TECHNICAL AND VOCATIONAL TRAINING

INSTITUTE

Welding Training and Technology Development

Center (WTTDC)

Technology Development Directorate

Project sector: Industry Development (Metal Engineering)

Training Manual

CNC Plasma Cutting Machine

I. Rationale:

Metal furniture and different metal craft artistic, stylists making is one of the most
promising business undertakings in the country today. This is evident in the products that are
currently being produced and imported from other countries.
Metal arts, design and other metal awesome products articles in furniture industry are
becoming more popular. The articles like chairs, sofas, tables, doors and beds are made in
quite attractive models with different designs on their arms and backs. Wooden furniture after
some period is worn out due to defects in wood quality and normal wear and tear. Due to
elegant appearance, durability and innovative designs, Metal furniture is becoming popular in
modern society. They are fast replacing the conventional art craft techniques practice in the
old Passion Method of metal forming in metal-wood-glass-plastic combine furniture
products.
The flourishing metal craft in the country has prompted the Federal TVET institutions
to develop CNC-operated Plasma Cutting Machine equipment that will improve the metal
forming technology (Plasma Cutting with Wrought Iron Mixture) of the industry, its
productivity, and the quality of its products. The machine is widely used in the ornamental
wrought iron industry.
TVET institutions are mainly expected to replicate new and selected technologies and
transfer the same to the relevant industry in order to increase the competitiveness of the sector
according to international standards. It's also needed that these technologies focus on creative
capacity building and greatly contribute to the economic development of the country
especially in manufacturing sector.

II. Project Objectives:

The general objective of this project is to design and develop a quality CNC Plasma Cutting
Machine that is easier to use therefore that could produce and supply the demands of the
Mixed-furniture and manufacturing industries. It will also train TVET Teachers and MSE
workers in enhancing their skills in the field of designing and fabrication.

Specifically, the project will achieve the following:

1 CNC Plasma Cutting, it has a diverse range of applications. These including cutting of
various sizes and thickness of metals and drilling a wide range of materials such as
Stainless Low, Medium, High carbon metals and alloy metals that cannot be cut with the
Oxy-Acetylene cutting process.

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 1

CNC Plasma Cutting Project
 2 The machine also creates much less material waste than other conventional cutting
methods. For many proactive shops, the reduction of material waste will result in
exponential savings and an increase in profit margins.
3 Projects that require high precision: This is the major advantage of CNC Plasma Cutting
machine. They deliver precise and accurate cuts with no variation from piece to piece.
4 Productivity: The machine has a huge advantage if you want to focus mainly on
productivity. They save a lot on labor, time, and ultimately money.
5 Uniformity in quality: CNCs delivers exact copy products and thus they are ideal for
maintaining quality in production.
6 The major advantage with CNC Plasma cutting is the fact that they can be operated
continuously and will only be switched off when maintenance practices are to be carried
out. They offer high class accuracy and generally reduce the amount of waste.
7 These machine offer immense advantages with its technology allowing innumerable
products to be built out of it.
8 These machines are ideal for any skill level. Unlike other manual operated metal cutting
machines that require experience and skill to handle, these machines can be handled even
by amateur CNC operator.
9 To substitute imported CNC Plasma machine.
10 To design and produce a CNC Plasma machine with lower Selling and maintenance cost.

III. Project description:

The proposed CNC Plasma machine is designed to improve the quality in making metal
furniture products and serve its purpose to help in other related manufacturing fabrication,
especially in the field of metal fabrication industries. Its design is simple but slightly a
stronger and stable machine made. The machine is easy to fabricate with use of available
materials in the local market in the country at a low cost price.

The machine is controlled by Mach 3 Interface Board and Mach 3 Operating software. The
machine is automated cutting solutions aimed at increasing the productivity of manufacturing
processes while enhancing product quality. CNC Plasma machine can cut a wide variety of
materials, anywhere from the most soft materials up to a harden types of metals, establishing
itself as a very flexible cutting device. The machine are powered by 3 sets of Nema 34
stepper motors are responsible for running the whole system of the machine. The cutting
device of the machine is the sets of high-frequency plasma inverter 60 models of Telwin
Machineries plasma cutting products. The main power supply was 3 phase which is suitable
for ideal metal working shops. The machine main component was easily assemble and

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 2

CNC Plasma Cutting Project
 disassemble and can cut a standard 1 whole size of sheet metal. Lastly, the machine has a
satisfying performance even the most unique manufacturing needs, providing shops with the
versatility and efficiency needed to improve operations, and helping to stay competitive in an
increasingly globalized marketplace. Although its flexibility and ease of use are often
considered the machine’s defining features, they also have several other characteristics that
make the machine a powerful well rounded cutting solution. The precision cutting offered by
many CNC Plasma is often enough to warrant the making of this incredible technology.
IV. Value Chain Analysis:

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CNC Plasma Cutting Project
V. Manufacturing Process:

1. Main Frame: 1 assembly

Tools and Materials needed:
 60mmx60mm square pipe
 60x60mm square pipe
 10mm flat bar
 Framing square
 Cut off machine or portable grinder
 Tape rule/Steel rule
 Welding machine
 Electrode E6013
 Steel rule
 Detailed drawing

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CNC Plasma Cutting Project
  Drilling machine/milling machine
a. Prepare materials tools and equipment.

b. Prepare and cut 2 pcs 60x60mm square pipe

(Upper and lower Rail) with a length of
2344mm as shown in the drawing using cut off
machine of portable grinder.

c. Prepare and cut 3 pcs 60x60mm square pipe

with a length of 165.28mm as (Rail bracket
vertical support) as shown in the drawing
using cut off machine of portable grinder.
d. Prepare and cut 4 pcs 60x60mm square pipe with a length of 2344mm as shown in the
drawing using cut off machine of portable grinder.

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 5

CNC Plasma Cutting Project
 e. Prepare and cut 2 pcs 60x60mm square pipe Vertical frame with a length of 915mm as
shown the drawing using cut off machine or portable grinder.
f. Prepare and cut 2 pcs 60x60mm square pipe with a length of 830mm as shown in the
drawing using cut off machine or portable grinder.
g. Prepare and cut 4 pcs 60x60mm square pipe as horizontal support frame with a length
of 1134mm as shown in the drawing using cut off machine or portable grinding machine.
h. Prepare and cut 28mm diameter with 60mm length round bar and tap drill with M12
(note: Tap before welding on the frame).
i. Prepare 18pc 10mm plate with a dimension of 50mm x 110mm as shown in the detailed
drawing using hydraulic sheering machine. (note: drill the plate together with the frame
follow the location on the dimension given in the detailed drawing)
j. All frame sub-assembly are detachable weld both ends of the square pipe with 10mm
plate. Assemble with caution using welding.
k. Prepare 4 pcs 10mm plate for footer base with a dimension of 60mmx60mm and drill at
the center with M12 shown in the detailed drawing using Hydraulic sheering machine.
And weld on the frame using MIG welding machine.

2. Working Table/Water tank assembly. 1 assembly

Tools and Materials needed:

3mm Sheet metal

3mm sheet metal
60mmx60mmx6mm angle iron
10mm plate
Hydraulic Sheering machine
Mig/mag welding machine
Ballpen hammer
Tape rule
Scriber
Hydraulic bending machine
Framing square
a. Prepare materials tools and equipment for the job.
b. Prepare, layout and cut 3 mm sheet metal following the dimension as given
in the detailed drawing Using hydraulic sheering machine.

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CNC Plasma Cutting Project
 c. Form and Bend the materials based on the design with a dimension of 2467mm x
1055mmx80mm, tack and full weld the material prepared using a MIG/MAG welding
machine.
d. Grind finish the welded part using a portable grinding machine.
e. Prepare and cut 3 pcs 60mmx60mmx6mm angle iron with the length of 2462mm using cut off
machine or portable grinding machine.
f. Drill and slot angle iron following the detailed drawing using drilling machine and portable
grinding machine.
g. Assemble and weld the angle iron on the location given in the detailed drawing using
MIG/MAG machine. ( prepare 10mm plate with the dimension of 50mmx50mm as bottom
spacer of the angle iron)

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CNC Plasma Cutting Project
 h. Prepare 22 pcs 3mm sheet metal (table top blade) as shown in the drawing, cut with angle
profile using a portable grinding machine.

Note: beware of the deformation of the materials during full welding brace the materials as
secure as possible since it’s a long span tank.

3. Upper and lower bearing bracket

assembly. 1 assembly
Tools and Equipment needed:
8mm plate
60mmx60mm square pipe
Hydraulic sheering machine
Steel rule
Portable grinding machine
Mig/mag welding
Ballpen hammer
Tri-square
Lathe machine
Milling machine/Drilling machine

a. Prepare materials tools and equipment.

b. (Upper bracket) Cut 8mm plate with a dimension as given in the detailed drawing using a
hydraulic sheering machine.
c. Drill the prepared materials on the location given in the detailed drawing using
milling/drilling machine.
d. Face and turn bushing with an outside
diameter of 34.5mm and inside
diameter of 20.5mm with a length of
70mm as given in the detailed drawing
using a lathe machine.
e. Cut 60mmx60mm square pipe with the
length given on he detailed drawing
using a cut off machine.
f. Drill the material on the desired
location shown in the detailed drawing,

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 8

CNC Plasma Cutting Project
 weld and assemble the prepared tapped bushing on the drilled materials and grind using a
portable grinding machine.
g. (Lower bearing bracket) cut 8mm plate with the dimensions given in the detailed drawing
using a hydraulic sheering machine.

h. Drill the prepared materials on the location given in the detailed drawing using
milling/drilling machine.
i. Face and turn bushing with an outside
diameter of 34.5mm and inside diameter
of 20.5mm with a length of 155mm as
given in the detailed drawing using a lathe
machine.
j. Cut 60mmx60mm square pipe with the
length given on he detailed drawing using
a cut off machine.
k. Drill the material on the desired location
shown in the detailed drawing, weld and
assemble the prepared tapped bushing on
the drilled materials and grind using a
portable grinding machine.
Note: Assemble and weld together the lower and upper rail, spring and bushing.
4. Acme lead arm post. 1 assembly
Tools and materials needed:
6mm plate
25mm round bar
Hydraulic sheering machine
Portable grinding machine
Steel rule
Tape rule
Tri-square
Mig/mag welding machine
a. Prepare and cut 6mm plate with a dimension given in the detailed drawing using a
hydraulic sheering machine/portable grinding machine.
b. Drill with M6 on the location given in the detailed drawing using a drilling machine
/milling machine.

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 9

CNC Plasma Cutting Project
 c. Face and turn round bar for bushing with a final OD of 23.50mm with an ID of 16mm
using lathe machine.

d. Assemble and weld all the sub-part following the detailed drawing.
Note: weld all subpart upon assembly
5. Acme lead arm shaft support: 1 pc
Tools and materials needed:
16mm round bar
M16 die set
Cut off machine
Portable grinding machine
Tape rule
Mig/mag welding machine
M24 nut

a. Cut 16mm round bar with a length of 1195.75 mm a given in the detailed drawing using
a cut off machine.

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CNC Plasma Cutting Project
 b. Thread the material with M16 with a length of 72.25mm using a die set as shown the he
detailed drawing.
c. Assemble and weld the M24 nut on the other side of the materials using Mig/Mag
welding machine.
6. Acme lead arm support: 1 assembly

Tools and materials needed:

60mmx60mm square pipe
4mm plate
Cut off machine
Portable grinding machine
Steel rule
Tape rule
Drilling machine/Milling machine
MIG/MAG welding machine
a. Prepare and cut 60mmx60mm square pipe with a length of
1235mm as given in the detailed drawing using a cut-off machine.

b. Prepare
bushing
with a 16mmOD
and tap drill with
M12 as shown in
the detailed
drawing using lathe machine
c. Drill the pipe with M16 as show in the detailed drawing using a milling machine/drilling
machine.

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CNC Plasma Cutting Project
 d. Assemble and weld the bushing on the square pipe using a MIG /Mag welding machine.
e. Drill and slot the square pipe with 10.5 diameter and 1100.50 long slot as given in the
detailed drawing using a milling machine/portable grinding machine.
f. Cut 4mm plate (Flange Bearing bracket) with a dimension of 86.46mm x 85mm as shown
in the detailed drawing using a hydraulic sheering machine.
g. Drill the plate with M6 on the location stated in the detailed drawing using a drilling
machine.
h. Assemble and weld the plate on the 60mmx60mm square pipe on the location given in the
drawing using MIG/MAG welding machine.
Note: assemble together with the fabricated flange bearing and acme lead screw with nut.
7. Acme nut: 1 pc
Tools and equipment needed:
40mm round bar
Brass
80mm round bar
Lathe machine
Milling machine
Micro meter
Caliper
Steel rule
a. cut brass material the length of 60mm x
55mm dimension as given in the detailed
drawing using a power hacksaw machine
b. Face and turn the material using lathe machine.
c. Drill and bore the material and an ACME THREAD with 25mm diameter as given in the
detailed drawing using a lathe machine.
d. Tap Drill the material with M8x 1.25p following the location given in the detailed
drawing using a milling machine.
8. Acme Lead screw: 1 pc
Tools and materials needed:
40mm round bar

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 12

CNC Plasma Cutting Project
 Tape rule
Lathe machine
Caliper
Micro meter
a. Prepare and cut 1 pc 40mm round bar with a desired length as given in the detailed drawing
using power hacksaw machine.
b. Face and turn the materials with a desired diameter of 25mm as stated in the detailed drawing
and perform Acme thread with the length of 1084mm using lathe machine.

c. Perform bearing fitting with the materials using a micro meter with a lathe machine and step
turn the materials following the detailed drawing.

9. Bracket holder for lead arm support : 1 assembly

Tools and materials needed:
8mm plate
Steel rule
Tape rule
Caliper
Drilling machine
Milling machine
MIG/MAG welding machine
Portable grinding machine
a. Prepare materials tools and equipment
b. Cut 2 pcs 8mm plate 86mm x 102mm dimension as shown in the detailed drawing using
a hydraulic sheering machine.

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CNC Plasma Cutting Project
 c. Drill with M12 on the location given on the detailed drawing using milling/drilling
machine.
d. Weld upon assembly the prepared
materials based on the given detailed
drawing using MIG/MAG welding
machine.
e. Cut 2 pcs 8mm plate with dimension
of 69mmx 91mm as shown on the
detailed drawing using a hydraulic
sheering machine.
f. Cut 1pc 8mm 91mmx76mm
dimension as shown I the detailed
drawing using a hydraulic sheering
machine.
g. Drill the prepared materials using a
drilling machine following the
location stated in the detailed
drawing.
h. Weld upon assembly all the prepared
parts using a Mig welding machine
Note: assemble the parts together
with the ACME lead arm support.

10. Bracket toothed belt holder

Tools and materials needed:

8mm plate
60mm length M12 bolt with bolt
10mm plate
Hydraulic sheering machine
MIG welding machine
Milling machine
Caliper
Steel rule
Center punch

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 14

CNC Plasma Cutting Project
 a. Prepare and cut 8mm plate following the dimension given on the detailed drawing
using a hydraulic sheering machine.

b. Drill the materials on the location given in the detailed drawing using a drilling
machine.
c. Assemble and weld the prepared parts following the detailed drawing using a
MIG/MAG welding machine
d. Prepare and cut 10mm plate with a
dimension given in the detailed drawing
using a hydraulic sheering machine.
e. Drill the materials on the location given in
the detailed drawing using a drilling
machine.
f. Assemble and Weld the prepared material
together with the M12 bolt following the
detailed drawing using MIG/MAG
welding machine.

11. Housing bearing of 42 O.D 17 I.D (inner and outer

bearing housing)

Tools and materials needed:

70mm round bar

Lathe machine
Milling machine with rotary indexing
Micro meter
Vernier Caliper

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CNC Plasma Cutting Project
 a. Prepare and cut 70 mm round bars with a desired length as given the detailed drawing
using a power hacksaw machine.

b. Face, turn, drill and bore (bearing fitting) the prepared materials following the dimension
given in the detailed drawing using a lathe machine.
c. (Inner housing)Tap drill the prepared materials with M6 and drill thru with M6 (outer
housing) using a milling machine with rotary indexing accessories.

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 16

CNC Plasma Cutting Project
 12. Lower stepper motor support (1 Assembly)

Tools and materials needed:

6mm plate
Hydraulic sheering machine
Milling/drilling machine
Portable grinding machine
Vernier caliper
Steel rule
a. Prepare, layout and cut 6mm plate following the dimension
as given in the detailed drawing using a Hydraulic sheering
machine.
b. Lay out the material and drill or slot every subpart following
the location given in the detailed drawing using a
milling/drilling machine.
c. Assemble and weld every subpart following the detailed
drawing using a MIG/MAG welding machine. (weld upon
assembly).
13. Middle Cover (1 assembly)

Tools and materials needed:

2mm sheet metal

Hydraulic sheering machine
Portable grinding machine
Milling/drilling machine
Caliper
Steel rule
Tri-square
File

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CNC Plasma Cutting Project
 a. Prepare, layout and cut materials on the desired dimension given in the detailed
drawing using a hydraulic sheering machine.
b. Drill every subpart on a location given on the detailed drawing using a drilling
machine
c. Assemble and weld all the prepared subpart following the detailed drawing using a
MIG/mag welding machine.

Note: weld all subpart upon assembly.

14. Protective railings(1 Assembly)

Tools and materials needed:

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CNC Plasma Cutting Project
 30mm square pipe
5mm plate
Portable grinding machine
Hydraulic sheering machine
Tape rule
Steel rule
Tri-square
MIG/MAG welding machine
Drilling machine
a. Prepare and cut 1 pc 30mm square pipe (railings) with a length of 2480 mm and cut 45
degree angle both ends diagonally as given on the detailed drawing using a portable
grinding machine.
b. Cut 2 pcs 30mm square pipe with a length of 130mm and cut 45 degree angle on 1 end
diagonally as given on the detailed drawing using a portable grinding machine.

c. Assemble and weld the prepared subpart following the detailed drawing using a
MIG/MAG welding machine.

d. Cut 2 pcs 60mmx60mmx5mm angle bar (bracket) with a length of

80mm as shown in the detailed drawing using a portable grinding
machine.
e. Drill the prepared materials on the location given on the detailed
drawing using a drilling machine.
f. Assemble and weld all the subpart as shown in the detailed drawing
using a MIG/MAG welding machine.

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CNC Plasma Cutting Project
 g. Cut 2 pcs 5mm plate with a dimension of 140mmx140mmx130mm as given in the detailed
drawing using a hydraulic sheering machine.
h. Bend the materials on 90 degree angle following the detailed drawing and weld on the
location given on the detailed drawing using MIG/MAG welding machine.
(Note: weld all subpart upon assembly)

15. Roller bolt (8 pcs)

Tools and materials needed:
40mm RHS
Power hacksaw machine
Lathe machine
Caliper
Micro meter
a. Prepare and cut 40 mm round bars with a length as given in the detailed drawing
using power hacksaw machine.

b. Turn and face with a desired dimension given in the detailed drawing using a lathe
machine.
c. Step-turn the materials into a bearing fitting with a dimension of equivalent to the
bearing required using a late machine.
d. Turn and thread the materials with M12x1.5p with a length of 30 mm as given in
the detailed drawing using a lathe machine.
e. Mill the head of the bolt with the required dimension as given in the detailed
drawing using milling machine with rotary indexing.
16. Roller bushing.
Tools and materials needed:
40mm round bar
Power hacksaw machine
Lathe machine
Caliper

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CNC Plasma Cutting Project
 Steel rule
Micro meter
a. Prepare and cut materials with a desired length as given I the detailed drawing
using a power hacksaw machine.
b. Face and turn the materials with the desired diameter and length of 20mm as given
in the detailed drawing using a lathe machine.

c. Drill and bore the materials with a desire outside diameter of 40mmand with an
inside diameter (bearing fitting) of 32mm considering the plus/minus 0.01 with
micro meter using a lathe machine.

17. Bearing bushing/spacer 32.5mmL. (8 pcs)

Tools and materials needed:
25mm round bar
Power hacksaw machine
Lathe machine caliper
a. Prepare and cut 25 mm round bars with a
desired length given in the detailed
drawing using a power hacksaw
machine.

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CNC Plasma Cutting Project
 b. Face and turn the materials with the diameter of 20mm and drill with M12 as shown in the
detailed drawing using a lathe machine.

18. Rail shaft: 4 pcs

Tools and materials needed:
30mm round bar
Power hacksaw machine
Lathe machine
Caliper
Milling machine
a. Prepare and cut materials with a desired length as given in the detailed drawing using
power hacksaw machine.
b. Face and turn the material with a diameter of 20mm as given the detailed drawing using a
lathe machine.
c. Step turn the tip of the shaft with a 16mmx31mmL and thread with M16x2.0p using a
lathe machine
d. Mill the head of the shaft to form a hex with a dimension of M26 across flat as given in the
detailed drawing using a milling machine with Indexing accessories.

19. Stepper motor stud bolt:

Tools and materials needed:
16mm round bar
Power hacksaw machine
Lathed machine
Caliper
a. Prepare and cut 16 mm round bars with a desired length
given in the detailed drawing using a power hacksaw
machine.

b. Face and turn the materials with a desired diameter of 14mm

with a length of 76mm as given in the detailed drawing
using a lathe machine.

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CNC Plasma Cutting Project
 c. Tap drill both ends of the materials with M6 and depth of 25.75 mm as given in the
detailed drawing using lathe machine.

20. Toothed gear shaft: single geared

Tools and materials needed:
20mm round bar
Power hacksaw machine
Lathe machine
Caliper
Milling machine
a. Prepare and cut materials with desired length a given in e
detailed drawing using a power hacksaw machine.
b. Face, turn and step-turn the materials with the desired
diameter and length as given in the detailed drawing using a
lathe machine.

c. Slot the material with the desired dimension as shown in the

detailed drawing using a milling machine.

21. Toothed gear shaft. Double geared shaft.

Tools and materials needed:
20mm round bar
Power hacksaw machine
Lathe machine
Caliper
Milling machine
a. Prepare and cut materials with desired length a given in e
detailed drawing using a power hacksaw machine.

b. Face, turn and step-turn the materials with the desired

diameter and length as given in the detailed drawing using a
lathe machine.
d. Slot the material with the desired dimension as shown in
the detailed drawing using a milling machine.

22. Stepper motor plate:

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CNC Plasma Cutting Project
 Tools and materials needed:
8mm plate
Hydraulic sheering machine
Milling/drilling machine
Caliper
Portable grinding machine
Center punch
a. Prepare and cut materials with a dimensions of
90mmx 90mm as shown in the detailed drawing
using a hydraulic sheering machine

b. Drill the materials with the location given in the

detailed drawing using a drilling machine.

c. Radius the corner of the materials with R5.00

using a grinding machine.

23. Toothed gear (16T, 18T , 32T and 64T)

Tools and Equipment needed:
CRS 40mm and 70mm
Lathe machine
Milling machine with indexing head
Caliper
Power hacksaw
Micro meter
a. Prepare and cut CRS with a desired length as shown in the detailed drawing using a power
hacksaw machine.

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CNC Plasma Cutting Project
 b. Face, turn and drill the materials following the dimension given in the detailed drawing
using a lathe machine.
c. Make a flying cutter that similar with the form of the teeth
d. Set up the materials in a milling machine thru using indexing head to process for a toothed
gear following the dimension in the detailed drawing (Note: use the formula of simple
indexing: 40/N-number of teeth).

e. Drilling and filing with the toothed gear following the deep and size of the keyway as
given in the detailed drawing using a milling machine.
f. Prepare and cut 2mm sheet metal (belts single/double stopper for 32T and 64T toothed
gear following the dimensions as given in the detailed drawing using a hydraulic sheering
machine.
g. Turn and drill the materials with a desired diameter as given in the detailed drawing using
a lathed machine
h. Assemble and weld the stopper with the 32T and 64T toothed gear as shown in the detailed
drawing using a MIG/MAG welding machine.
24. Stopper Motor Support assembly
Tools and materials needed:
6mm plate
Drilling /milling machine
Round file
Caliper
Portable grinding machine

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CNC Plasma Cutting Project
 a. Prepare and cut 6mm plate with a
dimension as given in the detailed drawing
using a hydraulic sheering machine.
b. Lay-out the materials, drill and slot with a
dimension as shown in the detailed
drawing using a drilling machine
c. Assemble and weld all sub-part following
the given detailed drawing using a
d. Chamfer all the corner using a portable
grinding machine and grind finished all the
welded parts. (Note: weld all sub-part upon assembly).
25. Acme lead screw M12x5p
Tools and materials needed:
CRS 20mm
Lathe Machine
Caliper
Micro meter
Milling machine
a. Prepare and cut materials with a desired length as
give in the detailed drawing using a power
hacksaw machine.
b. Face and turn materials with a desired diameter as
given in the detailed drawing using a lathe
machine
c. Acme Thread the materials with a desired pitch
as given in the detailed drawing using a lathe
machine.
d. Final for bearing fitting the materials observing
the tolerance as shown in the detailed drawing
using a micro meter with lathe machine.

26. Flange (for ACME 12x5p)

Tools and materials needed:
3mm plate
Hydraulic sheering machine
Lathe machine

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CNC Plasma Cutting Project
 40mm crs
Caliper
Micro meter
Milling machine
a. Prepare and cut materials with a desired dimension as given in the detailed drawing using a
hydraulic sheering machine.
b. Prepare and cut 40mm CRS with the length give in the detailed drawing using a power
hacksaw machine.
c. Assemble and weld the plate and CRS using a MIG/MAG welding machine.
d. Face and turn the materials and bearing fit with the
desired diameter using a micro meter and lathe
machine
e. Drill the materials with the location given in the
detailed drawing using a drilling machine.

27. Z axis frame

Tools and materials needed:
3mm plate
Hydraulic sheering machine
Drilling machine
Caliper
MIG/MAG welding machine
a. Prepare and cut materials with a dimension as
given in the detailed drawing using a
hydraulic sheering machine.
b. Drill the subpart on the location give in the
detailed drawing using a drilling machine.
c. Assemble and weld all sub-part following the
detailed drawing using a MIG/MAG welding
machine.

28. Z slider guide assembly.

Tools and materials needed:
2mm sheet meta
Caliper
Portable grinding machine

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CNC Plasma Cutting Project
 MIG/MAG welding machine
Hydraulic sheering machine
a. Prepare and cut 2mm sheet metal with the desired dimension as given in the detailed drawing
using a hydraulic sheering machine.
b. Drill the sub-part following the dimension n the detailed drawing using a drilling machine
c. Assemble and weld all parts using a MIG/MAG welding machine.

VI. Apply Protective Coating And Finishing

Tools and materials needed:

Paint primer
Paint (orange)
Hardener
All-purpose thinner
Sanding paper
Pallet
Body filler with hardener
Air compressor
Spray gun
PPE
1. Clean the surface of materials for debris before painting.
2. Mixed primer, hardener and all-purpose thinner and apply on the materials using air
compressor and spray gun.
3. Apply body filler as needed and sanding the parts until leveled
4. Apply again with primer for checking and retouch
5. Apply body filler again and sanding until fine and level
6. Then apply again with final primer.
7. Mixed enough lacquer colored paint and add hardener and all-purpose thinner.
8. Spray on the surface of the materials observing the distance of the materials from the
spray gun.
9. After applying, check if there are discrepancies of the output, if there are, repair with
sanding with water and spray again until 2 or 3 times coating.
10. Apply on the frame and other parts following the same process above.
11. After finishing the paint, assemble all the parts with caution.

VII. Electrical / Electronic Process

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CNC Plasma Cutting Project
 1. Control Box (Main Frame)
© Tools and Materials needed
•40mm x 30mm x 21mm Control Panel
•Cut off machine or portable grinder, angle grinder
•Tape rule or steel tape
•Detailed drawing
•Drilling Machine
•Portable drill, drill bits & step drill

Figure 1: Control Box

2. Procedures

a. Find an appropriate place in the front cover of the control panel for the placement of the
control switches of plasma cutting machine & main power of the power transformer.

b. Then, using the drilling machine or portable drill make a hole where the switches are
installing. Carefully tight the locks of the switches to avoid lose connection.

c. Using the angle grinder cut the portion of the control panel where the outlets of the 3-phase
source were installing. This power source is intended for the supply of plasma cutting machine.

d. Find an appropriate place for the installation of the 3-phase main power switch. The
installation is place outside the control panel, particularly outside of the control panel which is
accessible and cannot disturb the movement of the machine.

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CNC Plasma Cutting Project
e. Assemble the following components inside the control panel, find a place for every
components were it can install the wiring properly and easily.

3. Components to be install inside the control panel:

1. Circuit breakers
2. Magnetic contactors
3. MACH-3 module
4. Power transformer (220v primary, 24v secondary, 10A)
5. Digital stepper drive (2.4-7.2A 20-80 VDC for Nema 34 stepper)
6. Terminal blocks
7. Fun

Figure 2: Three Phase Main Switch

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 30

CNC Plasma Cutting Project
 Figure 2: Power & Control Circuit of Plasma Cutting Machine

Note:

1 If the coil of the magnetic contactor is 380v, use line 1 & line 2, or line 3 for A1 & A2 of the
contactor.
2 If the coil of the magnetic contactor is 220v, use the neutral line and either of the line 1, line 2, or
line 3.
3 Same power & control circuit is use in the power transformer, but if using the 380v source select
only two lines for the supply. But if using 220v source just select either of the three lines and the
neutral wire.

• Schematic Diagram for Limit Switches, Snubber Circuit, MACH-3 Microcontroller, Digital Stepper
Drive, & Stepper Motor

Figure 4: Schematic Diagram of MACH-3 Microcontroller

4. Materials

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 31

CNC Plasma Cutting Project
 VIII. LIST OF TOOLS & EQUIPMENT:

1.1. Tools Needed:

No. Qty. Name and Description Rem To be

arks purchase
1 1set Set of files Ok
2 5 pcs. each Measuring tools such as micrometer, vernier caliper, tape rule, steel rule Ok
Lay-out tools such as vernier height gage, scriber, divider, center punch &
3 2 pcs. each Ok
prick punch
4 2 pcs. Soft Hammer Ok
5 2 pcs. Crosspeen and ballpeen hammer Ok
6 2 pcs. Anvil Ok
7 2 pcs. Solid square big and small Ok
8 10 pcs. Paint brush Ok
9 2 pcs. Spray gun for air compressor painting Ok
10 2 pcs. Chipping hammer Ok
11 1 set Screw driver Ok
12 5 pcs. Hacksaw frame Ok
13 20 pcs. Hacksaw blade Ok
14 1 table Benchwork table vice Ok
15 2 pcs. each C-clamps (small & big) Ok
16 1 SET Set of drills 2mm to 13mm and tapered shank drill bit 14mm to 30mm Ok
17 1 SET Set of dies M3 to M20 Ok
18 1 SET Set of hand taps M3 to M20 Ok
Set of milling cutter: staggered tooth, plain side, face milling, slab milling
19 1 pcs. each Ok
Shell end mill, end mills cutter.
21 20 pcs. HSS tool bit cutter Ok
22 20 pcs. HSS center Drill BS#3 (10 pcs.) and BS#4 (10 pcs.) 0k
OVER-ALL REMARKS Just refer to the

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 32

CNC Plasma Cutting Project
 note!

1.2. Equipment Needed:

ITEM Rem To be
QTY. UNIT NAME AND DESCRIPTIONS
NO. arks purchase
1 5 Unit Lathe Machine with complete accessories Ok
2 2 Unit Vertical Milling Machine with complete accessories Ok
3 2 Unit Horizontal Milling Machine with complete accessories Ok
4 2 Unit Power Hacksaw Machine Ok
5 2 Unit Welding Machine with complete accessories Ok
6 2 Unit Upright Drilling Machine with complete accessories Ok
7 2 Unit Portable Grinder with complete grinding disc Ok
8 2 Unit Air Compressor for painting Ok
9 1 Unit Bending Machine / Roller Machine Ok
Slotting Machine / Shaping Machine with complete tools and
10 1 Unit Ok
accessories
11 1 Unit Cut-off Machine Ok
12 1 Unit Pedestal Grinder Ok
13 1 unit Radial drill machine Ok
14 2 unit Floor type drill press machine Ok
15 1 Unit Surface grinder machine Ok
The note
To be
Acetylene / oxygen Welding with complete tools and accessories purchase
16 2 tank
Note: oxygen and acetylene gas are empty. empty
tank for
refill
Just refer to the
OVER-ALL REMARKS
note!

IX. Technical Drawing and Assembly. CNC Plasma Cutting Machine

PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 33

CNC Plasma Cutting Project
PREPARED BY: TVTI/ WTTDC/ Technology Development Directorate 34
CNC Plasma Cutting Project