizontal milling machines are capable of removing material from a
stationary workpiece by moving the tool on a horizontally oriented spindle. Furthermore,
cutting tools on horizontal milling machines differ from those on vertical milling
machines. Vertical milling machine use longer and thinner cutting tools, whereas
horizontal milling machines use short and thicker cutting tools.

Vertical milling machines can't cut as deep or as heavy as horizontal milling machines.
As a result, manufacturers prefer to using them to cut grooves or slots in workpieces.

2.1.2 History of Milling Machines:

In 1816, Milling machines were invented to help make complex shapes. Later, in 1818,
Whitney invented the first milling machine. In the year 1818 Eli Whitney invented a
milling machine that required a less skilled operator. As good as it sounded back then but
yet it had many downsides regarding the surface finish as per usual and the dimensional
accuracy of the final product. [1]

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 Figure 2.3: Early design of milling machine [1]

2.1.3 Machining process:

Most machining process go through four main stages; each stage is implemented
by its own strategy and each stage has many strategies to be implemented through
depending on the material available.[1]
The stages are as following:
• Roughing:
In this step the process starts with raw stock and cuts it very roughly to
remove as much of the excess material as possible to shape the final model;
common strategies in this method are: horizontal, zigzag clearing, offset
clearing, plunge roughing, rest roughing
• Semi Finishing:
Generally, this process starts with the previously roughed part and start
cutting with an offset distance to the model. this leaves a semi-finished part
with a little material to be removed later on in the finishing process by the
cutting tool accurately.
• Finishing:
In finishing the MRR ‘material removal rate’ is minimal with a very
small feed rate, the step is small, and the spindle speed is raised to
produce accurate surface.

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 • Contour Milling:
Contouring is a respective procedure that can be used. work piece is adjusted
to allow the tool's cutting surface tangent to the ideal part features, rather
than stepping down in fine-grained increments to approximate the surface.
This results in a smooth, dimensionally accurate surface finish.

2.1.4 Conventional Milling Machine:

Conventional machining in general includes the removal of material using mechanical
force where either the tool or the work piece is fixed and the other one is rotating , both
the work piece and the cutting tool can be moved and adjusted to a different position but
In the traditional milling process the cutting tool rotates against the direction of feed
causing the removal of material , in this process the material is fixed to the table and the
cutter start cutting causing the chip size to start gradually increasing from zero till
removed totally from the workpiece. This cutting process usually causes hardening to the
material surface due to the heat caused by the friction from the cutting tool and the
workpiece, also causes tool wear and decreases the tool life. The chip material usually
falls back on the material causes errors in some cases

Figure 2.4: Comparison of conventional and non-conventional machines.

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2.1.5 Non-conventional machines:

Conventional machining processes (milling, drilling, turning) use a sharp cutting tool to
form a chip from the work to cut the metal by shear deformation. In addition to these
traditional methods, there is a group of other processes that use other methods and
mechanism to cut the material and remove the excess material unneeded. The term
nontraditional or non-conventional machining refers to methods that removes excess
material by different techniques than in traditional machining including mechanical,
electrical, thermal, or even chemical energy Without the use of a sharp cutting tool like
in the conventional methods.[6]

Figure 2.5: Non-traditional machines [6]

The nonconventional processes are often classified according to the form of energy used
to remove the material. There are four types for classification:

a) Mechanical:
In this type the action done is different from the one in the traditional method,
usually causes metal erosion using high frequency or high-pressured water stream
or abrasives.

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 b) Electrical:
These nontraditional processes are the reverse of electroplating using
electrochemical to remove material.
c) Thermal:
In this method thermal energy is used to cut or shape the work piece by applying
it to a portion of the work surface intended to be removed, causing that portion to
be removed by fusion and/or vaporization from the heat. This thermal energy is
caused and generated by the conversion of electrical energy.
d) Chemical:
Most materials (metals particularly) are sensible to chemical attack when a certain
acids or other etchants are added. In chemical machining, chemicals selectively are
added to remove material from portions of the work part needed to be removed,
whereas other portions of the surface are protected by a mask.

2.1.6 History of CNC machines

Computerized numerical controlled (CNC) machines use a machining technique that was
first invented in the early 18th Century, it was invented for the sake of achieving high
precision that can’t be achieved by the handcrafted men which marked the beginning of
industrialization.
However, it was not until the year 1947 that the development of automation was addressed
to help the company Parsons Works by the U.S to increase its productivity of helicopter
blades. The actual start points of using CNC was done by John T. Parsons by studying
the possibilities of controlling these machines using computer. It wasn’t until the year
1952 when Richard Kegg, collaborated with MIT to develop the first CNC milling
machine; five years later in 1958, he filed a patent for a “Motor Controlled Apparatus for
Positioning Machine Tool”. This was the commercial birth of the CNC technology. Figure
2.6 shows the 1958 CNC machine and figure 2.7 shows a modern CNC machine.

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 Figure 2.6: 1958 CNC Machine.

Figure 2.7: Modern CNC Machine

2.1.7 COMPUTER AIDED MANUFACTURING [ 2]

A computer-aided manufacturing system allow the manufacturer to regulate and

collaborate technical specifications to the machine in a systematic manner. The CNC
technology, which was created in the 1950s, was developed and progressed into the CAM
system.

CAM allows for easy and rapid computer programming as well as faster design
modification execution. Order placement, tool substitution, and scheduling are all
controlled by the CAM system, which integrates the CAD systems. When CAM is used

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in the manufacturing process, it increases overall efficiency; CAM is widely used in the
automotive, furniture, aviation, mechanical engineering, and electronic design industries.
The ability to customize the manufacturing process to meet customer needs and specific
designs is a huge benefit of the CAM system.

2.2 CNC Mill and CNC Router:

CNC machinery:

CNC machines use computer-controlled mechanisms to perform cuts by moving a tool

automatically around a work piece on axes in a serial manner. All CNC machines create
the product by using subtractive manufacturing, which means their work is done by
removing material from a work piece and not adding onto it. CNC: Computerized
Numerical Control (Computer + Numerical Control), the Numerical control is a type of
programmable automation that uses numbers, letters, and symbols to control processes.
CNC machining is a manufacturing process in which computers are used to control
machine tools such as lathes, mills, and grinders.

The rotational speed, movement form, and rate of movement are all factors that can be
programmed into a CNC machine to better determine the details of a cut. Although mills
and routers perform the same functions, there are some distinctions to be aware of.

Why is CNC Machining necessary?

To generate intricate curved geometries in 2D or 3D was hardly cost effective by all

mechanical means which require complex jigs to control the motions of the cutter.

• Machining components with high Precision

• Unmanned operations

• Improve production planning and increase the productivity

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Advantages of CNC Machining:

• Cheaper Tooling cost since templates and other fixtures are not required.
• Flexibility of operations, less scrap, more complex shapes.
• No need for skilled craftsmen for operating
• Easy machine adjustment to make with microcomputers and digital
readouts.
• Rapid program preparation and can be recalled at any time..

Limitations of the CNC:

• Initial cost of equipment is high

• Special maintenance and trained personnel
• Since breakdowns are costly therefore high preventative maintenance cost.

2.2.1 CNC Router

In modern machine shops, the CNC router is considered as a widely functional tool, with
its primary function to cut softer materials such as foam, wood, acrylic, plastic, and some
soft metals. It is generally constructed on a stationary table with a wider workspace, with
a spindle going along the three axes X, Y and Z.

Compared to CNC mills, CNC routers are mainly designed to run at high speeds, using
its rotational speed as the driving force in the making of cuts. Although routers usually
have three axes, for more complicated projects, there are variants of 4-6 axes that are
suitable.

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 Figure 2.8: CNC router.

CNC router highlights:

• Used for cutting softer materials such as plastic, wood and foam
• Placed with a larger workspace on a stationary table
• Includes a spindle running along the three axes
• Functions at considered high speeds
• Uses rotation speed to cut
• Makes 3D Cutting much simpler

2.2.2 CNC Mill

A CNC mill will perform basically the same tasks as a CNC router, for the most part,
although there are a few variations. Though router mills are often used for soft materials,
metals and tougher materials are usually cut by mills. It uses similar rotary cutting
equipment to those of a router, except with mills, the operation speeds are much higher.

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 Figure 2.9: CNC mill.

Most CNC mills move in an X-Y configuration instead of using a stationary table, with
the spindle moving over the workpiece on a linear axis. This means better clearance along
Z axis and allows thicker cuts for mills to do, as mills use torque instead of rotational
speed to create cuts.

CNC mill highlights:

• Designed for cutting tougher materials and metals

• Slow speeds for operation than CNC routers
• Movement in X-Y configuration
• Spindle moves along a linear axis above the workpiece for increased clearance
along Z axis
• Able to execute thicker cuts
• Makes cuts with higher torque

2.2.3 Motion of Machine:

1. Moving body fixed head (MBFH).

2. Fixed body moving head (FBMH).
3. Moving body moving head (MBMF).

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2.3 CAD / CAM:
Computer Aided Design (CAD) involves the use of computer hardware and graphics
software to generate design drawings. Modern CAD equipment enables the designer
to quickly produce very accurate and realistic images of products to be
manufactured. Computer Aided Manufacturing (CAM) is a system of automatically
producing finished products by using computer-controlled production machines.
CAD and CAM work together in that the digital model generated in CAD is inputted
to the CAM software package. The CAM software needs to know the physical shape
of the product (CAD model) before it can compose a proper set of fabrication
instructions to a production machine.[2]

2.4 CNC system elements:

A CNC machine system normally consist of six main elements:

• Part program
• Program input device
• Feedback system
• Machine control unit
• Machine tool
• Drive system
Figure below shows how those six system elements of a CNC machine works together.

Figure 2.10: CNC system elements.

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2.5 G-code:
G-Code is the language used in controlling CNC machines. It's one type of CNC
programming that CNC programmer’s use, the other type CAM programming. The
machine's CNC controller executes g-code, although there are other possibilities. Some
machines with proprietary formats can run g-code. It is the working language of CNC. To
make a part on a CNC machine, you tell the machine how to make the part using a G
Code Program [5], Table 2.1 shows some of the codes.

Table 2.1: MDI G-Code Quick Reference.

G00 Rapid motion mode.

G01 Linear Interpolation mode. Motion in a straight line at the feed rate
established by “F”.

XYZ Move to the specified coordinates.

ABC Move the rotational axis to the given angle.

S<rpm> Set spindle to rpm and start it turning clockwise.

M03

M05 Stop spindle.

M08 Coolant on

M07 Air coolant on

M09 Coolant off

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 Chapter III
Preliminary Design

3.1 Proposed design

This should be the proposed design for the Desktop CNC-Router we are working on.

Figure 3.1: Proposed Model of the CNC Router

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3.2 Main Components of CNC Router machines:
a. Frame:
The fame of the body supports the CNC machine and provide the required rigidity
to with stand and resist the forces made from cutting into the workpiece by the
cutting tool; larger models can have a welded base or legs attached for extra
support.
Most frames are either made from aluminium extrusion, steel weldments or even
wood as the frame material for cheaper option.

Figure 3.2: Router Model Frame

b. table:
The table of the CNC router machine can be made from several materials for
example: aluminum extrusion as shown in figure below or expendable material
like medium density fiberboard MDF. Commonly, the table may have features for
facilitating work holding like T-slots or hole grid.

Figure 3.3: Router Table

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c. Spindle:
A spindle can be said to be the heart of any CNC machine since it plays a huge
and a very important role in setting the potential performance of the machine. A
regular hand-held router or Dremel style tools are commonly used as spindles for
the CNC routers, for improvement a spindle with VFD “variable frequency drive”
can be used. Figure below shows the spindle, some spindles come with ATC
“automatic tool changer” at the top of the heap.

Figure 3.4: Router spindle

d. Axis Drive:
The axis drive system function is to convert the motor rotary motion into linear
motion to drive the axis into its sliding ways. There are several kinds of the axes
drive system for the CNC router machine figure 3.5 shows how the drive system
works and figure 3.6 shows an example of the axes drive system.

Figure 3.5: Drive system

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 Figure 3.6: Axis Drive
There are several factors that should be taken into consideration for choosing the
right drive system for the machine some of which are:

• Conversion of the motor’s torque to rapid movement speed at the right rpm
where the motor’s torque is at its peaks.
• Elimination of the lost motion or the backlash, which is a huge reason for
the reduction in the accuracy of cutting.
• The Cost.
• More specialized issues such as the ball screw whipping on a long-axes.

e. Ways (Axis):
Most common CNC routers have at least 3 axis x,y,z , an axes is some kind of
sliding way and a drive system that motorize the motion under computer control.
Figure below shows an example of the sliding way system.

Figure 3.7: Motion system.

V-Grooves includes the use of wheels with ball bearings that have a v shaped
groove in them, the wheels ride the edge of the rail, the rail can either be a
triangular edge on an extrusion or edge on an angled iron. The groove doesn’t
have to be v shaped since it can ride on a rounded shaft or curved edged therefore

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 it can also be cupped; V-shaped are the cheapest but the rounded is better with
accuracy.

Figure 3.8: Drivers.

f. CNC controller:
The CNC controller is the electronic part responsible for executing and running the g-
code for the programming and sending the required electrical signals to force the motors
to move in the intended required way to cut the part. Various types of software are also
used with the CNC router: CAD computer aided design for help designing the part, CAM
computer aided manufacturing to help manufacture the part designed by feeding the CAD
into the software and generating the g-code for it, there are several feeds and speeds
software for calculating the right parameters and condition for the machine to work and
perform correctly producing the required part with the intended dimension and accuracy.
g. Column(s).
h. Cutting tool.
i. Tool changer.
j. Tool holder.
k. Coolant tank.

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3.3 Structural Materials for Router:
The main goal from constructing a CNC router machine is building a lightweight
machine that can perform the exact same tasks of the full-sized CNC milling machine
without the heavy immovable parts that might cause vibration. Another reason is to have
the movable parts like the guide or the axis as light as it could be yet stiff and strong to
withstand the loads, thus causing a faster acceleration due to the lower inertia of the
movable parts mass with better accuracy due to less vibration caused by the previous
heavy immovable parts in the full-sized CNC machine with maintaining a low cost of
construction therefore The suggested structural material therefore will be:
• Aluminium
• Wood Composites

3.3.1 Design of power screws:

Power screws are used to provide the machine with the linear motion in a smooth
uniform way.in general power screws have different forms like acme form, square
form, and buttress threads. There are many types and models of power screws with
an average efficiency of between 30%-70% but the most famous one and most
efficient is the ball screw type with an efficiency more than 90%, power screws are
the most used for many reasons some of which are:
• Generate large forces like compactor press.
• Obtain precise axial movement.
• Require minimum effort to move large loads due to the high
mechanical advantage.

Types of power screws:

a. Acme form:
Commonly used for power transmission ex: lathe lead screws. They are easier to
manufacture when compared with the square thread model, an acme form is also
known for its superior root strength characteristics, and easy machining. It was
developed for machine tool drives; they can be used with split nuts and capable of
obtaining an efficiency of 70% with helix angles between 25 and 65 degrees then it
falls out. Figure below shows an example of an acme form.
22
 Figure 3.9: acme form power screw.

b. Square form:
A square form model is used for force or power transmission like linear jack clamps, it
has advantage of low friction and no radial forces being imposed on the mating nuts. A
square thread has the highest efficiency among the types of ball screws but is also the
hardest to machine however it is not preferable while using split nuts. Figure below shows
an example of a square form screw.

Figure 3.10: Square form power screw.

c. Buttress form:
This model has a strong low friction characteristic but yet is only designed to withhold
large forces and take them only in one direction, to increase its efficiency and make it as
equal as the square form then the loads are on a vertical thread. Figure below shows an
example of the buttress form.

23
 Figure 3.11: Buttress form power screw.

d. Recirculating Ball screw:

This form of power screws is used mainly for high speed and efficiency. Figure below
shows the assembly of a ball screw including the circular groove cut in the shaft and
the ball shaped nut which matches the shaft groove as well. The movement of the
balls in the groove force the nut to retain its position, when the nut rotates relative to
the shaft the balls move in one direction supporting the axial load along the groove
and once the balls reach the end they are directed back to origin by a ball guide
therefore causing the balls to be continuously recirculating.

Figure 3.12: ball screw assembly.

A recirculating ball screw has its own advantage over the conventional threaded
previously mentioned screwed but it has some disadvantages, here are some of its
advantages and disadvantages:

24
• Advantages:
1. High Efficiency more than 90%
2. Predictable life
3. Precise movement
4. No tendency for the slip-stick
5. Minimal thermal effects
6. Easily preloaded eliminate backlash
7. minimum friction
8. Smoother movement
9. Smaller size for same load

• Disadvantages:
1. Requires higher levels of lubrication
2. Tend to overhaul- Needs additional brakes if locking is required
3. Susceptible to contamination

e. Roller screws:
For this unit the nut includes several special threaded rollers arranged around the
central screw. Each roller takes part of the load. The roller screw system is
efficient and is capable of withstanding high loads. Figure below shows the
mechanism of roller screws.

Figure 3.13: mechanism of roller screw.

25
Calculations of Recirculating Ball screw:
Select work piece and tool type:
Workpiece and cutting tool selection:
▪ Work piece will be Aluminum
▪ Cutting Tool will be shank end mill Φ40 (high speed steel)
Selection of Vc and F:

Vc cutting speed [m/min] , Range of Vc from 150 to 360 [m ⁄min ]

F feed [mm] , Range of feed from 0.12 to 0.3 [mm]

Calculation of rotational Speed N (RPM):

𝑉𝑐
N= 𝐷.π [rpm]

N=rotational speed
D=diameter of tool
300
N= 40 ×318.47=2388.5250 [rpm]

Calculating the machine power:

C=feed factor ………. (C=from 1 to 1.2)
W=tool wear factor
W from 1.1 to 1.25 [light and medium milling]
Kp = power constant for milling
𝑘𝑤𝑠
Aluminium Kp= 1 (𝑐𝑚3 )

Calculating material removal rate:

𝑓. 𝑤 ⋅ 𝑑 cm3
𝑄=
60000 𝑠
d=depth of cut, d=2mm
w=width of cut, w=40mm
f=feed rate, f=0.3
0.3 × 4 × 0.2
𝑄= = 4 × 10−2 [cm3 /s]
60000

26
Efficiency factor (E) for tool:
For direct, belt drive E=0.9
Required Cutting power:
Pc= power at the cutting tool
Pc= 𝐾𝑝 × 𝑐 × 𝑤 × 𝑄 [Kw]
Pc= 1 × 1.2 × 1.1 × 4 × 10−2= 0.00528 Kw

Calculate drive motor power:

Pm= drive motor power [Kw]
𝑃𝑐
𝑃𝑚 =
𝐸
0.00528
= = 0.00587 [𝐾𝑤]
0.9

Calculate drive motor torque:

30 × Pm
Tm =
N×π

30×0.00587
Tm = = 0.234 [kN.m]
2388.525×π

Acting forces:

Figure 3.14: The acting forces

27
 𝑦𝑝
𝐹𝑡 = 𝐶𝑝 ⋅ 𝑡 𝑥𝑝 . 𝑆t ⋅ 𝑍 ⋅ 𝐵 𝑟 ⋅ 𝐷−𝑞

𝐶𝑝 for aluminium =19

𝑡 depth of cut =2mm
𝑥𝑝, 𝑦𝑝 for aluminium
𝑆t = feed per tooth
𝑥𝑝 = 0.86 𝑦𝑝 = 0.72 𝑆𝑡 = 0.018 − 0.08 = 0.08
Z number of teeth
z = 8, B, D = 40[mm]
r = 1, q = 0.86
𝐹𝑡 = (19) × (2)0.86 × (0.08)0.72 (8) × (40) × (40)−0.86 (9.81)
= 736[N]
Fx = 1.2Ft = (1.2) × (736) = 883[𝑁]
𝐹𝑦 = 0.2𝐹𝑡 = (0.2) × (736) = 147[𝑁]
𝐹𝑧 = 0.28𝐹𝑡 + tan 70 = (0.28) × (736) + tan 70 = 566[N]

Calculations of the chosen recirculating Ball screw:

t = 3mm E = 207[Gpa ] K=7
d = 15mm r = 2mm n = 10
Fc = 0.5Kg. f K = 2.8 𝜇 = 0.15
Fr = 0.001cm K1 = 0.5 L = 216mm
Fz = 566N Fx = 883N Fy = 147N
E: modulus of elasticity K: radius L: thread lead
𝑑: diameter n: angular speed 𝜇: coefficient of friction
Fz : Forces on Z-axis Fx : Forces on X=axis Fy : Forces on Y-axis
Fr
F = nFc + N
req
N = Fx = 883N
r (2 × 10−3 )
req = = = 7.14 × 10−4 m
K (2.8)
(0.001 × 10−2 )
F = 10 × 0.5 × 9.81 + × 883 = 61.41𝑁
(7.14 × 10−4 )
Q = Fz + F
𝑄 = 566 + 61.41 = 627.41N

28
 • Design calculation for strength:
dp = 13.5[mm] dm = 12.0[mm]
𝑡
𝜆 = tan−1 𝜆: 𝑙𝑒𝑎𝑑 𝑎𝑛𝑔𝑙𝑒
𝑑𝑝
(3 × 10−3 )
= tan−1 = 4.040
(𝜋 × 13.5 × 10−3 )
Q × dp (cos𝛼 × tan𝜆) + 𝜇
Mt = ×
2 cos𝛼 − (𝜇 × tan𝜆)
(627.41 × 13.5 × 10−3 ) cos 14.5 × tan (4.04) + 0.150
Mt = × = 0.9640N. m
2 cos 14.5 − 0.150 × tan (4.040)
2 𝑄 2 + (64 × Mt2 )
{𝜏} = √ , 𝜏: 𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑠𝑠
(𝜋d2m ) d2m

2 (627.41)2 + (64 × 0.96402 )

𝜏= × √
(𝜋 × 12 × 10−3 )2 (12 × 10−3 )2
𝜎y: stress
= 3970.6700[Kpa ]
𝜎y 200
{𝜏} = = = 28.570[Mpa ]
K 7

power screw is safe

• Design calculation against buckling:
𝜋2 × 𝐸 × 𝐼
𝑄𝑐 =
(𝐾1 × 𝐿)2
𝜋 2 × (207 × 109 ) × (2.03 × 10−9 )
𝑄𝑐 = = 355564.680𝑁
(0.50 × 216.0 × 10−3 )2
Q < 𝑄𝑐
power screw is safe
• Y-axis:
L = 570[mm] n = 12
N = Fz + Wt
𝑁 = (566) + (15 × 9.81) = 713.15N
Fr
F = nFc + N
req
(0.001 × 10−2 )
𝑃 = (12 × 0.5 × 9.81) + × 713.15 = 68.84N
(7.14 × 10−4 )
𝑄 = F + Fy
𝑄 = 68.84 + 147 = 215.84𝑁
𝑄 < 𝑄𝑐
power screw is safe

29
 • Calculation design for strength:
𝑡
𝜆 = tan−1
𝑑𝑝
−1
(3 × 10−3 )
𝜆 = tan = 4.04
(𝜋 × 13.5 × 10−3 )
𝑄 × 𝑑𝑝 (cos 𝛼 × tan 𝜆) + 𝜇
𝑀𝑡 = × = 0.33 𝑁. 𝑚
2 cos 𝛼 − (𝜇 × tan 𝜆)
2 Q2 + (64 × Mt2 )
{𝜏} = √
(𝜋d2m ) d2m

2 (215.840)2 + (64 × 0.3302 )

𝜏= × √
(𝜋 × 12.0 × 10−3 )2 (12 × 10−3 )2
= 1362.5400[Kp𝑎 ]
𝜏𝑚𝑎𝑥 < {𝜏}
power screw is safe
• Design calculation against buckling:
𝜋2 × 𝐸 × 𝐼
𝑄𝑐 =
(𝐾1 × 𝐿)2
2
𝜋 × (207.0 × 10 ) × (2.030 × 10−9 )
2 9
𝑄 = = 16252.730𝑁
(0.50 × 570 × 10−3 )2
Q < 𝑄𝑐
power screw is safe
• X-axis:
L = 600𝑚𝑚 n = 12
N = Fy = 147
Fr
F = nFc + N
req
(0.001 × 10−2 )
𝐹 = (12 × 0.50 × 9.81) + × 147 = 60.91N
(7.14 × 10−4 )
𝑄 = F + Fy
𝑄 = 60.91 + 147 = 796.910𝑁
𝑄 < 𝑄𝑐
power screw is safe

30
 • Design calculation for strength:
𝑡
𝜆 = tan−1
𝑑𝑝
−1
(3.0 × 10−3 )
𝜆 = tan = 4.040
(𝜋 × 13.50 × 10−3 )
𝑄 × 𝑑𝑝 (cos 𝛼 × tan 𝜆) + 𝜇
𝑀𝑡 = ×
2 cos 𝛼 − (𝜇 × tan 𝜆)
(796.91) × (13.5 × 10−3 ) cos (14.5) × tan (4.04) + 0.15
𝑀𝑡 = ×
2 cos (14.5) − (0.15) × tan 4.04
= 1.22N ⋅ m
2 Q2 + (64 × Mt2 )
{𝜏} = √
(𝜋d2m ) d2m

2 Q2 + (64 × Mt2 )
{𝜏} = √
(𝜋d2m ) d2m

2 (796.91)2 + (64 × 1.222 )

𝜏= × √
(𝜋 × 12 × 10−3 )2 (12 × 10−3 )2
= 16023.84[Kp𝑎 ]
𝜏𝑚𝑎𝑥 < {𝜏}
Power screw is safe
• Design calculation against buckling:
𝜋2 × 𝐸 × 𝐼
𝑄𝑐 =
(𝐾1 × 𝐿)2
𝜋 2 × (207 × 109 ) × (2.03 × 10−9 )
𝑄2 = = 46081.18𝑁
(0.50 × 600 × 10−3 )2
Q < 𝑄𝑐
power screw is safe

31
3.3.2 Selection of Bearings:
A bearing is a machine element that constrains the relative motion between parts to only
the desired motion, this allow free rotation around the specific axis and free linear motion
or movement; Also, to prevent any unintended motion. Bearings are classified according
to the motion they allow, the operation principle and the applied loads direction that they
can handle.

Principle of operation:
There are many operation principles for bearings those are six of which and examples
on some of them:
• Plain bearing: bushing or journal bearings.
• Jewel bearing: load is carried by an axle which is rolling slighting off the centre.
• Rolling element bearing: ball bearing and roller bearings.
• Fluid bearing: gas or liquid is what hold the load.
• Flexure bearing: motion being supported with a load element which bend.
• Magnetic bearing: load is carried by a magnetic field.

Figure 3.15: ball bearing.

32
Permitted Motions:
• Axial rotation like shaft.
• Linear motion like drawers.
• Spherical rotation like joints.
• Hinge motion like elbow.

Friction
Reducing the friction in bearings is very important for better efficiency and increase
bearing life by reducing wear and extending bearing use at higher speeds and avoiding
overheating or failure of bearing. Bearings can reduce friction by the nature of its shape,
material, mechanism or by using fluids “lubricants” between surfaces, this can be done in
different ways:

• shape: gains leverage by using rollers.

• material: bearing material used.
• fluid: the low viscosity of fluid,
• fields: using electromagnetic fields,

Speed
Each bearing type have its own operating speed limit often specified in ft/s or m/s.
Rotational bearings typically describe performance in terms of the equation D*N where
D is the diameter of the bearing often in mm and N is the rotation rate in RPM revolutions
per minute. Plain bearings normally handle lower speeds, rolling element bearings handle
higher speed, followed by fluid bearings and then comes the magnetic bearings which
limited by the centripetal force overcoming the material strength. Figure below shows
some of the bearings.

33
 Figure 3.16: Types of bearings.

3.3.3 Guide way:

Linear Motion
The linear motion system “LM” is responsible mainly for three main tasks:
• Supporting the machine parts.
• Guiding the machine linear motion with minimum frictions.
• Supporting secondary loads like torques and lateral loads.
Figure 3.17 shows an example of the linear motion system.

Figure 3.17: linear motion system.

34
Supporting machine components
The linear motion system should be able to handle the weight of machine’s
components while moving it along the linear axis and meeting linearity and precision
without any deflection in motion or slight turns to the sides, for example the linear
motion system holding the gantry and moving it along the x-axis must be able to do
so while supporting the gantry’s weight with low friction motion and no deflection.

Providing precise linear motion

Since the primary task of a linear motion system is to provide a precise linear motion
with no deflection t it should also be with minimal friction therefore choosing the right
LM system for the CNC machine is very important because it will affect every motion,
precision and accuracy of the machine.

Supporting secondary loads

Beside supporting the machine’s weight, the LM system should also be capable of
supporting secondary loads like torque and lateral loads, the system setup various
from one machine to another while some setups require only one dimensional load
rating like supporting vertical load “ weight”; other applications require multi-
dimensional load rating take the LM system for a Router CNC machine as an example
it is required to support vertical loads liked weights of components while also
supporting torsion forces due to cutting process.

Linear motion system categories:

• Fully supported system.
• Partially/End supported system.

In fully supported LM system the support is throughout the entire length motion of the
system. In such a system the ability to support load is more without having to sacrifice
linear precision or having deflection. A good CNC router machine will have fully
supported linear motion system on all of its axes, other machines may use a LM system
on x and y axis but not on the z axis rather an end support system. The length of the axis

35
has a huge role on choosing the type of system so as the length increase it becomes more
necessary to have a fully supported system like linear rails or track rollers as an example.

On the other side, there is the partially or end supported system which are supported on
the end , these systems are not so preferable due to machine weight or the forces which
can cause deflection or deformation, as example of this system is the linear rod or the
bushing setup. Figure 3.18 shows an example of the system.

Figure 3.18: linear motion system.

Advantages of Linear Guide System:

• Very robust
• High accuracy due to their construction
• High efficiency due to the use of ball bearing to roll the load
• Less work done by drive system to move load

Choosing the right bearing and guide system plays a he role in the accuracy of the
system, however there are several alternatives for an accurate linear motion for
example, the bronze bushings is known for its high load capacity but it has a low
accuracy while on the other side the profile rail linear guides have a high load capacity
as the bronze bushings but a higher accuracy. In most industrial applications a linear

36
 rolling element is the most used bearing when it comes to critical applications since
they generate much lower friction than its alternative sliding bearing therefore it can be
used with a smaller motor and drive system while still running at higher speeds they
also eliminate the effect of stick-slip that usually causes chatter, they have a predicted
lifetime and doesn’t tolerate tolerance over time period.

Round Rail Bearing System

As much as rail bushings and profile rail bearings are good linear guides but they are
not the major ones, Round rail ball bushing is a type of bearing that accommodates best
with torsion misalignment that is caused by the inaccuracies in carriage, base
machining or even machine deflection with a minor increase in stress of bearing
components. The design of self-aligning in all directions stands tall against the poor
parallelism and the variation in rail heights, this type of bearing allows smooth travel
to wider tolerance surfaces. The following table shows a comparison between the
strength of the bearings in an end system.

Table 3.1: Bearing strength

To establish an axis motion around rail guides fixing the two ends of the shaft is
necessary. Round linear bearings is able give a gap up to 24times the shaft diameter
making it more useful in the arrange of applications like pick-end-place gantry
system. The guide’s accuracy dependent only on the accuracy of the end support
mounting. Figure 3.19 shows an example of the round rail bushing.

37
 Figure 3.19: Round rail bushing bearing.
Selection Options

For round and profile rail bearings, the process of sizing and selection is similar, but
not the same. Vertical loads, horizontal loads or pitch roll or yaw moment loads, or
any combination thereof, can be loads acting on linear and guided bearings. The
magnitude and direction of loads may also vary. From the combination of the
different load vectors to which the linear bearing system load vectors are connected,
a resulting load vector must be established at each bearing. For that given bearing,
the load under which each linear bearing is subjected is called the dynamic equivalent
load. Depending on the most heavily loaded bearing, the system is then dimensioned
Due to the larger contact surface, roller rail bearings can handle higher loads
compared to ball profile rail bearings. Machine builders can downsize from an
atypical ball profile rail assembly to a smaller roller assembly without compromising
load capacity. Figure 3.20 shows an example on the selection.

Figure 3.20: selection option

38
Linear Bearing accuracy
It is the variation in the height over the travel distance, a +/- 0.0008in is the best achievable
accuracy for a 120in length in round rails while in profile rail bearings its +/- 0.0001in. in
some applications where accuracy is very critical profile rail bearings are the best option
for better accuracy, there are two other types of profile rail bearings which are ultra and
super and they can offer even a better accuracy than a standard one. Figure 3.21 shows
how the accuracy of linear bearing looks.

Figure 3.21: linear bearing accuracy.

Machining the surface to a high flatness tolerance and the addition of a reference edge can
help improve the accuracy. Preloading the bearing in both round and profile bearing is
used to remove minimize deflection by removing internal clearance in bearings, this
preload is done by generating interference fit between both the outer race rolling element
and the inner race of the bearing. However, the heavier the preload in the bearing the
smaller initial carriage to rail deflection. Preloading in rail round bearing can be achieved
by adjusting, using under sized housing bore or even over-sized shaft.

39
3.4 Control system
The controller of the CNC machine is its brain, it completes all important links between
the computer system and the machine mechanical components. The primary task of the
controller is to receive the conditioned signals from the computer or indexer and interpret
these signals to a mechanical action/motion through motors. A controller has a several
components and each of them work in unity to produce the required motor movement.
The term controller here refers not only to a specific part but to a whole machine system
that include stepper motors, servo drivers, protection security, power source, power
control, limit switch interfaces, and other components and peripherals.
Control Parts:
• Controller
• Breakout board
• Power supply unit
• Interface
• Motors
• Motors driver
• Switches

Figure 3.22: Controller system.

40
 ❖ Controller
Controllers require an operator to build a program for the controller to run, this
can be achieved by the help of several software like CAD and CAM along with
the controller software to create the required numerical code like the one
described earlier G-code.

Types of Controller software:

i. K Cam
ii. Mach3
iii. Other
In this project Mach3 will be the used software since Mach3 turns a PC into a full powerful
economical machine controller and make a regular PC able to replace the Controller unit.

Mach3 Features:
• Spindle speed control.
• Relay control.
• Full customized interface.
• Ability to generate G-code through LazyCam or wizards.
• G-code visual display.
• Allow direct importing of files like BMP, HPGL, JPG, other files
using LazyCam.
• Convert regular PC into a fully featured powerful 6-axis CNC
controller.
Figure below shows the Mach3 software and the ability to select from
a variety of operations.

41
 Figure 3.23: Operation selection in Mach3.

❖ Motors
A motor is a device that convert electrical energy into a mechanical energy that
provides the required torque for motion, figure 3.24 shows an example of motors.

Figure 3.24: Stepper motor.

Motor types
As much as there are motor models but when it comes to cnc machinery there are two
main types:
• Stepper motor
• Servo motor

42
Each one of these models get there required operation parameters like power, direction, or
rotation information from the driver or the amplifier, however there is a difference in the
way of using them and a better preference for each type which will be illustrated further
more next. Figure 3.25 shows a comparison between a stepper motor and a dc motor.

Figure 3.25: Stepper motor vs DC motor rotation

43
Open loop stepper vs closed loop servo
A. Open loop
An open loop system is a system where the communication between a motor and the
control system is one way where there is no feedback in the figure 3.26 shows an example.

Figure 3.26: Open loop System

Open loop system uses stepper motors where the stepper motor does not require a feedback
hardware. Open loop system for CNC is much simpler and cheaper than a closed loop
system.

44
B. Closed loop:
closed loop system has a feedback with an encoder to monitor motor’s output, a closed loop
system can correct flaws and errors in velocity, position, and acceleration. Figure 3.27 shows
how a close loop system works.

Figure 3.27: Closed loop system

• Stepper motors advantages:

i. Ability to operate in open loop
ii. Position error for a single step.
iii. non‐cumulative errors inbetween steps.
iv. Discrete pulse controls the motor position
• Stepper Motors disadvantages:
i. Fixed increments of motion.
ii. Lower efficiency.
iii. High oscillation overshoot to a step input.
iv. Limited power output.
v. Limited ability to handle large inertial loads.

Spindle selection
Workpiece and cutting tool selection:

▪ Work piece will be Aluminum

▪ Cutting Tool will be shank end mill Φ40 (high speed steel)

45
 Chapter IV
Conclusion and Future Work

4.1 Conclusion:
To conclude what this project have discussed so far is the main differences between CNC
mill and CNC router, the history of milling machine through time, how it started and how it
has been developed over time, it also discussed the main differences between conventional
and non-conventional machining. This project also illustrate the components of a CNC
router, how they are connected together and how the whole system works as a whole, the
design calculations for stresses, strength, bearings, power screw, spindles to decide the right
choices for the machine’s bearing, type of power screw and spindle.

In conclusion, the CNC router is a better choice when it comes to high productivity and fast
production needs. When cutting in soft material, a CNC router is a good choice and for 3D
modeling it will also be the better choice. A CNC router is much cheaper and lighter in
weight when compared with the CNC mill and require smaller area. The following
conclusions are extracted:

• After reviewing the previously existing CNC machines and the CNC routers it was
found that a CNC router is much cheaper and easier to operate. A suitable and simple
model was selected and proposed.
• Some of the machine components have been preliminary designed and will be
manufactured like the power screw while, other components like the motors and
bearings will be selected and purchased.
• The control unit will be chosen to be based on the Mach3 software program since it
is easier to use.
• Purchasing and manufacturing of the parts will be completed in the in the Grad II
period of study along with the simulating and testing of the final design will be
conducted.

46
4.2 Future work:
A detailed timeline for manufacturing simulating and testing of the proposed machine is
presented in the following Gant chart.

Table 4.1: Future plan Gant chart.

2021
Activity/period
APR MAY JUN JUL

Drawing the final design of the

machine and the calculations

Programming and Simulation of

machine

Market survey and analysis

Component purchasing and

manufacturing

Testing the machine and presenting it

Report writing activities and

presentation

47
 References
[1] Koren, J. (1983) Computer Control of Manufacturing Systems, 1st Edition, McGraw-
Hill, Tokyo, 40(2):603–614.
[2] McMahon, C. and Browne, J. (1998) CADCAM—Principles, Practice and
Manufacturing Management, 2nd Edition, Addison- Wesley, Reading, MA, 47(2):525–
540
[3] Diamond, W.J. (2001). Practical experiment design for engineers and scientists. Third
edition. John Wiley & Sons. New York.
[4] MCP2551 High-Speed CAN Transceiver Data Sheet (2003). Microchip Technology,
Document No.DS21667D.
[5] https://www.sciencedirect.com/science/article/abs/pii/S0890695598000182 [Accessed
20 Dec. 2020]
[6] https://www.sciencedirect.com/science/article/abs/pii/S0924013601009414 [Accessed
15 Jan. 2021]
[7] http://www.stadna.com/forums/index.php?mode=t&t=8279.html [Accessed 25 Jan.
2021]
[8] https://www.americanmicroinc.com/cnc-milling-vs-cnc-router.html [Accessed 22 Feb.
2021]
[9] L. Houpert, F. Chevalier. (2012) Rolling Bearing Stress Based Life—Part I: Calculation
Model. Journal of Tribology 134:2.

48
 ‫جامعة اكتوبر للعلوم الحديثة و االداب‬
‫كلية الهندسة‬
‫قسم هندسة النظم الصناعية‬

‫تصميم و تصنيع الة تعمل بالتحكم الرقمى بواسطة الحاسوب‬

‫مشروع التخرج‬
‫قدم ضمن متطلبات درجة الباكلوريوس في الهندسة الصناعية و النظم‬

‫إعداد‬
‫‪١٦٤١٩١‬‬ ‫عبدهللا وليد عبدالعزيز‬
‫‪١٧٤٦٩٩‬‬ ‫عمرو هشام فتحي‬

‫أشـــراف‬
‫الدكتور‪/‬طارق الحسينى‬

‫‪Fall 2020‬‬

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 ‫الخالصه‬
‫ادخلت آالت التحكم العددي الحاسوبي تحسينات تدريجية في مناطق التصنيع‪ .‬في الماضي ‪ ،‬لم يكن‬
‫تحقيق االنتاجية حتي المستوي المثالي ممكنا بسبب عدد من الجوانب السلبية مثل ازعاج االشكال و‬
‫االحجام‪ ،‬غياب العمال المهرة‪ ،‬و اكوام الهدر و الخردة بسبب االخطاء و مستويات الجودة و الدقة‪.‬‬
‫من خالل استخدام االت التحكم العددي الحاسوبي‪ ،‬يمكن التغلب علي كل هذه الجوانب السلبية‪ ،‬و‬
‫سيكون هذا هو هدف المشروع الظهار اهمية هذه االالت‪.‬‬
‫الهدف من هذا المشروع هو تصميم و تصنيع آله تعمل التحكم الرقمى بواسطة الحاسوب موضعيه‬
‫صغيره‪ .‬ال تعد اجهزة سطح المكتب بديال عن نظيرتها كامله الحجم ولكنها اقل تكلفه و سهلة‬
‫االستخدام و تتطلب مساحة صغيرة‪.‬‬
‫فى هذا المشروع‪ ،‬سيحدث تصميم و تصنيع نموذج أولى لجهاز التوجيه اآلله بعد مراجعة اشهر‬
‫النماذج الموجوده سابقا‪ .‬سيتم اجراْ حسابات التصميم الختيار أبعاد العناصر المختلفه للجهاز‪ .‬ثم‬
‫تطوير نظام كهربائى يتضمن التحكم و البرمجه و الربط بين وحدة التحكم و وحدة الكمبيوتر و‬
‫الجهاز‪.‬‬

‫تصميم آالت‪ ،‬مواد‪ ،‬التصميم الحاسوبى‪ ،‬آالت التحكم العددي الحاسوبي‪.‬‬ ‫الكلمات البحثية‪:‬‬

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