A Low-cost Web-based Learning Platform for

CNC Machining Education

N. Muthupalaniappan, A. Maruthupandi, S. Pandian*, A. John Paul Antony and Shunmugham R.

Pandian, Senior Member, IEEE

National Manufacturing Policy sets an ambitious target of 25%

Abstract-Computer numerical control (CNC) machines play a share of manufacturing in GDP and manufacturing employment
central role in modern manufacturing. CNC machining skills of 100 million by the year 2022. Every new manufacturing job
provide high-paying manufacturing jobs to graduates of
also creates an additional two to three jobs in related activities.
engineering and technology. Hands-on laboratory instruction is
essential for effective student learning in the area of
In 2009, China's manufacturing workforce exceeded 100
CAD/CAM/Manufacturing Technology, but the high cost of million, whereas around the same time India's organized
commercial and even educational CNC machines like mills and manufacturing sector employment was less than 11 million.
lathes constrains the scope of instruction in CNC machining. In Micro, small, and medium enterprises account for 95% of total
this paper, an inexpensive two-axis lathe prototype is developed industrial activity in India [3]. Moreover, in terms of the
using off-the-shelf materials and components, open source Global Manufacturing Competitiveness Index in 2010, India
hardware, and open source CAM and CNC software. The
was second in the world next only to China and ahead of South
machine can be adapted for large scale use in engineering colleges,
Korea (third) and USA (fourth). It was predicted to maintain its
polytechnics, and industrial training institutes (ITIs). To make the
rank in 2015 [3].
CNC learning even more affordable, accessible and less resource­
intensive, a web-based learning platform for using the lathe is
India has a large youth population (the so called
developed. demographic dividend) who must be provided gainful
employment. The manufacturing sector offers promise in this
Index Terms- CNC lathe, CAM, Arduino microcontroller, venue for graduates and dropouts of colleges, polytechnics,
web-based learning. ITls, and high schools, since with increasing automation of
software and knowledge work the hitherto productive
information technology (IT) sector that directly employs 2.5
I. INTRODUCTION million cannot be expected to provide major employment to
AS economies evolve, historically they make the this segment of the Indian youth population. As China's
transition from agricultural (primary) sector, to population ages rapidly and its factory wages keep rising, an
estimated 85 million manufacturing jobs are expected to be
industrial (secondary) sector, to services (tertiary) sector. For
outsourced from China to other countries, including India [4].
example, the share of agriculture in Indian economy declined
Accordingly, the Indian government has recently started a
from 51.9% in 1950-51 to 13.7% in 2012-13, when industry
Make in India campaign to promote the manufacturing industry
had 21.5% and services had 64.8% share [1]. In modern
[5]. However, the success of this campaign depends very much
economies, the manufacturing industry sub-sector provides on the availability of high quality manufacturing technology
numerous high-quality, high-wage jobs. With 17.5% of the education and training, which in turn needs affordable teaching
world's population, India's manufacturing GDP output was the and training equipment and other educational resources in the
tenth largest in the world at US$240 billion in 2013. However, areas of CNC machining, robotics (FMS and CIM) and 3D
India's Asian neighbor China, with approximately 20% of the printing.
world's popUlation, has become the World's Factory and the A 2013 study by the McKinsey Global Institute [6] lists 3D
world's largest manufacturing nation in 2010 by overtaking the printing, advanced robotics, cloud technology, mobile Internet,
USA. In 2013, China had $2.9 trillion in manufacturing output Internet of Things, Semi-autonomous and autonomous vehicles,
(twelve times India's manufacturing output) versus $2.43 and Renewable energy as among 12 major disruptive
trillion from the USA [2]. In India, the organized technologies of our times. Many of these technologies are
manufacturing sector (with 10 or more workers per enterprise) based on the use of actuators, sensors, controllers, and software
employs only 20% of factory workforce, while the unorganized for value addition, innovation, and competitiveness. Therefore,
manufacturing sector employs 80%. India's 2011 hands-on education in CNC machines and related technologies
like robotics can also provide students with creative,
innovative, problem solving, and R&D skills.
An inexpensive 2-axis horizontal CNC lathe is developed in
N. Muthupalaniappan, A. Maruthupandi, A. John Paul Antony, and this paper for laboratory instruction in CAD/CAM and CNC
Shunmugham R. Pandian are with Velammal College of Engineering &
machining. Off-the-shelf components like stepper motors and
Technology, Madurai 625009, TN, India (phone: +91 9940298725; e-mail:
[email protected]). motor drivers are used for building the machine. Arduino open
S. Pandian is with Louisiana School for Math, Science, and the Arts, source microcontroller is used for motor control, and open
Natchitoches, LA 71457, USA (e-mail: [email protected]). source CAM and CNC software is used for turning operations.
978-1-4799-8159-5/14/$31.00@2014 IEEE

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To make the machine even more affordable and accessible, a Several VR-based CNC machining systems also incorporate
web-based learning platform is developed enabling remote haptic feedback to the learners using head-mounted displays,
operation of the lathe for instructional purposes. data gloves, projection screens, and so on. For example, the
CNC Partner Virtual Reality System developed by Li, et al at
Harbin Institute of Technology and produced by Shenzhen Hite
II. REVIEW OF CNC MACHINING EDUCATION Intelligent Equipment Co. Ltd, et al was installed in over 200
vocational schools in China [15]. A low-cost remote machining
Due to the emergence of planned obsolescence, high-tech
system with an older model of CNC mill (that does not provide
gadgets with short lifetimes, and fast-changing fashion
Internet connectivity) has been developed by Monroy, et al.
products, flexible manufacturing systems (FMS) have bec? me
[16]. In this system, students can upload their CNC programs to
the heart of modern industry. Education in computer aided
the machine from, and download programs from the machine
design (CAD), computer aided manufacturing (CAM), � N� ,
to, their portable devices (like tablet and laptop computers),
and computer integrated manufacturing (CIM) technologies IS
using Bluetooth, wireless, and LAN.
accordingly crucial in Indian engineering colleges,
The virtual training platforms allow learning of CNC milling
polytechnics, and ITls as well as some high schools that
and turning operations at user's pace. However, under Indian
provide vocational training.
conditions the costs of VR gloves, stereo glasses, workstations,
Over 70% of modern manufacturing in US and UK depends
and high-resolution displays are prohibitively high to realize at
on the use of CNC machines [7], and skilled machinist jobs are
the user end, like colleges, polytechnics, and ITls. Most
well-paying and abundant in number. Machinists need to be up
educational institutions do not also have sufficiently fast
to date in operations and programming of CNC machines, like
broadband Internet connections for the graphics-intensive VR
mill, lathe, router, and laser/plasma cutter as well as the
data communications to be effective.
emerging 3D printers. All these machines operate on similar
With rapid advances in materials science and electronics, the
principles such as use of stepper/AC servo motors, mo�or
cost and size of actuators, sensors, controllers, memory, and
drivers, controllers, and computer software for executmg
computers have been on the decline, along with an increase in
motion control commands. The main differences are in the
their power and capabilities. Therefore, mechatronics
mechanical design and the use of the tool for end operations
researchers are focused on coming up with in-house, build­
(material removal, cutting, carving, etc.).
your-own (BYO), or do-it-yourself (DIY) design, development,
Traditional education in CAD/CAM/CNC machining [9] has
and testing of laboratory equipment and systems, including
been hampered by the high cost of industry-grade machines
robots, work cells, and CNC machines, e.g., [17] - [20].
used in teaching laboratories, as well as the high cost of
Recently, two of the authors have developed a low-cost, 3-
CAD/CAM software even at academic discounts. Therefore,
axis CNC vertical milling machine for teaching purposes [21].
many engineering educational institutions in India typically
The design was based on a pre-assembled high-density
carry only one each of CNC mill and lathe. The maintenance
polyethylene frame and used three NEMA19 stepper motors
and operating costs of these machines are high, and moreover
with off-the-shelf motor drivers. The mill is capable of
they are overdesigned for student learning. The lab instructor
machining with light-density materials like foam, machinable
and technician demonstrate the operation of the machines, and
wax, wood, PVC, and aluminum. 3D model designs for
the students do not generally get an opportunity to work hands­
commercial or open source CAD software can be converted to
on with the machines. Breakdown of the machines due to
G code using open source software for operation by the motors.
incorrect operation by students can result in expensive repairs,
The desktop CNC mill can be readily scaled up to a larger
as the machines are often imported and spare parts need to be
size, higher accuracy, and power capability, simply by use of
imported too. Alternatively, students write CNC programs by
high power stepper motors, high current motor drivers, and
hand, and execute them on computer simulation software for
high resolution power transmission mechanisms. The design
the specific machines [8].
and operation principles can also be extended in a
Simulation of CNC machining is safe and flexible but the
straightforward manner to other CNC machines.
results do not provide students the feel and satisfaction of
Better use of the desktop CNC machines for education and
directly operating physical machines. Moreover, simulation
training can be ensured by connecting a few of the machines in
experiments do not often reveal the effects of real-world
a LAN or to the Internet, and enabling teleoperation or web­
constraints like power supply fluctuations, finite word limits of
based machining with over LAN or Internet with real-time
digital hardware, motor backlash, static and dynamic friction in
mechanisms, and so on. multimedia feedback [22] - [23]. Therefore, a web-based
Over the past decade or so, several academics have focused learning platform for teleoperation of the proposed CNC lathe
on the use of virtual learning environments using Virtual by remote users is proposed in this paper.
Reality (VR) technologies for imparting training in CNC
machining, e.g., [10] - [14], Typically, these systems are based
on software tools like Virtual Reality Modeling Language
(VRML), Java, and HTML so that users can work with III. WEB-BASED MACHINING OF A CNC LATHE
interfaces similar to those of industrial CNC machines, modify The principle of web-based machining with a CNC machine is
the parameters of machining, and view the results of their illustrated in Fig. l. The user (client) at college, school, or
programs in computer graphics animation.

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home can log in from a web browser with a specified user ID weight compact chuck is planned to be added to the high-speed
and password onto the web server of the laboratory, as spindle motor.
specified by a domain server name or IP address. The CNC The main specifications of the assembled CNC machine are
machine is connected to the server via a script written in PHP. listed below:
The browser page shows CNC controls for manual control (jog
mode for testing the range and limit points of motion), or
automatic control by uploading the user's G code program.

Fig. 1. Web-based machining system for CNC machines

The user interface is written in HTML language. On the Table 1. CNC lathe specifications
same browser page, the user can view in real time the
machining operation of the CNC machine using video from an X axis travel 320 mm
on-site pan-tilt-zoom (PTZ) camera focused on the work piece. Y axis travel 300 mm
The user interface also provides buttons for camera control. Tool piece height 220 mm
The live streaming uses the BroadCam video streaming server.
Tool diameter 3 mm
If the user's Internet connection is not sufficiently fast so as to
view live streaming in good quality, the video of the machining Chuck size 13 mm
operation on the user's program can be stored on the server for Stepper motors 2xNEMA 23, 10 kg-cm
later retrieval by the user. The server also provides audio torque, 1.8°, 200 stepirev, 2-
feedback to the user, so that the sound of the machining also is phase, 4 wire, bipolar, 2.8A
audible for a realistic learning experience. In the case of Lead screws Stainless steel, 2xM8 360mm
machining from a school classroom, say, audio/video feedback long, thread pitch 2 mm
from the user is provided to the laboratory personnel so that Spindle motor 230 V AC rotary drill used
instructions can be passed on for change of tool or work piece, Power supply 24 V, ISA, 360 W, switching
etc. power supply
Stepper motor Single axis, rated SA, peak
A. Mechanical System drivers 3.SA, rated 12 V to SO V DC,
up to 1116 microstepping,
The body of the CNC lathe is made of 8 mm medium density adjustable step, current, and
fiberboard (MDF) sheets. The X and Z linear motion are half-decay
achieved with two NEMA23 stepper, lead screws, guide rods, Microcontroller Arduino Uno, R3 board, with
and related accessories. The lathe has a fixed gantry and a ATmega328P @ 16MHz
mobile bed, with a limited working range. For compactness, the Frame material 8 mm MDF board
electronic control system is mounted onto the side of the
machine. Presently, an AC corded drill is used as a spindle
A photograph of the 2-axis horizontal CNC lathe is shown in
motor with fixed speed, but in future a DC/AC servo spindle
Fig. 2.
motor and large size chuck will be used as the drill has limited
speed and torque to deal with stronger materials. Also, a light-

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 IV. CNC MACHINE CONTROL SOFTWARE

In a CNC machining, the part to be machined is designed in

2D or 3D CAD software, which produces a model or drawing
as output in one or more standard formats. The CAM software
takes the CAD model as input and produces output as machine
readable code to be fed to the microcontroller for control of the
motors of the CNC machine.
The machine readable code is in the form of alphanumeric
instructions expressed as G and M code for feeding to the lathe
via the microcontroller. In this work, the open source G-code
controller grbl for Arduino microcontroller is used.
Compiled Arduino programs produced as .hex files. The free
Fig.2. Assembled 2-axis CNC lathe
Arduino hex uploader software XLoader is used to upload the
hex file to Arduino. In the fmal step, the open source
The CAD model of the 2-axis lathe is shown in Fig. 3.
Universal-G-Code-Sender program is used to send the G-code
produced by the CAM software for the machining job to the
microcontroller.
The Universal-G-Code-Sender program has three modes of
operation. In the File Mode, the user selects the G-code ASCII
file for machining. In the Command Mode, the user can enter G
code instructions interactively, and view the resulting operation
in the video live streaming window. Similarly, in the Manual
Control Mode the user can manually increment and decrement
motions along the individual axes. This helps the user visualize
the range of motions of the lathe.
The prototype 2-axis CNC lathe has been tested with sample
G code files for turning operations on acrylic and wax with
satisfactory results.

Fig. 3. CAD model of 2-axis lathe

V.CNC MACHINING WITH GOOGLE SKETCHUP

B. Electronic Control System

Google SketchUp (now, called simply SketchUp [24]) is an
Single-axis stepper motor drivers are used each axis of easy-to-use 3D modeling program used for applications in
motion, so that in the case of motor drive problems the single engineering design, architectural design, animation, etc. Lite
boards can be swapped out, without the trouble of replacing an versions are free to use, and are becoming popular among
entire multi-axis driver board. Of late, dedicated Arduino shield school and college students. SketchUp 3D models can be
stepper driver boards to interpret the machine motion exported in DXF or STL file fonnats to a CAM software.
commands sent from the microcontroller are also available on In this work, we use PyCAM which is an open source
the market, though they do not supply sufficient currents for toolpath generator for 3-axis CNC machining systems, and
large motors such as the NEMA23. The DC power supply is works with 3D (2D) contour models from STL (DXF) files
connected between +24 V and Ground, and can provide up to [25]. It generates G code that can be used with the
36 V with a 9.7 A current rating. grbIIXLoaderlVniversal-G-Code-Sender software.
The screenshot of a 3D model imported from CAD software
C. Arduino-based Control into PyCAM is shown in Fig. 4.

The Arduino microcontroller is programmed in a high

level language similar to C and comes with its own integrated
development environment.
The Arduino development board is connected to a Windows
PC via USB interface and so the lathe can also be controlled
from a desktop or laptop Pc. As a result, students can use their
own laptop computers for CAD/CAM design, and then connect
them to the laboratory CNC machine. The CNC lathe can also
be operated using Apple and Linux PCs.

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