THE UNIVERSITY OF LAHORE

FINAL YEAR PROJECT MID TERM REPORT

Remove this TITLE OF PROJECT

Designing CNC Router For Laser Cutting Machine”

Group No Fall 2021 / 30

Name of Students with Registration Qasim Umar / BSEET01183018
Number Muhammad Usama / BSEET01183021

Shift Morning

Supervisor: Sir Usman Zahid

Department of Technology
DOCUMENT REVISION HISTORY:

S. COMMENTS ACTION
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 Table of Contents:
LITERATURE REVIEW: ...................................................................................... 3
PROBLEM STATEMENT: ................................................................................... 4
OBJECTIVES .......................................................................................................... 6
METHODOLOGY: ................................................................................................. 6
UTILIZATION OF PROJECT WORK ................................................................ 7
PHASES .................................................................................................................... 8
PROJECT TIMETABLE/ GANTT CHART ..................................................... 15
REFERENCES ...................................................................................................... 16

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 use equal space on both sides

INTRODUCTION:

Computer numerical control (CNC) machines play an important role in the manufacturing industry.
These complex machines are controlled by a computer and provide a level of efficiency, accuracy and
consistency that would be impossible to achieve through a manual process. CNC machining can be
defined as a process in which pre-programmed computer software dictates the movement of factory
machinery and tools. As a result, manufacturers can produce parts in less time, reduce waste and
eliminate the risk of human error.

This manufacturing process is used to control a wide variety of complex machinery, which will be
discussed in this article. Essentially, CNC machining makes it possible for three-dimensional cutting
to be completed by following one set of prompts. CNC machines are designed to manufacture a wide
variety of items. As such, there are several different types of commonly used CNC machines.

It’s important to know that these are not your average machines. They require the skills of a trained
professional to be able to produce high quality commercial products. All of the following machines use
G-code, which is the language that a CNC machine understands. These types of machines are similar
to CNC plasma machines the only difference is that lasers are mostly used for cutting and are great
when it comes to cutting metals, plastic or hardwood. Depending on the density and strength of the
material, the intensity of the laser can be adjusted.

LITERATURE REVIEW: Use equal space

Based primarily on the nature of the machine tool design practice, requirements for the knowledge
centric frame-work with integration of process and knowledge are analysed in consideration of the
design objects, the D&D process, the knowledge-centric demand and its implementing and monitoring
demand. Then, the framework of knowledge-centric CNC machine tool D&D process management
used in the CNC machine tool industry is proposed, which includes the modelling, simulation and its
execution and takes the knowledge into consideration. The design process of KVC1050N Vertical
machining centre is also studied as an example to demonstrate the feasibility and availability of the
proposed framework. The results of this study significantly contribute to efforts to achieve knowledge
and process integration in CNC machine tool D&D. In a word, ongoing efforts are being taken to make
the framework more practical in the industrial application. Thus, this solution can serve machine tool
companies in this important industry sector by increasing machine tool development capabilities,
improving work efficiency and ultimately reducing development cycle time and costs [1]. V. K. Pabolu
et al. [2] discuss the design and implementation of low-cost three-dimensional computerized numerical
control system (CNC) for industrial application. In this paper prototyping an Embedded CNC machine
was created. Detail description of different modules such as software development,
Electronic/Electrical development along with technical details of their implementation has been given
in the published paper. J. B. Jayachandraiah et al [3] provide the idea to develop the low-cost Router
system which is capable of 3 axes simultaneous interpolated. The low cost is prototyping is achieved
by incorporating the features of standard PC interface with microcontroller base CNC system in an
Arduino based embedded system. With limited budget the author concludes that small 5 machine tools
to fabricate small parts can provide flexibility and efficiency in manufacturing approach and reduce
the capital cost, which is beneficial for small business owners. N. R. Saharkar et al. [4] design the CAD
Model in Solid works and done the FEA analysis in hyper mesh tool providing the appropriate
constrains, loads, and moment values. According to the author he got the stress value around 14 Mpa
which is less than the allowable stress value of M.S. concluding the design is safe. Author also

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generates the G & M codes by simulating the CAD file in Power mill software which is nothing but
the CAM software. S. Pandian et al. [5] develop low cost 3 axis CNC machine using of- the- shelf
component, stepper motors with drivers, Arduino open source, microcontroller and open-source motor
control software. Author used ready to assemble kit from Zen Tool works, USA. Kit provided stepper
motor, lead screw, guide rod, anti-backlash falanz and spring. He made the Body with high density
PVC. The machine has fix gantry and mobile bed so there is restriction in working area. Author
develops Low-cost CNC machine only for educational purpose. M. Nowak et al. [6] formulated
methods of selection of geometric and physical structure of the mobile machine by specifying the
design requirements and the development of the elimination conditions based on these requirements.
The selection procedure was based on an analysis of the functional description of the required shaping
movements, carefully developing appropriate conditions for the elimination of alternatives using the
information concerning the needs of future portable machine operators. G. Swingier [7] gives the
results of research on selection on geometric kinematic structure of newly designed milling machine.
There were various types of structure combination available for milling machine, author suggested
best procedure and help to select useful combination of machine parts with desired output provided
with constraints of machine. R. Genting [8] implements 3-Axis CNC Router for Small Scale Industry.
Research about realization of low-cost CNC machine by B. Jayachandraiah [3] discusses the
development of a low cost 3Axis CNC router. This research [3] is main literature review on hardware
than mechanic design. Paulo et al. [9] 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 [10] that presents a controlling system for CNC
machines to mill and drill PCB board also performed by [11]. Object of PCB result of milling and drill
and detail of test result is not shown in the paper. Research on the development of algorithms for CNC
machine control by Desai [12] describes the development 6 of algorithms for interpreters and
interpolators and then tested on CNC machines for linear as well as circular interpolation. After
reviewing above papers, we can say that, CNC machine tools must be better designed and constructed,
and must be more accurate than conventional machine tools. Digital control techniques and computers
have undoubtedly contributed to better accuracy and higher productivity. However, it should be noted
that it is the combined characteristics of the electric control as well as the mechanical design of the
machine tool itself that determine the final accuracy and productivity of the CNC machine tool system.
High productivity and accuracy might be contradictory. Because high productivity requires higher
feed, speed and depth of cut, which increases the heat and cutting forces in the system. This will lead
to higher deflections, thermal deformations and vibration of the machine, which affects in accuracy.

PROBLEM STATEMENT:

The basic function of CNC machining is to take a blank piece of material, such as a block of plastic or
a similar item, and transform it into a finished product. The CNC machine does this by telling the
machine shop tool exactly how to move, and exactly what pieces of the material to cut away, to
eventually arrive at the desired result. It has many similarities with 3D printing, in that a computer
supplies digital instructions to tools that then work to create a finished product. Because the entire
creation process is distilled into a set of precisely coded directions, the process is much faster, more
efficient and less error-prone than if it were being done by hand. Several of the technologies commonly
used to actually create the finished products include drills, lathes, milling machines and other newer
technologies like laser cutting machines, plasma cutting machines, water-jet cutting material, electron
beam machining tools and many more. Materials that are commonly crafted with CNC machining
include aluminium, steel, copper, titanium, wood, fiberglass, foam and plastic. No matter how fast and
efficient CNC machines is, they’re not infallible. They develop problems and need maintenance just

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like any other type of machine or tool. And like any other tool, there are certain things you can do that
might inadvertently damage these machines. There are also definite steps you can take to keep them in
good working order. While there are certainly any number of problems that can lead to issues and errors
within CNC machining, some problems are more commonplace than others. These problems are also
ones that are easy to overlook and easy to misdiagnose.

Poor or Improper Maintenance

CNC machines need to be carefully cleaned and lubricated on a regular basis — otherwise, problems
can begin to arise. A lack of cleaning could lead to a build-up of dirt and debris. This might seem to be
purely a hygiene issue, but it can have real implications in the machine’s output. For example, if you
begin to notice the material sliding around during the cutting process, a build-up of dirt could be
preventing the machine from working correctly and providing the most accurate instructions. If this
issue continues to go unchecked, it will create challenges as the machine struggles to locate and hold
materials still. This leads to greater issues with accuracy and precision, and ultimately leads to more
errors. Improper lubrication can lead to machine parts sticking or not moving as smoothly as they
should. This can lead to errors, as well as overheating and air blockage. Both overheating and a lack of
air can also cause problems like material movement during the process.

Improper Settings or Tools

Perhaps one of your tools is becoming blunt, a cutting coolant or lubricant is failing to work correctly
or a tool is moving at the wrong speed. All these issues will cause similar sorts of problems. The most
likely result of one or more of these issues is the appearance of small burn marks around the edges and
corners of the material. The reason for this is simple. If the tool is moving too slowly, the material will
be under the cutting edge for longer than it should be. This results in the burning and scarring you’re
seeing. Similarly, if the coolant is not working correctly, things could be getting too hot, and the edges
of the material might be getting singed as a result. If one of your tools itself is burned, you’ll need to
adjust the settings as needed for that particular tool so it isn’t scarring the material. Or, if the tool is
blunt and not cutting correctly anymore, it could just be time to replace it altogether. Aside from burned
edges, some other visual signs of these types of problems to keep an eye out for are rough edges, visible
cutting marks and raised edges. All of these are indicators that something is not working exactly as it
should be in your machine.

Poor or Improper Programming

Another issue that could lead to serious problems in your CNC machining is incorrect programming.
This is a simple cause-and-effect problem, since the programming directly controls the creation of the
product. Therefore, if the programming is incorrect, the product will have problems. These problems
can be difficult to detect, especially when there are new or inexperienced employees involved. These
employees may not have a completely accurate understanding of the machine’s process and may enter
the coding incorrectly. They may not realize their error, although they recognize something is wrong.
To fix the problem, inexperienced employees may try to power the machine off, then on again. This
can jump-start the machine and cause it to correct the problem. Meanwhile, the original problem — the
incorrect coding — remains undetected. To avoid this scenario, make sure every employee receives full
and proper training on how to correctly code a CNC machine. This way, these kinds of easy-to-avoid

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mistakes will be less likely to happen, and you’ll be more likely to have a smooth and issue-free CNC
machining process

OBJECTIVES:

Computer numerical control (CNC) machines utilize a process in which pre-programmed computer
software dictates the movement of factory tools and machinery. This process is used to run many
different types of machinery, including grinders, lathes, mills and routers. This machinery cuts, drills,
grinds and shapes a variety of materials, from metal to plastic.

CNC machines are used to create detailed, intricate parts that serve a wide variety of industries. These
include:

• Commercial
• Electronics
• Medical
• Optical
• Marine industry
• Cutting industry

METHODOLOGY:

In contrast to mechanical cutting, which utilizes cutting tools and power-driven equipment, and waterjet
cutting, which utilizes pressurized water and abrasive material, laser cutting employs a laser cutting
machine to produce cuts, engravings, and markings. While laser cutting machines vary from model to
model and application to application, the typical setup includes a laser resonator assembly, mirrors, and
a laser cutting head which contains a laser focusing lens, a pressurized gas assembly, and a nozzle. The
basic laser cutting process includes the following stages:
• beam generation
• beam focusing
• localized heating and melting
• material ejection
• beam movement

Each stage is integral to the laser cutting process and, when properly executed, producing a precise
cut. Block diagram of Router design Figure 2.

Beam Generation

The term “laser” comes from the acronym LASER or Light Amplification by Stimulated Emission of
Radiation. Essentially, this acronym summarizes the basic principles of laser generation—stimulation
and amplification. Along with these principles, the laser resonator employs the processes of
spontaneous emission and stimulated emission to produce a high-intensity beam of light that is both
spatially and spectrally coherent (i.e., a laser beam).

Beam Focusing

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The focusing lens focuses the laser beam through the centre of the nozzle at the end of the laser cutting
head incident to the workpiece’s surface. By focusing the beam, the lens concentrates the beam’s energy
into a smaller spot, which increases the beam’s intensity (I). The following equation illustrates the
underlying principle behind this occurrence:

Where P represents the power of the initial laser beam, and πr2 represents the cross-sectional area of
the beam. As the lens focuses the laser beam, the radius (r) of the beam decreases; this decrease in
radius reduces the cross-sectional area of the beam, which in turn increases its intensity since its power
is now distributed across a smaller area.

Localized Heating and Melting, and Material Ejection

As the beam strikes the material’s surface, the material absorbs the radiation, increasing the internal
energy and generating heat. The high intensity of the laser beam allows it to heat, melt, and partially or
completely vaporize a localized area of the workpiece’s surface. The weakening and removal of the
affected area of the material forms the desired cuts. Siphoned into the laser cutting head and flowing
coaxially to the focused beam, the assist gas—also referred to as the cutting gas—is used to protect and
cool the focusing lens, and may be used to expel melted material out of the kerf—the width of the
material removed and of the cut produced—and support the cutting process. Laser cutting employs
several different types of material cutting and removal mechanisms, including fusion cutting, chemical
degradation cutting, evaporation cutting, scribing, and oxidation cutting.

Beam Movement

Once the localized heating, melting, or vaporizing has started, the machine moves the area of material
removal across the workpiece to produce the full cut. The machine achieves the movement either by
adjusting the reflective mirrors, controlling the laser cutting head, or manipulating the workpiece. There
are three different configurations for laser cutting machines, defined by the way in which the laser beam
moves or is moved over the material: moving material, flying optics, and hybrid laser cutting systems.

UTILIZATION OF PROJECT WORK:

Laser cutters are a good all-around tool because they can be used to make different style of design.
Common laser cutters are primarily used to cut materials like wood, acrylic, cardboard, paper and etc.
Reduced noise in operation over CNC. Excellent repeatability. A range of tools is not needed to run
the machine. Reduced waste.
• High Accuracy and Precision Cuts.
• Low Lead Times with No Need to Replace or Modify Tooling, Lower Costs.
• Can Handle Jobs of Almost any Complexity.
• Higher Sheet Utilization with Less Waste.
• Causes No Damage or Warping, Even to Thin Materials.
• Low Power Consumption.

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And laser cutting gives you very clean vertical lines but also with discoloration, and limited to thin
materials, while CNC cutting allows you to work through thick materials and to cut to very specific
depths to form truly three-dimensional objects.

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PHASES:

Phase 1:

In the first phase we search about our project from Google and YouTube. From Google we find the
history of CNC based machine and equipment’s that used in manufacturing. We also search latest CNC
laser router, which are used in latest CNC based machine setup. Then we find the equipment’s need in
our project from online websites and from there we got more information and prices and varieties.
And from YouTube or Google we watch different videos about our project to get better ideas to make
our project. CNC Lasers can affordably cut and etch a wide variety of materials, even the non-metallic
materials that typically cannot be cut by Flame or Plasma processes. Lasers can cut various materials,
including natural materials like leather.

Phase 2:

After searching we go to markets that are related to CNC and related item to our project like
“Hall Road”. In Hall Road market we see different CNC laser routers. From another shop we
purchased stepper motor of CW-motor Company and different weirs or Arduino or Arduino
cnc shield and stepper motor drivers, lamination wooden sheet, screw rod, coupling, laser, or
screws, Arduino uno cable or Power supply. Then we going in wood shop for cutting or making
x,y,z axis for fitting table. All components figure is here Figure 1. Laser, Figure 2: Arduino
Uno, Figure 3: CNC Shield, Figure 4: CNC Shield driver. Figure 5: Arduino Uno CNC Shield
with derives, Figure 6: Stepper motor, Figure 7: Coupling, Figure 8: Screw rod, Figure 9: USB
cable, Figure 10: Power Supply, Figure 11: Cable or connectors

Figure 1. Laser

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 Figure 2: Arduino Uno

Figure 3: CNC Shield

Figure 4: CNC Shield driver

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Figure 5: Arduino Uno CNC Shield with derives

Figure 6: Stepper motor

Figure 7: Coupling

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 Figure 8: Screw rod

Figure 9: USB cable

Figure 10: Power Supply

Figure 11: Cable or connectors

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Phase 3:

After purchasing we work on its parts. This project is a small CNC laser cutting router that can
be assembled from store-bought and laser-cut parts for without machine tools. (If you have
access to a shop with a chop saw and a drill press that'll be helpful, but you can get by with a
hacksaw and some wrenches.) As pictured, it has about working volume, but it can easily be
expanded and modified.

I've included both AutoCAD DXF files for the custom parts, as well as an Arduino sketch for
controlling.

The Steps:

(1) Setting expectations, and words of caution

(2) Buy parts and find tools

(3) Laser cut the custom parts

(4) Assemble the Z-axis

(5) Assemble the X-axis carriage

(6) Assemble the Y-axis and bed

(7) Assemble the frame

(8) Wire it up

(9) Tuning, tweaking, and milling tips

(10) Software you may find useful

Assembling the Frame or Parts and wired all stepper motor with Arduino Uno CNC Shield
with derives with power supply,

Figure 12: Arduino Uno CNC Shield with derives with power supply

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 Figure 13: Arduino Uno CNC Shield with derives wired

Figure 13: wired stepper motor or tie the wire

Align the pictures and use same size

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 Figure 14: Assembling and fitting z axis

Figure 15: Testing laser

Use same font for caption

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PROJECT TIMETABLE/ GANTT CHART

Sub-project Timeline
Fabrication Project part 1(01 Dec 2021 to 31 Jan 2022)
Controlling Project part 2 (01 Feb to 13 Mar 2022)

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REFERENCES:

Contact/ reference list:

Name/Phone Number Address

Electronic solutions / (042) 37313533 Electronic solutions 1st floor Sarwar
Center, Hall Rd, Garhi Shahu, Lahore,
Punjab 54000
IC shop / 0322 4401074 7-Data market16 ،-A Hall Rd, Garhi
Shahu, Lahore, Punjab 54000

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Development Process Management Framework”, International Journal of Production Research, Vol.
52, No. 20, 2014.
[2] V. K. Pabalu and K. N. H. Shrinivas, “Design and Implementation of Three-Dimensional CNC
machine”, International Journal of Computer Science and Engineering, Vol. 02, pp. 2567-2570,
November 2010.
[3] J. B. Jayachandraiah, O. Vamsikrishna, P. Abdullah khan, R. Ananda Reddy, “Fabrication of
Low cost 3 axis CNC Router”, International Journal of Engineering Science Invention, ISSN
(online):2319-6734, ISSN (print) 2319-6726, Vol. 3 issue. 6, June 2014.
[4] N. R. Saharkar, G. M. Dhote, “Prototype Development of Milling Machine Using CAD/CAM”,
International Journal of Science and Research, ISSN 2319:7064, Vol.4, Issue 8 2015.
[5] S. Pandian, R. Pandian, “Low cost build your own three axis CNC mill prototype”,
International Journal of Mechanical Engineering and Robotics, ISSN 2321-5747, Vol. 2, 2014. [6] M.
Nowak and D. Jastrzębski, “Selection of Kinematic Structure for Portable Machine Tool”, Advances
In Manufacturing Science and Technology, Vol. 36, No. 1, 2012.
[7] G. Szwengier, “Selection of Milling Machine Kinematic Structure Preliminary Selection of
Structure Variants”, Archives of Mechanical Technology, Vol. 32, No. 1, 2012.
[8] R. Ginting, S. Hadiyoso and S. Aulia “Implementation 3-Axis CNC Router for Small Scale
Industry”, International Journal of Applied Engineering Research, ISSN 0973- 4562 Vol. 12, No. 17,
January 2017.
[9] Paulo, Rogério and Maria “Prototype CNC Machine Design”, International Conference on
Industry Applications, 2010.
[10] M. A. A. Ali, A. M. A. E. L. Shaikh and S. F. Babiker, “Controlling the CNC Machine using
Microcontroller to Manufacture PCB”, Conference of Basic Sciences and Engineering Studies
(SGCAC), pp. 116-120, 2016. [11] D. P. Desai and D. M. Patel, “Design of Control Unit for CNC
Machine Tool using Arduino based Embedded System”, International Conference on Smart
Technologies and Management for Computing, Communication, Controls, Energy and Materials
(ICSTM), pp. 443-448. 2015. 57

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[12] R. S. Lin, S. L. Chen, and J. H. Liao, “Advanced Curve Machining Method for 5-Axis CNC
Machine Tools”, Published at International Multi Conference of Engineering and Computer Scientists,
Vol. 2, March 2016.

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