ACKNOWLEDGEMENT

I take this opportunity, to express my sincere gratitude towards all the people who
are directly or indirectly supported me for successful completion for this seminar.
First and foremost, I am grateful to Prof. D. D. Sancheti being my seminar guide;
he has been a constant source of motivation for me. He has generously given his
time and expertise in checking the minute details of the report. During this seminar I
experienced that the direction of GURU plays very important role in our life. I am
very thankful for his valuable recommendation and suggestions.

I pleasently thankful to Prof. D. H. Darekar (Seminar co-ordinator), Dr. S.D.

Sancheti(HOD of Mechanical) and Dr. M. D. Kokate (Principal, College of
Engineering, Chandwad.) for providing such opportunity to me.

All this is possible due to the blessings of my parents. I would like to thank all my
teachers, friends for giving the really wonderful environment during the entire
period of seminar.

Mr. Khanore Kiran Anil

Seat No: T150410889

TE-A (MECH)

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 LIST OF FIGURES
Fig.No. Description Page No.
1 Cnc Router Machine 6
2 Block Diagram Of Cnc Machine Design 8
3 Mechanical Setup 9
4 Cnc Machine Viewed From Top Left Corner 9
5 Actual Design Of Cnc 10
6 Basic Cad Design Of Cnc 10
7 Block Diagram Of Electronic Design Of Cnc Machine Based On 11
Microcontroller With Some Supporting Software.
8 Stepper Motor 12
9 Arduino 13
10 Stepper Motor Driver 13
11 Actual Machine & Working 14
12 Workpiece On Cnc Router Before Machining 15
13 Workpiece On Cnc Router After Machining 15
14 Furface Finish Measurement 15
15 (A)Marking Result On Wood Board (B)Marking Result On Pcb 16

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 CONTENTS

SR.NO. DESCRIPTION PAGE NO.

Acknowledgement I

List Of Figures Ii

Contents Iii

Abstract Iv

1 Introduction 1

2 Objectives 2

3 Literature Review 3

4 Methodology 4

4.1 Researchmethod 5

4.2 Mechanical Design 5

4.3 Design 7

4.4 Electronic Design 8

5 Components 9

5.1 Stepper Motor And Accessories 9

5.2 Power Supply 9

5.3 Stepper Motor Driver 10

6 Results And Analysis 13

7 Future Scope 14

8 Conclusion 15

9 Refferences 16

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 ABSTRACT

This paper discusses the design and realization of complex 3-axis CNC machines based on
microcontroller which combined with spindle drill. This machine can be used for Cutting, Engraving
and Marking on wood, acrylic and PCB objects. Design picture that have been made on the PC sent to
the microcontroller using serial communication then CNC perform execution on object according to
point coordinates. Drill spindles will create patterns on objects automatically according to the design
drawings. After testing, the CNC machine can be used for cutting, engraving and marking on wood,
acrylic and PCB to 2D or 3D objects with 98.5% of carving accuracy and 100% of depth accuracy.
This machine works on a object with maximum size of 20 x 20 cm.

Keywords: CNC Carving Router, Arduino Microcontroller, Universal G code generator,

Stepper and Spindle motor, CNC Router, Surface roughness (SR), Taguchi methodology,
ANOVA.

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 3 Axis CNC Router

1.INTRODUCTION
Working with automatic mechanical equipment demands precise, accuracy, speed, consistency and
flexibility. In this case it takes the help of embedded computer applications to do the job. One of the
mechanical equipment combined with microcomputer that has been widely used is a CNC machine
(Computer Numerically Controlled). CNC machines are used for mechanical work such as cutting,
engraving, drilling and others. The computer technology used to control, parse and execute certain
objects based on user command. In the manufacturing industry, the use of CNC machines greatly
affects the increased production .

In Indonesia, CNC machines have not been developed so that they are imported directly from other
country. This has an impact on the industry that is difficult to develop because the price of CNC
machines still expensive. The challenge is how to make CNC machines with good performance but low
cost so that it can contribute to the acceleration of domestic manufacture industry.

CNC machines are popular and widely used in the industry is a CNC that can form objects on acrylic,
glass, wood and plate, mostly using laser, knife, or drill as cutting media. Research on the manufacture
of CNC machines and fundamentals of embedded algorithms with the aim of producing high
performance CNC machines with low cost has been widely practiced. Research about realization of
low cost CNC machine by Jayachandraiah , discusses the development of a low cost 3-Axis CNC
router. This research is main literature review on hardware dan mechanic design. Research by Paulo,
realizes a 3 axis CNC machine as well as a LabVIEW-based application program as an instruction
giver. The paper does not specifically specify the use of the CNC machine. Other realization of CNC
machine by Ali, present a controlling system for CNC machines to mill and drill PCB board also
performed by. Object of PCB result of milling and drill and detail of test result not shown in paper.
Research on the development of algorithms for CNC machine control by Desai, in his paper discussed
the development of algorithms for interpreters and interpolators and then tested on CNC machines for
linear as well as circular interpolation.

Other fundamental research by Awari, conducted a study for the Selecting parts for low cost CNC
milling machines that can be used in Small Scale Industry. The realization of CNC machines by Pawar
to draw objects. The main purpose of this work is to make efficient, reduce errors, and also increase the
accuracy of the production. However in that paper has not been discussed in detail these parameters.

From the review of the studies described above can be concluded that research on CNC both hardware
manufacture and algorithm development is active in order to produce a good performance CNC
machine but still at a low cost. Therefore in this paper is discussed a design of cheap 3-axis router CNC
machine based on microcomputer as its main control. In this CNC machine mounted spindle drill that
can move automatically by stepper motor. This CNC router machine can be used as a tool to form 3-
dimensional objects such as cutting, engraving, marking on wooden, acrylic and PCB objects. This
paper also discussed in detail the results of testing the CNC performance parameters.

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 3 Axis CNC Router

Fig.1 CNC Router Machine

2. OBJECTIVES

The main objective of this project to develop a low cost automatic mini CNC machine for PCB
drawing and drilling, wood engraving and glass cutting. This system reduces the cost of machine and
increases the flexibility

3. LITERATURE REVIEW

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 3 Axis CNC Router

1. Suhas Magdum, Akshay Kurle, Prajay Kharat, Ismail Mallick, Pravin Bamane: To reduce the
size of machine with computer ability, mini CNC which is also known as CNC Router is
introduced. In the past few years, there have been an increasing number of enthusiast peoples
and businesses invested in a carving router system. In this paper, we are going to discuss the
development of low cost CNC Carving Router machine.
2. M.Bhavani, V.Jerome, P.Lenin Raja, B.Vignesh, D.Vignesh: The aim of this project is used
to reduce cost and complexity of machine. This project deals with the design of automatic
CNC machine for PCB drawing and drilling, wood engraving and cutting, glass cutting.
3. R.Ginting, S. Hadiyoso and S.Aulia: This paper discusses the design and realization of
complex 3axis CNC machines based on microcontroller which combined with spindle drill
Drill spindles will create patterns on objects automatically according to the design drawings.
After testing, the CNC machine can be used for cutting, engraving and marking on wood,
acrylic and PCB to 2D or 3D objects with 98.5% of carving accuracy and 100% of depth
accuracy.
4. Mr.Dhruv H. Patel, Prof. V. N. Patni : In this paper we have study on CNC Router, influence
of various machining parameters like, tool speed (rpm ), tool feed (mm/min), and depth of cut
(mm). In the present study, experiments are conducted on Composite material of Acrylic resin
and Aluminium TriHydrate with three levels and three factors to optimize process parameter
and surface roughness.
5. Dr.B.Jayachandraiah, O.Vamsi Krishna, P.Abdullah Khan, R.Ananda Reddy : : Increase in
the rapid growth of Technology significantly increased the usage and utilization of CNC
systems in industries but at considerable expensive. The idea on fabrication of low cost CNC
Router came forward to reduce the cost and complexity in CNC systems. The lower cost is
achieved by incorporating the features of a standard PC interface with micro-controller based
CNC system in an Arduino based embedded system.

4. METHODOLOGY

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 3 Axis CNC Router

Taguchi Method Taguchi Method is developed by Dr. Genichi Taguchi, a Japanese quality
management consultant. The method explores the concept of quadratic quality loss function and uses a
statistical measure of performance called Signal-to- Noise (S/N) ratio. The S/N ratio takes both the
mean and the variability into account. The S/N ratio is the ratio of the mean (Signal) to the standard
deviation (Noise). The ratio depends on the quality characteristics of the product/process to be
optimized. The standard S/N ratios generally used are as follows: - Nominal is Best (NB), Lower the
Better (LB) and Higher the Better 68 (HB). The optimal setting is the parameter combination, which
has the highest S/N ratio. In this study lower the better is used.

The G code is interfaced with Arduino CNC based controller by GRBL module which is used to
convert the code inconvenient controller code i.e serial to USB converter. Hence it acts like interfacing
module between PC to Controller.

This code is further passed to stepper motor by easy drivers which converts the code and as per
instructions the steppermotor moves. We need three axis X,Y,Z which operates as follows X stepper
motor move left and right Y steppermotor moves front and back and Z stepper motor up and down as
per given dimensions these axis’s will move on..

4.1 Research Method

The first step in the operation of CNC machine was calibrating the tool, it was aimed to know whether
the stepper motor and any other system were working according to the program that has been
configured. Followed by setting the starting position of the spindle drill on the CNC machine using
Universal Gcode Sender software both automatically and manually by hand spinning. Spindle drill
speed can be set up to a maximum speed of 12000 rpm (rotation per minute). After the CNC machine is
calibrated, the design with the *.gcode extension format was uploaded using Universal Gcode Sender
to Arduino Uno with serial communication.

The microcontroller will read the data as a command and provide logic to the A4988 motor driver. The
data received by the motor driver was used to drive 3 Nema 17 X, Y and Z axis stepper motors, so that
a pattern will be formed on the object according to the design. The whole system block diagram that
has been designed is shown in Figure 1.

4.2 Mechanical Design :

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 3 Axis CNC Router

Fig.2 BLOCK DIAGRAM OF CNC MACHINE DESIGN

The main tools in mechanical design consist of multiplex board, stepper motor, linear bearing, ball
bearing, linear shaft, leadcrew and nut, coupling beam, power supply and spindle drill. Figure 2 is a 3D
design of CNC machine made using AutoCad software.

Fig.3 MECHANICAL SETUP

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 3 Axis CNC Router

Fig.4 CNC MACHINE VIEWED FROM TOP LEFT CORNER

4.3 Design

A CNC could be designed various ways. One of them are fixed router with movable bed type and
another type of design is with 3axis router movement what we have used here. A computer aided
design was created first to analyse

Fig.5: ACTUAL DESIGN OF CNC

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 3 Axis CNC Router

Fig.6: BASIC CAD DESIGN OF CNC

4.4 Electronic Design:

Fig.7 Block Diagram Of Electronic Design Of Cnc Machine Based On Microcontroller With Some
Supporting Software.

The electronic system used on microcontroller based CNC machine was the power supply which used
as a voltage source on personal computers and CNC machine. Personal computer was used as a device
to run some software such as Xloader, Universal Gcode Sender, and Arduino IDE, also to send design
file to Arduino Uno microcontroller using serial communication. 12V 10A power supply was used as a

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 3 Axis CNC Router

voltage source for A4988 driver motor to run the 3 Nema 17 stepper motors which controlled by
Arduino Uno microcontroller, and 12V fan voltage source was used as a driver motor and Arduino Uno
cooler to avoid overheating that could damage the component. 48V 10A power supply was used as a
voltage source for spindle drill, the voltage that goes into the spindle drill was set using a motor
controller. The 3 Nema 17 stepper motors will move the spindle drill in the direction of the X, Y and Z
axes, so that the object can be formed in the wood board according to the design. Display of
microcontroller based CNC machine that has been built can be seen in Figure 4.

5. COMPONENTS

5.1 Stepper motor & Accessories:

It’s a combination of stepper motor drive connected with GT2 pulley with Grub screw that is
mechanical linear bar and linear bearings that drives rotational motion into liner motion with minimum
friction. Traveling bar dimension 4mm X 250 mm for Y-Axis and 3 mm X 184 mm for X-Axis.Geared
Stepper Motor with 1:30, 12V. The stepper motor as represented in Fig. 2 have 1/30 step angle and the
speed is directly proportional to the pulse frequency where it stands of the higher the output voltage
from the easy driver the more level of torque drive. Microcontroller Board: Uno r3 it’s an Arduino
Board it’s selected to be the control unit in this project, which it’s used as a motion control board. The
Arduino Uno is a microcontroller board based on the ATmega328 as shown in Fig. 3. It has 14 digital
input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz ceramic
resonator, a USB connection, a power jack, an ICSP header, and a reset button. It contains everything
needed to support the microcontroller; simply connect it to a computer with a USB cable or power it
with an AC-to-DC adapter or battery to get started.

Fig 8:STEPPER MOTOR

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 3 Axis CNC Router

5.2 Power Supply:

12V SMPS (Switch mode Power Supply) is used for stepper motor driver. 2V SMPS is used to power
the microcontroller board (Arduino Uno3). The microcontroller is flashed with GCODE interpreter
firmware written in optimized ‘C’ language.

Fig 9:ARDUINO

5.3 Stepper Motor Drivers:

It’s kind of driver that receive steps signal from microcontroller and convert it into voltage electrical
signals that turn the motor. This driver is called l298n Driver V4.5 as shown in Figure.5 that required
6V – 30V supply to power the motor which can power any type of step motor.

Fig 10 STEPPER MOTOR DRIVER

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 3 Axis CNC Router

Fig.11 ACTUAL MACHINE AND WORKING

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 3 Axis CNC Router

Fig. 12 Workpiece on CNC Router before machining

Fig.1 3 Workpiece on CNC Router after machining

Fig 14: SURFACE FINISH MEASUREMENT.

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 3 Axis CNC Router

6. RESULTS AND ANALYSIS

To be able to test the CNC machine in doing cutting, engraving and marking into the wood board, the
first step that must be prepared was making the design form. Then prepare the wood board in size of
the design form and then clip above the CNC machine cross section so it won’t change position during
the workmanship. Upload the design using Universal Gcode Sender software into the Arduino using
serial communication.

Cutting System Test

Cutting is a technique for cutting wood using a drill bit with a shape according to the design. The
cutting system was tested on a wood with 20mm thickness, using 3mm endmill drill bit, 12000 rpm
spindle speed and 20mm cutting depth. Image design using Vetric Aspire 8.5 software, design example
is a square shape with 6x6cm width. Cutting test process can be seen in Figure 5.

EngravingSystem Test
Engraving is a technique of carving on wooden material surface with different depths, so images or
letters can be recognized. The engraving system was tested on a wood with 20mm thickness, using
3mm vbit 600 drill bit, 12000 rpm spindle speed and 7mm engraving depth. Image design using Vetric
Aspire 8.5 software, design examples using writing combined with engraving pattern. Engraving test
process can be seen in Figure 6.

Marking System Test

Marking is a technique of carving on material surface with the same thin depths. Usually marking was
used to put a mark or a brand on a metal or a non metal material. The marking system was tested on a
wood with 20mm thickness, using 3mm vbit 600 and endmill drill bit, 12000 rpm spindle speed and
1mm and 0.5mm marking depth. Image design using Vetric Aspire 8.5 software, sample design using
writing combined with carving pattern. In addition to wood, the marking also tested on a PCB to create
the electronic circuit as shown in Figure 7.

(a) (b)

Fig 15. (a) Marking result on wood board. (b) Marking result on PCB.

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 3 Axis CNC Router

7. FUTURE SCOPE

The machine can be replaced by a laser to make it work like a laser engraving or cutting machine.
Engraving machine can be used on wood. The pen can also be replaced with a powerful drill so that it
can be used for both milling and drilling purposes. The servo can be replaced with a stepper motor and
the pen with a 3-D pen to make it a 3-D printer which can print objects with dimensions. By
extrapolation of the axes, the working area of the machine can be extended keeping the algorithm
unaltered.

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 3 Axis CNC Router

8. CONCLUSION

The CNC router machine was successfully built using ATmega328p and IC4988 microcontrollers
combined with 3 Nema 17 stepper motors, with 20x20cm cross-sectional area and using 500 Watt
Spindle Air Cooled drill type.The CNC machine can be used for cutting, engraving and marking on
wood to form 2D or 3D objects with 98.5% carving accuracy and 100% depth accuracy. The process of
synchronizing the 3 stepper motors was controlled using GRBL library and Universal Gcode Sender
Software.

1. From the graph of S-N ratio it can be observed that optimal value of surface finish is obtained at first
level of Tool feed, third level of Spindle speed and second level of Depth of cut.
2. Optimal value of surface finish is 0.79 μm.
3. From the ANOVA it can be seen that percentage contribution of feed rate is maximum and it means
Feed rate is the most dominating factor for modelling surface finish.
4. Taguchi robust design is suitable for modelling surface finish in CNC Router.

Considering the above efforts by researchers, the aim of these paper is to give the effective solution to
the small-scale industries and hobbyist people, who are really looking for the quality and productivity
using the CNC router for different materials including wood. Hence the aim of achieving the dual goal
in single stroke is performed on CNC router machine used for manufacturing of precise part and to
reduce cost of machine without any imperfection in accuracy or precision of machine.

This project is about building a mechanical prototype of a CNC ROUTER which is able to draw a PCB
layout and Wood engraving.This setup of hardware with a combination of G-code gives better accuracy
and reduces the work load. G code make easy to find the information of locations of all stepper motor
moving, as the status of our moving motor are directly seen on computer hence we can start or stop the
machine whenever we are needed. Making a small machine brings an flexibility to do work.

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 3 Axis CNC Router

9. REFFERENCES
1) Siripen Supadarattanawong and Supasit Rodkwan, “An Investigation of the Optimal Cutting
Condition’s in Parawood Machining Process On a CNC Wood Router”- Kasetsart j. (Nat. Sci.
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