International Interdisciplinary Journal of Scientific Research Vol. 1 No.

3 December, 2014

DESIGN AND FABRICATION OF A CNC MACHINE FOR

ENGRAVING AND DRILLING

Khan LA 1, Mehtab U 2, Hasan EU 3, Hussain Z 4

1
Associate Professor/Associate Dean University of Lahore Islamabad Campus

2,3,4
Department of Mechatronics Engineering, Air University, Pakistan

Abstract
The paper is focused on the research of On-machine measurement system for a CNC multi-axis milling
machine. This research is aimed at the suitable selection of measuring parameters for On-machine
measurement system in order to reach an accurate and reliable quality control of the mechanical part.
Theoretical information and overall concept of research are also presented.

Keywords— CNC multi axis milling machine, on-machine measurement, quality control

Introduction
The importance of improving machine accuracy is well recognized due to increasing demand of reducing the
product dimensional tolerance. Quality control is one of the important parts of production process which can
be performed through many possible ways with different measuring gauges and equipment. New products
following trends of designers and requirements of industrial applications with free form surfaces demand
instruments with high ability of measuring. Regarding many advantages of On-machine measurement
system, the utilization of the system has become a subject of many researchers. These systems allow
controlling the parts directly on the machine tool, and also the process can be integrated directly to the
machining process, whereas the delays from transportation and measuring process performed on coordinated
machine are omitted.

System Overview
The CNC Engraving Machine consists of an X-axis, Y axis (gantry, Cutting table, Spindle, Base & Frame),
and Z-axis linear drive system (plunge arm, frame etc). However, CNC Control card and Computer are the
typical parts of a CNC machine and together formed the complete control unit of the machine. A standard
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International Interdisciplinary Journall oof Scientific Research ISSN: 2200-9833
33 www.iijsr.org

system configuration is shown in Fig ig 1, showing the essential parts of a CNC m machine. Ball screw
mechanism is used for 3 axis drive sys
ystems as it provides reliability and durability of to the system. This
mechanism has a high mechanical effici
iciency and a very low cost of maintenance. The he actuators used were
stepper motors as accurate rotation was
as required in the process and stepper motor pro rovides such accuracy
without any compromise at torque.

Fig
F 1 System Flow diagram

Mechanical Modeling

+ = net (1)
1)

Electrical Modeling
Using Kirchoff’s Voltage Law
V Input =

(2)
2)
The net torque of stepper motor is
m sin ∆ (3)
3)
m = hold on/ rated = 1.5 Nm/A
Substituting (1) in (3)
+ = m sin ∆ (4)
Now, Substituting (2) in (4)
+ = m sin ∆ "

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International Interdisciplinary Journal of Scientific Research Vol. 1 No. 3 December, 2014

Taking Laplace
# $ #% &#' m sin ∆ () # *(5)
→ ,-./ 0/1-23 4.5 27-#
8 % 9% 9%
% %
0.318 0.0179 " 6.28 4.01 " 10BC DE
Substituting values in (5)
4.5
# $4.01 " 10BC # % 1.5 #' 1.55 60 " 2 F 3.21 0.05 G
#
So,
BI.JK BI.CLM
- 0.17 − 0.209. 0.034. (6)

S.No Parameter Value

1. ∆ 2
2. 60
3. M 0.32 kg
4. R 0.0179 m
5. Fc 9.81 N
6. b 1.56 N/s
Table 1 Parameters used for the solution of equations from 1 through 5

Spindle Motor Power Calculations

Input Power = VI
Efficiency = 80%
MJ
POutput = 80" W = 7.68 W
NII
P required = required " 9
required → Required Torque for routing PCB (Copper + Bakelite or Fiber)

required = 0.012 Nm
OP
9 = 628.3 )QR
P required = 7.54 W
P required < P Output
Motor can be used.

S.No Parameter Value

1. OP
628.3
)QR
RPM
2. Input Voltage 12 V

3. Current 0.8 A
4. PInput 9.6 W

Table 2 Parameters used to calculate spindle motor power

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International Interdisciplinary Journal of Scientific Research ISSN: 2200-9833 www.iijsr.org

Spindle Motor Modeling

RPM = 6000
OP
9 = 628.3 )QR
tm = K Im (7)
E = k 9m (8)
N%
K= = 0.019 V/s
J%L.C
G=1
Ro = G Ed / Im = 15 Ohms
Using Newton’s 2nd Law of Motion
∑ = M - b9m – L (3)
IM = M / K
Using Kirchoff’s Voltage Law
EM = G ED - Ro IM
EF = h 9m
e = ED - EF
EM = Ge + Ro IM (9)
G=1
So,
M = K " (ED - h 9m - k 9m) Ro (10)
Substituting equation (5) in equation (3)
9m + b9 m = k/ Ro [Ed - h9m - k 9 m] – L (11)
9 m = [JD + (B+K / Ro + K h/ Ro) = – L + K Ed / Ro
2
(12)
B= FC/9 = 0.02/628.3 = L max / Imax = 0.012 / 0.8 = 0.015
By using the values given in table 3and solving equation (7), we get
9 m [(1.28 D +1)] =17 Ed – 6.6 x 104 L
T, = Static Gain = 17
,
= Disturbance Sensitivity = -6.6 x 104
V , = Time Constant = 1.28 seconds
M.WK "NIXY
Natural time constant = J / B = = 3 seconds
C.NL "NIXY
Homogenous complimentary solution is
9 m (1.28 D + 1) = (17" 2) - 6.6 " 104 (6 " 10-5)
9 m (1.28 D + 1) = 200 (13)
9 m (1.28 D + 1) = 0
D = -0.78
9 mh = A e-0.78t
Complimentary solution is
%II
9 mc = N.%L N
9 m (t) = A e -0.78t
+200
Initial conditions at 9m = 0 and t=0
9m = 0
0 = A +200
A = -200

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International Interdisciplinary Journal of Scientific Research Vol. 1 No. 3 December, 2014

So,
9 m (t) = 200 (1 – e-0.78t)

S.No Parameter Value

1. J 9.54 x 10-5 Nm

2. FC 0.02 (2000
RPM)
3. 9mc 200

Table 3 Parameters used for spindle motor modeling

Ball Screw Calculations

Required Accuracy = 0.0254 mm
Step of motor = 2O
%
L "( ) = 0.0254
CJI
L = 4.572 mm (Pitch of Lead Screw)
Percentage of Error = 1.57 %
Can be neglected. OK to use

Conclusion
The project started with a machine capable of only point to point motion with many drawbacks (accuracy,
jerks etc).The existing machine features are compared with the professional CNC machine.
After comparison and making the required improvements, the machine is in a position to mill complex
contours on PCB, soft wood and soft metals with considerable accuracy and speed. Achieving this primary
goal is the result of improvements in both electrical and mechanical design. Exploring new software with
better capabilities also helped us in achieving this goal. The workspace and job clamping system is also
improved.

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International Interdisciplinary Journall oof Scientific Research ISSN: 2200-9833
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Z-axis Tool X-axis

axis
Y-axis
PCB sit-in for engraving
ing and drilling
d

Fig 2 Fabricated working model of CNC

CN engraving and drilling machine

Fig 3 PCB board engraved by the deve

eveloped CNC machine
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International Interdisciplinary Journal of Scientific Research Vol. 1 No. 3 December, 2014

References

[1] Katsuhiko Ogata, Modern Control Engineering, 4th Edition, Prentice Hall Of India, New Delhi, 2004

[2] Kelly James Floyd, Patrick Hood-Daniel, Build Your Own CNC Machine, 1st Edition, Springer-
Verlag, New York, 2009.

[3] Geoff Williams, CNC Robotics: Build Your Own Shop Bot, 1st Edition, McGraw Hill, New York,
2003.

[4] Seames, S. Warren, Computer Numerical Control, 4th Edition, Thomson Learning Inc., New York,
2002.

[5] Overby Alan, CNC Machining Handbook: Building, Programming, and Implementation, 1st Edition,
McGraw Hill, New York, 2010.

[6] Madison James, CNC Machining Handbook, 1st Edition, Industrial Press Inc., New York, 1996.

[7] Albert Alan, Understanding CNC Routers, 1st Edition, FPInnovations, Ottawa, 2011.

[8] Valentino James , Goldenberg Joseph, Introduction to Computer Numerical Control, 5th Edition,
Prentice Hall, New York, 2012