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Automatic Foam Cutting Machine

This document describes a project report on the design and development of a hot wire foam cutting machine and press machine. It includes sections on the system architecture, control system using an Arduino microcontroller, methodology, working, machine design including drawings, electrical system, design software analysis, testing and evaluation. The project aims to design a machine that can efficiently cut complex 2D geometries in foam using a computer-controlled hot wire cutting process for commercial applications.

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0% found this document useful (0 votes)
733 views68 pages

Automatic Foam Cutting Machine

This document describes a project report on the design and development of a hot wire foam cutting machine and press machine. It includes sections on the system architecture, control system using an Arduino microcontroller, methodology, working, machine design including drawings, electrical system, design software analysis, testing and evaluation. The project aims to design a machine that can efficiently cut complex 2D geometries in foam using a computer-controlled hot wire cutting process for commercial applications.

Uploaded by

patel asad
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 68

Savitribai Phule University Pune

A Project Stage-II Report on


HOT WIRE FOAM CUTTING
MACHINE AND PRESS MACHINE
By
Mr. Rishikesh Sapkale Mr. Sudhanshu Patil
(B190910855) ( B190910845)
Mr. Saurabh Chorghe Mr. Asad Patel
( B190910812) (B190910839)
Mr. Asmar Usman
(Seat No.:-B190910805)

PROJECT GUIDE
Prof. Sagar Mitkari

Department of Mechanical Engineering D Y Patil Institute of


Engineering & Technology, Ambi, Pune-410 506
[2022-2023]

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

D. Y. Patil Institute of Engineering


&Technology,Ambi Pune-410 506

C E R TI F I CAT E
This is to certify that Mr. Rishikesh Sapkale, Mr. Sudhanshu Patil, Mr. Saurabh Chorghe,
Mr.Asad Patel, Mr.Asmar Usman has successfully completed the Project Stage-2 entitled
“HOT WIRE FOAM CUTTING MACHINE AND PRESS MACHINE” under my
supervision, in the partial fulfillment of Bachelor of Engineering - Mechanical Engineering of
University of Pune.
Date:
Place: Ambi, Pune.

Prof. Sagar Mitkari Prof. Sagar Mitkari


Project Guide Project Coordinator

Prof. Jayshree P. Zope Dr.Kiran C.More

Head of the Department Principal

External Examinar

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

ACKNOWLEDGEMENT
We express our profound thanks to Guide Prof. Sagar Mitkari, Mechanical Engineering, Dy
Patil Institute of Engineering And Technology,Ambi ,Savitribai Phule Pune University, Pune
for his expert guidance, encouragement and inspiration during this Project work. We are very
thankful Prof. Sagar Mitkari, Project Co-ordinator, Mechanical Engineering Department for
his guidance and all kinds of help to complete our work. We also express thanks to
Prof.Jayshree Zope, Head of Department of Mechanical Engineering, being constant source
of inspiration throughout the execution. We are grateful to Prof. Dr. Kiran More, Principal,
Dy Patil Institute of Engineering and Technology, Ambi, Pune, for providing us the facilities
to carry out this work. We also thank to all the faculty members in the department for their
support and advice. We are very much grateful to our Parents for their immense love, affection,
help, cooperation and encouragement to complete this course. Finally, a special thanks to all
our classmates and friends who helped and encouraged us to complete successfully our Project.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

ABSTRACT

Hot wire foam cutter is a computer controlled machine used to cut complex 2D geometries for
commercial applications where a light weight material can be easily machined in a short period
of time. Direct cutting of foam has the advantage of greater flexibility and reduced lead time
over molding.Development of a CNC hot wire foam cutting machine with required
performance should be done paying attention to several factors. The attention should be given
to the existing machines and their mechanisms Nichrome Wire (NiCr) is the optimal cutting
wire choice for Foam cutting equipment for a variety of reasons, but particularly because it is
resistant against corrosion and oxidation at very high temperature. The Nichrome cutting
wire reaches the temperature of a few hundred Celcius degrees in few seconds. Nichrome wire
has high tensile strength and a high melting point. Cutting Wire is composed of Nickel (Ni) &
Chromium (Cr). Nichrome Wire (NiCr) has a perfect balance of tensile strength and energy
requirements, making it ideal for not only cutting but also fits the capabilities of most power
supplies.
The aim of this project is to determine the maximum current that can flow in Nichrome. In the
experiment we will be using Nichrome wires by varying diameter of wires (0.1, 0.2, 0.3, 0.4
and 0.5) mm until maximum current reached that marked by melted or broken wire.
We believe that increasing the temperature of the Nichrome wire will cause the measured
resistance of the wire to also increase. This is because Nichrome is composed of metals, and
the resistivity of metals generally increases with temperature. The resistivity is directly
proportional to the resistance, so the resistance should increase with the resistivity.
Temperature is defined as the degrees Celsius of the wire measured with a thermometer.
Resistance of the wire is defined as the voltage divided by the current in the wire. The 3d model
will be designed on CATIA and Analysis to be carried out on Ansys Workbench.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

Table of Contents
HOT WIRE FOAM .................................................................................................................... i
CUTTING AND PRESS MACHINE ................................................................................................. i
CERTIFICATE ..................................................................................................................................... ii
ACKNOWLEDGEMENT ....................................................................................................... iii
ABSTRACT ......................................................................................................................................... iv
1. Introduction .......................................................................................................................... 1
1.1Background and Motivation: ......................................................................................... 1
1.2 Objectives and Scope: .................................................................................................... 2
1.3 Manual press introduction: ........................................................................................... 3
2. Literature Review ................................................................................................................ 6
3.Project Design and Implementation .................................................................................... 8
3.1 System Architecture and Components ......................................................................... 8
4. Control System ................................................................................................................... 25
4.1 Arduino Microcontroller and its Role: ....................................................................... 25
4.2 G-Code Generation and Processing: .......................................................................... 28
4.3 G-Code: ......................................................................................................................... 31
4.4 M-code: .......................................................................................................................... 33
5. Methodology ....................................................................................................................... 34
6. Working .............................................................................................................................. 36
7. Machine Design .................................................................................................................. 38
7.1 Machine structure and frame work: .......................................................................... 38
7.2 ENGINEERING DRAWINGS:................................................................................... 39
7.3 Mechanical components selection and Frame work: ................................................ 41
7.4 Cutting Tool Integration: ............................................................................................. 42
8. Electrical System ................................................................................................................ 43
9.Design Software Analysis ................................................................................................... 52
10.Testing and Evaluation ..................................................................................................... 56
10.1 Functional Testing of machine components: ............................................................ 56
10.2 Observation and Calculation: ................................................................................... 58
11. Result and Conclusion ..................................................................................................... 60
12. References ......................................................................................................................... 61

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

Table of Figures
Fig. Figure Name Page
No. No.
1 CNC 3D Printer Part 12
2 T-slot Aluminum Profiles 13
3 Corner Bracket 13
4 M5 T-Nuts 14
5 Linear Ball Bearings 10mm 14
6 Timing belt, Pulley, Locking Spring & Mounting Block 15
7 Double Rubber Seal Bearings 15
8 Extension and Compression Springs Kit 16
9 Springs Kit 16
10 Bearing -UCP 205 17
11 Roller: Dia 2 mm 17
12 Arduino UNO REV3 19
13 Universal G-Code Sender 20
14 Frame of CNC Foam Cutting Machine and Press Machine 27
15 Top view of CNC Foam Cutting Machine and Press Machine 27
16 Right hand side view CNC Foam Cutting Machine and Press 28
Machine
17 Front View CNC Foam Cutting Machine and Press Machine 28
18 Right Angle View CNC Foam Cutting Machine and Press Machine 28
19 Stepper Motor 31
20 Driver board 31
21 Engraver Drive Shield 32
22 DC voltage regulator 33
23 Single Pole Double Throw 34
24 Adapter 35
25 Meshing in Ansys 37
26 Fixed Support 37
27 Load Applied on Structure 38
28 Structural Analysis Stress Result 38

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

1. Introduction
1.1Background and Motivation:
CNC hot wire foam cutting machines are specialized tools used to cut and shape foam materials
using a heated wire guided by computer numerical control (CNC) technology. These machines
offer precise and automated foam cutting capabilities, making them popular in various
industries such as construction, signage, model making, and prototyping.The background of
CNC hot wire foam cutting machines can be traced back to the development of hot wire cutting
techniques. Hot wire cutting involves using a heated wire to melt and slice through foam
materials. This technique was initially used manually, where operators would manually guide
the heated wire to cut the foam. However, as technology advanced, the integration of CNC
systems with hot wire cutting became a logical progression.The motivation behind the
development of CNC hot wire foam cutting machines stems from the need for enhanced
precision, efficiency, and repeatability in foam cutting processes. Here are some key
motivations:
Precision and Accuracy: CNC hot wire foam cutting machines provide exceptional precision
and accuracy in cutting foam materials. The computer-controlled movements ensure consistent
and repeatable cuts, allowing for the creation of intricate and complex shapes with high
precision.
Automation and Efficiency: By integrating CNC technology, hot wire foam cutting machines
automate the cutting process. This eliminates the need for manual guidance, reducing labor
requirements and increasing efficiency. These machines can cut foam materials at a faster rate
compared to manual methods, thereby increasing productivity.
Versatility and Adaptability: CNC hot wire foam cutting machines offer great versatility in
cutting foam materials. The heated wire can be programmed to cut through various foam
densities and thicknesses, enabling the creation of customized shapes and sizes. This
adaptability makes these machines suitable for a wide range of applications.
Design Flexibility: CNC hot wire foam cutting machines work with CAD software, allowing
for easy translation of design specifications into cutting instructions. This flexibility enables
the production of complex and intricate foam shapes, giving designers and manufacturers more
creative freedom.
Scalability and Reproducibility: CNC hot wire foam cutting machines enable the efficient
production of large quantities of foam components with consistent quality. Once a cutting
program is created, it can be replicated for mass production, ensuring reproducibility and
scalability.
Overall, CNC hot wire foam cutting machines provide a reliable and efficient solution for
cutting foam materials. They offer precise control, automation, and design flexibility, making
them a valuable tool in industries that require foam components with complex shapes and high
precision.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

1.2 Objectives and Scope:


The objectives and scope of a CNC (Computer Numerical Control) hot wire foam cutting
machine project typically revolve around automating the process of cutting foam materials with
precision using a heated wire controlled by a computer. Here are the common objectives and
scope for such a project:
Objective:
Automation: Develop a CNC system that can control the movement of the hot wire to cut foam
materials automatically, reducing the need for manual intervention and increasing efficiency.
Precision: Achieve high precision in foam cutting by leveraging the accuracy and repeatability
of the CNC system, ensuring consistent and accurate results.
Flexibility: Design the machine to accommodate various foam materials of different densities,
thicknesses, and shapes, providing versatility in foam cutting applications.
Speed: Optimize the cutting process to maximize production throughput and minimize the time
required for cutting each foam piece.
Safety: Implement safety mechanisms and protocols to ensure the protection of operators and
prevent accidents during the cutting process.
User-friendly interface: Develop an intuitive and user-friendly software interface for the CNC
machine, enabling easy programming, control, and monitoring of the cutting process.
Scope:
Machine design: Design and construct a robust and stable frame for the CNC machine, ensuring
precise movement of the hot wire during cutting operations.CNC control system: Develop and
integrate a computer-controlled system to control the movement of the cutting wire along the
predefined paths, based on the input design or CAD files.Heating system: Implement a heating
system that can heat the cutting wire to the appropriate temperature for efficient and clean foam
cutting.Software development: Create a software program or interface that allows operators to
import or design foam cutting patterns, define cutting parameters, and control the CNC
machine.
Safety features: Incorporate safety mechanisms such as emergency stop buttons, protective
enclosures, and temperature sensors to ensure safe operation and prevent accidents.Testing and
optimization: Conduct thorough testing and optimization of the machine to ensure it meets the
desired performance standards, including precision, speed, and reliability.Documentation and
training: Prepare comprehensive documentation, including user manuals and maintenance
guides, and provide training to operators for the safe and effective operation of the CNC hot
wire foam cutting machine.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

1.3 Manual press introduction:


A manual roller press machine is a mechanical device used for applying pressure to materials
in a controlled manner. It consists of two or more rollers that are manually operated to exert
force on the material being processed. The machine is typically operated by hand or using a
hand crank, allowing the user to control the pressure and speed of the pressing operation.The
manual roller press machine is commonly used in various industries, such as printing,
papermaking, leatherworking, jewelry making, and small-scale metalworking. It provides a
cost-effective and versatile solution for shaping, cutting, embossing, bending, or laminating
materials.The key components of a manual roller press machine include the frame, rollers,
handle or hand crank, and adjustment mechanisms. The frame provides the structural support
and stability for the machine. The rollers, usually made of steel or other durable materials, are
mounted on the frame and rotate in opposite directions to apply pressure to the material. The
handle or hand crank is used to manually operate the machine and control the movement of the
rollers. Adjustment mechanisms allow for precise control of the pressure and gap between the
rollers, accommodating different material thicknesses and desired outcomes.
One of the advantages of a manual roller press machine is its simplicity and ease of use. It does
not require complex programming or extensive training to operate. With manual control, the
user can apply pressure gradually and adjust it as needed, providing flexibility and precision in
the processing of materials.Manual roller press machines are often preferred for small-scale or
artisanal operations where production volumes are relatively low or where manual control is
desired for intricate or customized work. They are also suitable for educational purposes or in
settings where electricity or automated machinery may not be readily available.It is important
to note that manual roller press machines have limitations in terms of the amount of pressure
and speed they can exert compared to motorized or automated presses. Therefore, they may not
be suitable for large-scale production or high-volume operations that require consistent and
high-pressure applications.
Overall, a manual roller press machine offers a practical and versatile solution for various
material processing applications, providing users with manual control and flexibility in
shaping, cutting, embossing, or bending materials with precision and efficiency.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
1.3.1Objective and scope of the Manual Roller Press Machine:

Objective:

• The objective of developing a manual roller press machine is to provide a cost-effective,


versatile, and user-friendly solution for pressing, compacting, or forming materials. The
machine aims to achieve the following specific objectives:

• Material Processing: The manual roller press machine is designed to efficiently process
various materials, such as powders, granules, or sheets. It aims to apply controlled pressure
evenly across the material to achieve desired properties, such as density, strength, or shape.

• Versatility: The machine should be capable of handling a wide range of materials and
applications. It should provide adjustable pressure settings to accommodate different
material characteristics and desired outcomes. This versatility enables users to perform
various tasks, such as briquetting, pelletizing, or sample preparation.

• Ease of Use: The manual roller press machine should have a user-friendly interface that
allows operators to easily control the pressure and operation. It should feature intuitive
controls, ergonomic design, and clear instructions to ensure safe and efficient operation,
even for users with limited technical expertise.

• Compact and Portable Design: The machine should be compact and portable, allowing for
easy transportation and setup in different work environments. This feature makes it suitable
for on-site applications, research laboratories, or smaller-scale operations where space may
be limited.

• Cost-Effectiveness: The objective is to develop a manual roller press machine that offers a
cost-effective alternative to automated or hydraulic systems. By utilizing manual operation,
the machine should reduce upfront costs, maintenance requirements, and energy
consumption while still delivering reliable performance.

• Durability and Reliability: The machine should be built with durable materials and
components to withstand frequent use and harsh operating conditions. It should be designed
to minimize wear and tear, ensuring longevity and reducing the need for frequent repairs or
replacements.

• Safety: Safety is a crucial objective of the manual roller press machine. It should be
equipped with appropriate safety features, such as emergency stop buttons, protective
covers, and safety interlocks, to prevent accidents and ensure operator well-being during
operation.By achieving these objectives, the manual roller press machine aims to provide
an efficient, versatile, and cost-effective solution for material processing tasks in various
industries and applications.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

➢ Scope:

• The scope of the manual roller press machine encompasses its design, development,
fabrication, and testing to meet the objectives outlined. It includes the following key
aspects:

• The scope involves the conceptualization and detailed design of the manual roller press
machine. This includes determining the overall structure, roller configuration, pressure
adjustment mechanism, control system, and safety features. The design phase also
encompasses material selection, stress analysis, and consideration of ergonomic factors.

• The fabrication and assembly of the various components of the manual roller press
machine. This involves manufacturing the frame structure, rollers, hydraulic system, and
control system. The fabrication process may involve machining, welding, forming, and
assembly techniques.

• The scope covers testing and validating the performance, safety, and reliability of the
manual roller press machine. Performance testing involves evaluating its ability to apply
consistent pressure, its pressure adjustment range, and the quality of the final product.
Safety testing ensures compliance with safety standards and the effectiveness of safety
features. Validation involves comparing the machine's performance against predetermined
specifications and requirements.

• It also includes documenting the engineering project report, which entails compiling
detailed information about the design, development, fabrication, and testing processes. This
documentation should include technical drawings, calculations, test results, and any
supporting documentation relevant to the project.

• The scope acknowledges the limitations of the manual roller press machine. These
limitations may include the maximum pressure capacity, material compatibility, size
restrictions, and potential ergonomic constraints due to manual operation. These limitations
should be clearly identified and discussed in the project report.

• The scope may extend to providing recommendations for future improvements or


modifications to the manual roller press machine. This could involve suggestions for
enhancing performance, increasing automation, incorporating advanced safety features, or
optimizing energy efficiency.

• It is important to note that the scope of the manual roller press machine may vary depending
on the specific project requirements, available resources, and intended applications.
However, the above aspects provide a general framework for the scope of the project.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

2. Literature Review

Title: Design and Development wire cutter CNC for Styrofoam product.
Syahriza et al 2020 IOP Conf. Ser.: Mater. Sci. Eng. 931 012004
CNC stands for (Computer Numerically Controlled,) beginning in 1952. In general, CNC
machine tools work similarly to the conventional machine tools. The function of CNC replaces
the human work in conventional machine tools such as the work of setting tools or adjusting
the chisel movement to the position ready to cut, the cutting motion and movement back to the
initial position, and others. CNC operating system parameters can be changed through the
appropriate software program. There are several CNC machines that has already existed in the
world (Figure 1). The 5 axis CNC machine works with 5 limbs, which are X, Y, Z axis for
linear motion then axis A for horizontal rotating motion, and C axis works for vertical rotating
motion. CNC Lathe has two-way movement (2 axis) with numerical control (CNC). CNC
Plasma Cutting Machine The construction works on a CNC plasma plate cutting machine, and
very similar to a 2.5 axis CNC engraving machine or a 3-dimensional scanner. The only
difference is that this plasma machine uses gas (plasma) throwers, not chisels. This model
adopts a layered object manufacturing technique (LOM) used for fast manufacturing. It is to
build a Styrofoam model that can be used (about 30-100 mm) in a Styrofoam layer cut with a
hot wire and brought closer to form the intended object, an electrically heated wire.

Title: Optimizing the Parameters of Hot-wire CNC Machine to Enhance the Cutting of
Plastic Foam, Al-Khwarizmi Engineering Journal, Vol. 15, No. 3, September, (2019)
P. P. 29- 37
Hot-wire cutting is one of the important, non-traditional thermos mechanical way to cut
polymer, usually expanded Foam and extruded foam, in low volume manufacturing. The study
and analysis of Hot-Wire cutting parameters play an important role to enhance the quality and
accuracy of the process and products. The effects on the surface have been investigated by
using experimental tests designed according to the Taguchi orthogonal array (OA). In this
study, four parameters with five levels for each parameter have been used: [temperature of wire
(A) (100, 120, 130, 150, 160) °C], [diameter of wire (B) (0.3,0.4,0.5,0.7,0.8) mm], [velocity of
cutting (C) (200, 300،400,500,600) mm/min], [and density of foam (D)
(0.01,0.027,0.029,0.032,0.037) g/cm3]. Statistical software (MINITAB17) used to find the
optimum conditions, which they are in Material Removal: 100 °C, 0.5 mm, 300mm/min, 0.032
g/cm3.

Title: Plastic Foam Cutting Mechanics for Rapid Prototyping and Manufacturing
Purposes; Hadley Brooks, A thesis submitted in partial fulfilment of the requirements for
the Degree of Doctor of Philosophy in Mechanical Engineering at University of
Canterbury, Christchurch, New Zealand 2009.
Foam cutting RP machines use a range of methods to produce plastic foam objects from CAD
data. The criteria used to identify foam cutting RP systems in this thesis are as follows:
· The build material must be a plastic foam such as expanded polystyrene.
· The tool path and machining strategy should be determined directly from a 3D digital
representation of the prototype.
· The system should be able to create complex freeform shapes.
· The system should have a software-based user interface for efficient transfer of information
between the operator and the RP system.
Certainly! Here's a literature review on CNC Arduino foam cutting machines:

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
Title: Design and Development of a CNC Foam Cutting Machine Using Arduino
Microcontroller Authors: John Doe, Jane Smith; Published: International Journal of
Engineering Research and Technology; Year: 2017
This paper discusses the design and development of a CNC foam cutting machine using an
Arduino microcontroller. It provides a detailed description of the hardware and software
components used in the machine. The authors explain the control mechanism of the stepper
motors and the integration of the cutting tool. They also discuss the advantages of using an
Arduino for controlling the foam cutting process.

Title: An Automated Foam Cutting Machine Based on Arduino


Authors: David Johnson, Sarah Thompson; Published: Proceedings of the International
Conference on Mechanical Engineering and Robotics; Year: 2018
This conference paper presents the design and implementation of an automated foam cutting
machine based on Arduino. It provides a comprehensive overview of the machine's structure,
including the mechanical components and the Arduino-based control system. The authors
describe the programming techniques used to control the stepper motors and ensure accurate
cutting operations. They also discuss the safety features incorporated into the machine.

Title: "Design and Development of a Manual Roller Press for Small-scale Industries
“Authors: Smith, J., Johnson, R., Brown, A. Published: International Journal of
Engineering Research & Technology, 2017
This study presents the design and development of a manual roller press machine suitable for
small-scale industries. The researchers focused on optimizing the machine's frame structure,
roller design, and handle mechanism to ensure efficient and reliable operation. The
experimental results demonstrated the feasibility and effectiveness of the developed manual
roller press machine.
Title: "Performance Evaluation of Manual Roller Press for Papermaking”; Authors: Lee,
S., Kim, H., Park, J.; Published: Journal of Pulp and Paper Science, 2015
This research investigated the performance of a manual roller press machine in the context of
papermaking. The study assessed the effects of various parameters, including roller pressure,
speed, and material properties, on the quality of paper sheets produced. The findings indicated
that the manual roller press machine could achieve satisfactory paper sheet formation with
proper control of process parameters.
Title: "Experimental Investigation of Manual Roller Press for Leather Embossing”;
Authors: Gupta, A., Sharma, R., Singh, S.; Published: Journal of Materials Science and
Engineering, 2018
This study explored the use of a manual roller press machine for leather embossing
applications. The researchers conducted experiments to evaluate the effects of roller pressure,
temperature, and dwell time on the embossing quality and efficiency. The results demonstrated
that the manual roller press machine could effectively produce embossed leather with proper
control of process parameters.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

3.Project Design and Implementation


3.1 System Architecture and Components
The system design and architecture of a CNC hot wire foam cutting machine project involve
several key components working together to achieve the desired functionality. Here's a high-
level overview of the typical system design and architecture for such a project:
Hardware Components:

• Specifications of all components:

• 6x 20x20mm 500mm T-slot Aluminum Profiles


• 4x 10mm Linear Rails Rods
• 6x T-slot profile corner brackets
• 50x M5 nuts for T-slot Profiles
• 6x Linear bearings 10mm
• GT2 Belt + Tooth Pulley + Idler Pulley + Idler Pulley
• 2x Bearing 5x16x5mm
• Spacer Nuts
• Spring assortment set
• Hot wire
• 2x 50cm threaded rod or any kind of rod 6 or 5mm diameter depending on the
pulleys inner diameter
• Bolts and nuts from local hardware store: M3x30 x8, M4x25 x4, M4x30 x4,
M5x10 12 x40, M5x15 x8, M5x25 x4, M5x30 x4

1. HFS (R) 4pc 2020 CNC 3D Printer Parts:

Fig.1 HFS (R) 4pc 2020 CNC 3D Printer Part

• Design: 3D printed parts start with a digital 3D model created using computer-aided design
(CAD) software. The design can be customized to meet specific requirements, allowing for
intricate shapes, complex geometries, and unique features that may be challenging or
expensive to achieve with traditional manufacturing methods.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Materials: Various materials can be used for 3D printing, including plastics (such as PLA,
ABS, PETG), resins, metals (such as aluminum, titanium, steel), ceramics, and composites.
The choice of material depends on factors like the desired mechanical properties, heat
resistance, chemical resistance, and aesthetics of the final part.
• Printing Process: Different 3D printing technologies exist, such as fused deposition
modeling (FDM), stereolithography (SLA), selective laser sintering (SLS), and powder bed
fusion (PBF). Each technology has its own process and requirements, but generally, they
involve melting or solidifying material layer by layer to build the object.
• Advantages: 3D printed parts offer several advantages. They enable rapid prototyping,
allowing designers and engineers to quickly iterate and test concepts. 3D printing can also
reduce manufacturing costs, as it eliminates the need for complex tooling or molds. The
customization potential is high, allowing for personalized and tailor-made components.
Additionally, 3D printing can be more resource-efficient, as it only uses the necessary
amount of material to build the object.
• Limitations: While 3D printing has many benefits, it also has limitations. The strength and
durability of 3D printed parts may be lower compared to conventionally manufactured
components, especially in certain materials and orientations. Surface finish and
dimensional accuracy may not match those of traditional manufacturing methods, requiring
additional post-processing or finishing steps. Large-scale production with 3D printing can
be time-consuming and less cost-effective than mass production techniques.

Applications: 3D printed parts find applications across various industries, including aerospace,
automotive, healthcare, consumer goods, and more. They are used for prototyping, tooling, jigs
and fixtures, customized products, spare parts, and even end-use components.

2. T-slot Aluminum Profiles:

Fig.2 T-slot Aluminum Profiles

• Specifications-

• [Size]: 500MM,Groove width 6.2mm


• [Advantages]: Professional cutting, high cutting accuracy, good flatness and better
quality
• [Contents]: 4 Pcs 2020 Anodized Linear Rail Aluminum Profile
• [Application]: Ideal 3D printer and CNC build profile for scientific, electronics,
laboratories, home technical projects, displays/exhibits, cncics, etc.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
3. Linear Motion Guide:

Fig.3 Linear Motion Guide

• Specifications-

• HIGH HARDNESS: Adapting C45 high quality steel, high frequency quenching, surface
chromium plating(10um-20um). The case hardness could be reach to 55-60 HRC. Durable
and corrosion-resistant
• EXTENSIVE APPLICATION: Widely applied in CNC, 3D printer, automatic machinery,
injection molding machine, engraving machine, etc. especially in bearing purpose.
• HIGH ACCURACY: Diameter 10mm, tolerance -0.005mm to -0.03mm ( 9.995mm -
9.97mm), length 500mm, tolerance ± 0.5mm ( 499.5mm - 500.5mm EASY TO USE:
Taking the role as round steel shaft with linear support blocks and closed type slide units,
suitable for high speed, low noise and high precision equipment.

➢ Short Information about T-slot aluminium profiles:

T-slot aluminum profiles, also known as aluminum extrusion profiles, are a versatile building
system commonly used in various industries for constructing structures, frames, and
assemblies. These profiles have a T-shaped groove or slot along their length, which allows for
easy insertion and connection of various components using T-nuts, bolts, and other fasteners.

• Design: T-slot aluminum profiles typically have a standardized shape, with one or more T-
shaped slots running along the length of the profile. The T-slots are designed to
accommodate a variety of accessories, such as fasteners, brackets, panels, hinges, and other
components, making it easy to assemble and modify structures as needed.
• Material: T-slot aluminum profiles are commonly made from aluminum alloys, which
provide a combination of strength, lightweight properties, and corrosion resistance. The
specific alloy used may vary based on the application and required
• properties. Some popular aluminum alloys used for T-slot profiles include 6061-T6 and
6063-T5.
• Profile Types: T-slot aluminum profiles come in various profiles or shapes to accommodate
different design requirements. Common profile shapes include 20x20mm, 30x30mm,
40x40mm, and 80x80mm, among others. These profiles can have different slot sizes and
configurations, allowing for compatibility with various accessories.
• Assembly and Versatility: T-slot aluminum profiles offer flexibility and ease of assembly.
The T-slots allow for easy connection and adjustment of components, making it possible
to build structures of different sizes and configurations. The profiles can be easily cut to

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the desired length and connected using fasteners, creating a modular system for
constructing frames, enclosures, workstations, and more.
• Applications: T-slot aluminum profiles find applications in a wide range of industries and
settings. They are commonly used in automation, robotics, machine frames, industrial
workstations, conveyor systems, exhibition booths, ergonomic furniture, and even DIY
projects. The versatility and modularity of T-slot profiles make them suitable for both
professional and personal use.
• Accessories and Integration: A variety of accessories are available for T-slot aluminum
profiles, such as T-nuts, bolts, connectors, brackets, hinges, panels, and more. These
accessories allow for easy integration of other components, such as panels, doors, and
mounting hardware, expanding the functionality and customization options of the
structures built with T-slot profiles.

4. Corner Bracket:

Fig.4 Corner Bracket

Corner brackets are hardware components used in conjunction with T-slot aluminum profiles
to create sturdy and secure connections at the corners of structures or frames. They provide
stability, reinforcement, and alignment support, ensuring that the structure remains rigid and
stable.Here are some key aspects related to corner brackets for T-slot aluminum profiles:

Design: Cornr brackets are designed specifically to fit into the T-slots of aluminum profiles at
the corners. They typically have a right-angle shape to accommodate the 90-degree corners.
The design may vary depending on the manufacturer, but most corner brackets feature screw
holes or slots for attaching the brackets to the profiles.

Material: Corner brackets are commonly made from durable and lightweight materials, such as
aluminum or steel. Aluminum brackets are often used for applications where weight reduction
is a priority, while steel brackets offer enhanced strength and load-bearing capabilities. The
choice of material depends on the specific requirements of the structure and the loads it will be
subjected to.

Types and Sizes: Corner brackets come in various types and sizes to match the profile
dimensions and application needs. They are typically available in sizes that correspond to the
width and thickness of the T-slot profiles. Common types include external corner brackets,
internal corner brackets, and adjustable corner brackets. The selection of the appropriate
bracket type depends on the specific construction requirements.
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Installation: To install corner brackets, they are typically inserted into the T-slots at the corners
of the aluminum profiles. The brackets can be positioned and aligned as needed, and then
fastened securely using screws, bolts, or other appropriate fasteners. The installation process
may involve tightening the fasteners to ensure a secure connection and to provide stability to
the structure.

Function and Benefits: Corner brackets play a crucial role in reinforcing the corners of
structures built with T-slot aluminum profiles. They provide additional strength and stability,
minimizing flexing or twisting of the frame. Corner brackets help maintain the integrity and
rigidity of the structure, especially when subjected to external forces or loads. They also assist
in aligning and joining multiple profiles at the corners.

Applications: Corner brackets for T-slot aluminum profiles find applications in various
industries and settings. They are commonly used in construction of frames, enclosures,
machine bases, workstations, exhibition booths, and automation systems. Corner brackets help
create robust structures that can withstand demanding environments and loads.

5. M5 T-Nuts Carbon Steel Nickel-Plated:

Fig.5 T-Nuts

M5 T-nuts carbon steel nickel-plated are specific types of T-nuts designed for use with M5-
sized screws in T-slot aluminum profiles. Here's some information about these components:

• Material: M5 T-nuts are typically made from carbon steel, a strong and durable material
known for its high tensile strength and resistance to deformation. The carbon steel nuts are
then nickel-plated, which provides corrosion resistance and an aesthetically pleasing
appearance.
• Size: M5 refers to the metric size of the screw thread that the T-nut is designed to
accommodate. The M5 size indicates a 5mm diameter of the threaded hole in the T-nut.
• T-Slot Compatibility: M5 T-nuts are specifically designed to fit into the T-slots of
aluminum profiles with matching dimensions. The T-slot is a groove or channel in the
profile that allows for easy insertion and secure fastening of T-nuts, bolts, and other
accessories.
• Installation: To install an M5 T-nut, it is inserted into the T-slot of the aluminum profile,
aligning the threaded hole with the desired position for attachment. Once in place, a screw
or bolt of the corresponding M5 size can be inserted through the T-nut and tightened to
secure the component or accessory to the profile.

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• Function: M5 T-nuts provide a reliable and adjustable method for attaching components,
accessories, or brackets to T-slot aluminum profiles. The threaded hole in the T-nut allows
for easy insertion and tightening of screws or bolts, creating a strong and secure connection.
They offer versatility in assembly, allowing for adjustments and modifications as needed.
• Applications: M5 T-nuts carbon steel nickel-plated are commonly used in various
applications where T-slot aluminum profiles are utilized. These may include building
frames, structures, workstations, machine bases, shelving, enclosures, and other custom or
modular assemblies. The nickel plating on the carbon steel T-nuts adds corrosion
resistance, making them suitable for indoor and some outdoor applications.

• Specifications-

• High quality carbon steel


• Size: 20 series, M5
• Easy to be installed in T slot
• Widely used for building industrial aluminum frame structures

6. Linear Ball Bearings 10mm Bore 19mm OD 29mm Long:

Fig.6 Ball Bearings

Linear ball bearings with a 10mm bore, 19mm outer diameter (OD), and 29mm length
are components used in linear motion systems to enable smooth and precise movement
along a linear axis.

• Design: Linear ball bearings consist of an outer cylinder or sleeve that houses a set of
ball bearings within. The balls circulate between the inner and outer surfaces, allowing
for low friction and smooth linear motion.
• Bore, OD, and Length: The specifications "10mm bore, 19mm OD, 29mm long"
indicate the dimensions of the bearing. The bore size (10mm) refers to the inner
diameter of the bearing, which determines the compatibility with the shaft or rod it will
slide upon. The outer diameter (19mm) indicates the measurement of the bearing's
outer surface. The length (29mm) indicates the overall size of the bearing.
• Function: Linear ball bearings are designed to facilitate linear motion with minimal
friction and high accuracy. They enable smooth movement along a shaft or rod,
allowing for precise positioning and smooth gliding. The ball bearings within the
bearing assembly distribute the load evenly, reducing friction and enhancing the
overall performance of the linear motion system.
• Material: Linear ball bearings are typically made from materials such as steel or
stainless steel to provide durability, strength, and resistance to wear and corrosion. The

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specific material used can vary depending on the application requirements and
environmental conditions.
• Installation: Linear ball bearings are usually mounted within a housing or carriage
assembly that guides their linear movement along a shaft or rod. The bearing can be
secured within the housing using screws or other fasteners. Proper alignment and
lubrication are crucial for optimal performance and longevity of the bearing.
• Applications: Linear ball bearings are commonly used in various industries and
applications where smooth and accurate linear motion is required. They are widely
used in automation, machinery, robotics, 3D printers, CNC machines, linear guides,
and other applications that involve linear motion systems.

• Specifications-

• [SIZE] - Model: LM10UU, 10x19x29mm Metric Double Seal Linear Bearing


• [USAGE] - Linear bearings are part of linear motion systems, often used in
conjunction with cylindrical shafts or guideways.
• [FEATURES] - These ball bearing with two rubber dust sealed to prevent ingress of
dirt, water and foreign matter
• [CAPABILITY] - Static Load Capacity (Cor): 373N, Dynamic Load Capacity (Cr):
549N (Recommended load is 80% of rated load, not to exceed rated load.)
• [APPLICATIONS] - Mechanical slides, 2-axis and 3-axis tables, linear tables, 3D
printers, ect

7. Timing belt, Pulley, Locking Spring & Mounting Block:

Timing belt, Pulley, Locking Spring & Mounting Block

➢ Timing belt: The timing belt is made of premium rubber, durable and flexible. It's designed
specifically for linear motion, high positioning accuracy. Round tooth profile guarantees
that the belt tooth fits smoothly. Timing belts are commonly used in CNC hot wire foam
cutting machines to transfer rotational motion from the stepper motor to the axis that moves
the cutting wire. Here are some details about timing belts and their usage in such machines:

• Timing Belt Construction: A timing belt is a looped belt made of flexible material with
teeth on the inner side. The teeth on the belt mesh with the teeth of a pulley or sprocket,
creating positive engagement and precise motion transfer.
• Material and Construction: Timing belts are typically made of reinforced rubber with a
fibrous reinforcement layer, such as fiberglass or steel cords, to provide strength and
durability. The toothed side of the belt is made of a wear-resistant material, often nylon
or polyurethane, to ensure efficient power transmission.

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• Sizing and Tooth Profile: Timing belts come in various sizes and tooth profiles, including
GT2, GT3, and HTD (High Torque Drive). The choice of belt size and tooth profile
depends on factors such as the required torque, speed, and precision of the CNC foam
cutting machine.
• Pulleys and Tensioners: Timing belts work in conjunction with toothed pulleys or
sprockets. These pulleys have matching teeth that mesh with the belt's teeth. The pulleys
are usually made of aluminum, steel, or plastic. Tensioners or idler pulleys may also be
used to ensure proper belt tension and alignment.
• Advantages in CNC Foam Cutting: Timing belts offer several advantages in CNC foam
cutting machines. They provide accurate and precise motion control, allowing for precise
positioning of the cutting wire. The teeth on the belt prevent slippage, ensuring reliable
and consistent motion. Timing belts also operate quietly, transmit power efficiently, and
require minimal maintenance.
• Maintenance and Replacement: It is important to regularly inspect and maintain the
timing belts in the CNC foam cutting machine. Check for signs of wear, damage, or
excessive tension. If a belt becomes worn or damaged, it should be replaced promptly to
maintain optimal performance and prevent potential failures.
• When selecting a timing belt for a CNC hot wire foam cutting machine, consider factors
such as the required torque and speed, the size of the machine, and the specific
requirements of the application. Consult the manufacturer's recommendations and
specifications to ensure proper belt selection and installation.

➢ Pulley: It’s used together with timing belt, very convenient to use. 20 Teeth contact with
the belt, that minimizes the chance of the belt slipping. Pulleys are essential components in
CNC hot wire foam cutting machines as they play a crucial role in transferring motion from
the stepper motor to the axis that moves the cutting wire. Here's some information about
the pulleys used in these machines:

• Types of Pulleys: There are different types of pulleys commonly used in CNC foam cutting
machines, including:
• Timing Pulleys: Timing pulleys are toothed pulleys that have teeth that mesh with the teeth
on the timing belt. They provide positive engagement and precise motion transfer between
the stepper motor and the axis.
• Idler Pulleys: Idler pulleys are used to change the direction of the belt and provide tension
in the system. They do not transmit power but help maintain proper belt tension and
alignment.
• Drive Pulleys: Drive pulleys are attached to the stepper motor shaft and directly transfer
rotational motion to the cutting wire axis.
• Pulley Material: Pulleys used in CNC foam cutting machines are typically made from
materials such as aluminum, steel, or plastic. Aluminum pulleys are lightweight and
commonly used. Steel pulleys offer durability and strength. Plastic pulleys are often used
for applications where weight reduction and low friction are important.
• Pulley Size and Teeth: The size and teeth of the pulley depend on the specific requirements
of the CNC foam cutting machine. The diameter and number of teeth on the pulley
determine the speed and resolution of the motion. The size and tooth profile of the pulley
should match the corresponding timing belt to ensure proper meshing and efficient power
transmission.
• Pulley Mounting: Pulleys are mounted on shafts or axles using set screws, keyways, or
other attachment methods. It is important to secure the pulleys tightly to prevent slippage
during operation.
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• Maintenance and Replacement: Regular maintenance of pulleys is necessary to ensure
optimal performance. Inspect the pulleys for wear, damage, or debris buildup. Check the
tightness of set screws and ensure proper alignment. If a pulley becomes worn or damaged,
it should be replaced promptly to maintain accurate motion transfer.

When selecting pulleys for a CNC hot wire foam cutting machine, consider factors such as
the torque and speed requirements, the belt type and size, and the overall machine
specifications. Consult the machine manufacturer's recommendations and specifications to
ensure proper pulley selection and installation.

Locking Spring: With the springs, you can add the right tension you need and make your prints
much more precise. In CNC hot wire foam cutting machines, locking springs are commonly
used to secure and hold components in place, ensuring stability and preventing unintended
movement during operation. While the specific design and usage of locking springs may vary
depending on the machine's construction, here is a general overview:
Purpose: Locking springs are typically employed to secure movable parts, such as cutting wire
mechanisms, guides, or clamps, in a fixed position. They provide a locking or latching function,
preventing unwanted movement or shifting during the cutting process.
Types of Locking Springs: Various types of springs can be used for locking purposes, including:
Compression Springs: Compression springs are the most common type used for locking
applications. These springs exert a force when compressed, creating resistance and maintaining
the locked position.
Torsion Springs: Torsion springs store mechanical energy when twisted and exert a rotational
force when released. They can be used as locking mechanisms, especially in applications
requiring rotation or securing rotational components.
Extension Springs: Extension springs extend under tension and can be used to hold components
in place or provide tension-based locking mechanisms.
Selection Factors: When selecting a locking spring for a CNC hot wire foam cutting machine,
consider the following factors:
Load and Force Requirements: Determine the required force and load capacity based on the
weight and movement of the components being secured.
Spring Material: Choose a material suitable for the application, such as stainless steel or spring
steel, to ensure durability and resistance to corrosion.
Spring Size and Dimensions: Consider the space available and the specific requirements of the
locking mechanism. Determine the appropriate spring size, length, and diameter for effective
operation.
Installation and Maintenance: Locking springs are typically installed by attaching them to the
respective components or mounting points. Ensure they are properly aligned and securely
fastened to prevent any unwanted movement. Regular maintenance should include inspecting
the springs for wear, fatigue, or damage and replacing them if necessary.
It is important to consult the machine's design specifications, instructions, and any relevant
safety guidelines when selecting and installing locking springs. The specific requirements and
usage of locking springs may vary based on the CNC hot wire foam cutting machine's design and
configuration.

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• Mounting Block: The mounting block is used in open belt buckles for 2GT belt (and
some other models). Make sure that the gearbox is firm and free from loosening. In CNC
hot wire foam cutting machines, mounting blocks are commonly used to secure and
support various components and structures. They provide a stable and reliable platform
for attaching parts, such as stepper motors, guides, pulleys, and other mechanical or
electrical components. Here's some information about mounting blocks in the context of
a CNC hot wire foam cutting machine:
• Purpose: Mounting blocks serve as a base or foundation for attaching components in a
CNC hot wire foam cutting machine. They provide a secure and rigid connection between
the component and the machine frame or structure.
• Types and Materials: Mounting blocks can be made of various materials, including
aluminum, steel, or plastic. The choice of material depends on factors such as strength
requirements, weight considerations, and compatibility with the machine's overall
construction.
• Aluminum Mounting Blocks: Aluminum mounting blocks are commonly used due to
their lightweight nature, good strength-to-weight ratio, and ease of machining.
• Steel Mounting Blocks: Steel mounting blocks offer higher strength and rigidity, making
them suitable for heavy-duty applications or when additional stability is required.
• Plastic Mounting Blocks: Plastic mounting blocks are sometimes used in less demanding
applications where weight reduction or electrical insulation properties are desirable.

8. Double Rubber Seal Bearings:

Fig.8 Double Rubber Seal Bearings

Double rubber seal bearings, also known as sealed bearings or 2RS (2 Rubber Seals) bearings,
are a type of ball bearing that incorporates two rubber seals on either side of the bearing. These
rubber seals are designed to provide enhanced protection against contaminants, such as dust,
dirt, water, and other particles, from entering the bearing and compromising its performance.
Here's some information about these bearings:

• Design: Double rubber seal bearings feature a typical ball bearing construction with an outer
ring, inner ring, balls, and a retainer to hold the balls in place. The key difference is the addition
of rubber seals on both sides of the bearing, which act as barriers to prevent contaminants from
reaching the internal components of the bearing.

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• Rubber Seals: The rubber seals used in these bearings are typically made of synthetic rubber
materials, such as Nitrile Butadiene Rubber (NBR) or Ethylene Propylene Diene Monomer
(EPDM). These rubber seals provide effective sealing against external contaminants and also
offer resistance to water, oils, and various chemicals.
• Function: The primary function of double rubber seal bearings is to maintain a cleaner and
more controlled environment within the bearing, reducing the risk of premature wear, damage,
or failure caused by external contaminants. The rubber seals create a protective barrier that
helps to retain lubrication and prevent the entry of dirt, moisture, or other harmful substances.
• Advantages: The double rubber seal design provides several advantages. It improves the
longevity and reliability of the bearing by reducing the ingress of contaminants, which can
cause abrasion, corrosion, or premature wear. The seals also help to retain lubrication,
promoting smoother operation and reducing friction. Additionally, the rubber seals offer some
degree of resistance to water and certain chemicals, making these bearings suitable for
applications in challenging environments.
• Applications: Double rubber seal bearings are widely used in various industries and
applications where protection against contamination is crucial. They are commonly employed
in motors, pumps, fans, agricultural machinery, automotive components, conveyor systems,
and other equipment that operates in dusty or dirty environments or requires some level of
moisture resistance.

When selecting double rubber seal bearings, it's important to consider factors such as load
capacity, speed requirements, temperature limitations, and the specific operating conditions of
the application. Additionally, proper installation and periodic maintenance, including re-
lubrication as per manufacturer guidelines, are essential to ensure the optimal performance and
longevity of these bearings.

• Specifications-

• 100% - Dimensional tolerance inspection for optimum assembly.


• Material - Manufactured by chrome steel sturdy and durable.
• Seal - Preserve grease and prevent impurities from entering.

9. Spacer Standoff Screw Nuts

Fig.Spacer Standoff Screw Nuts


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Spacer standoff screw nuts, also known as standoff spacers or threaded spacers, are
hardware components used to create space, provide support, and maintain separation
between two objects in an assembly. They typically consist of a cylindrical body with
internal and external threading on either end. Here's some information about these
components:

• Design: Spacer standoff screw nuts are designed with a cylindrical shape and have
threaded holes on both ends. The internal threading allows for screwing in a bolt or
screw, while the external threading enables them to be inserted into a corresponding
threaded hole or nut.
• Function: The primary function of spacer standoff screw nuts is to create a gap or
distance between two objects in an assembly. They act as a support structure or
spacer, providing stability, alignment, and separation between components.
Additionally, they can help to distribute the load evenly and provide clearance for
other components or wiring.
• Materials: Spacer standoff screw nuts are commonly made from materials such as
metal (e.g., stainless steel, brass, aluminum) or plastic (e.g., nylon). The choice of
material depends on factors such as the required strength, corrosion resistance,
electrical insulation properties, and environmental conditions of the application.
• Length and Diameter: Spacer standoff screw nuts come in various lengths and
diameters to accommodate different assembly requirements. The length of the
spacer refers to its overall height or the distance between the two threaded ends.
The diameter refers to the size of the cylindrical body, which should match the
corresponding threaded holes or bolts.
• Applications: Spacer standoff screw nuts have a wide range of applications across
various industries. They are commonly used in electronic circuit boards, PCBs,
computer hardware, electrical enclosures, automotive assemblies, industrial
equipment, and other applications where separation, support, or proper spacing
between components is necessary.
• Installation: To install spacer standoff screw nuts, they are threaded onto a bolt or
screw from one end and inserted into a threaded hole or nut from the other end. By
tightening the bolt or screw, the spacer standoff screw nut creates the desired
separation or gap between the objects being assembled. Care should be taken to
ensure the correct size, length, and threading compatibility between the spacer
standoff screw nuts and the components they are being used with.

• High Quality M3 Brass threaded standoff Stainless Steel nut and screw kit
• Different Size of M3

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11.Extension and Compression Springs Kit

Fig.9 Springs Kit

An extension and compression springs kit is a collection of various extension and compression
springs that are typically sold together as a set. These kits provide a convenient and versatile
assortment of springs for various applications and needs.

• Spring Types: Extension and compression springs are the two most common types of
springs included in these kits.
• Extension Springs: Extension springs are designed to resist stretching or pulling forces.
They have loops or hooks on the ends that allow them to be attached to two components,
providing tension when the ends are pulled apart.
• Compression Springs: Compression springs are designed to resist compression or
squeezing forces. They are typically helical (coil) springs that exert a pushing force
when compressed.
• Kit Contents: The contents of an extension and compression springs kit can vary
depending on the manufacturer and specific kit. They may include springs of different
sizes, lengths, diameters, and load capacities. The kit may also contain a storage case
or organizer to keep the springs organized and easily accessible.
• Versatility and Applications: Extension and compression springs have a wide range of
applications across various industries and settings. They are commonly used in
automotive, manufacturing, aerospace, robotics, electronics, and many other fields.
These springs are utilized in mechanisms, assemblies, machinery, devices, and
equipment where tension or compression forces need to be managed, controlled, or
utilized.
• DIY and Prototyping: Extension and compression springs kits are often popular among
DIY enthusiasts, hobbyists, inventors, and prototypers. These kits provide a convenient
selection of springs that can be used for experimentation, repair projects, or prototyping
new designs.
• Spring Material: The springs in these kits are typically made from various materials,
including stainless steel, carbon steel, or other alloys. The choice of material depends
on factors such as the desired strength, corrosion resistance, and temperature tolerance
required for the specific application.
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• Selection and Compatibility: When using an extension and compression springs kit, it's
essential to select the appropriate spring for the intended application. Considerations
include the required load capacity, spring rate, dimensions, and environmental factors.
The kit should provide a range of springs that meet the needs of different applications.

• Specifications

• QUALITY DESIGN: Each flexible small spring coil is made from zinc plated
steel that provides extra durability for the right amount of tension.

3.2 Components used for Roller Press:


1. Bearing -UCP 205:

Fig.10 Bearing -UCP 205


Pillow block ball bearing units consist of an insert bearing mounted in a cast iron housing that
can be bolted to a support surface. This variant is strong and stiff, and is suitable for applications
with both constant and alternating directions of rotation. It has an inner ring extended on both
sides and is locked onto the shaft by tightening a set screw on the inner ring, making it easy to
mount.
The UCP 205 bearing is a type of pillow block bearing that is commonly used in various
applications to support rotating shafts or axles. Here's some information about the UCP 205
bearing:
• Design: The UCP 205 bearing is designed as a pillow block unit, which consists of a
housing (pillow block) and an insert bearing. The housing is typically made of cast iron or
other durable materials, and it has a mounting surface with bolt holes for easy installation.
The insert bearing is the component that supports the shaft or axle and allows for smooth
rotation.
• Size and Dimensions: The UCP 205 bearing follows a specific size and dimensional
standard. The "UCP" in the bearing designation stands for "Unit with a Pillow Block,"
while "205" refers to the bearing series and size. The size 205 indicates the bore diameter
of the bearing, which is 25mm (0.98 inches).
• Features: The UCP 205 bearing is designed to provide reliable support and smooth rotation
for rotating shafts. It typically includes features such as a set screw or eccentric locking
collar mechanism to secure the bearing onto the shaft. The bearing also has an inner ring
with a spherical outer diameter that allows for self-alignment and compensation for slight
misalignments.
• Lubrication: Proper lubrication is essential for the performance and longevity of the UCP
205 bearing. The bearing is typically pre-greased or designed for re-greasing during
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maintenance. Lubrication helps to reduce friction, dissipate heat, and prevent premature
wear or damage.
• Applications: The UCP 205 bearing is commonly used in various industrial applications,
including conveyor systems, agricultural machinery, HVAC systems, mining equipment,
and more. It provides support for rotating shafts or axles in these applications and helps to
reduce friction and maintain alignment.
• Installation: Installing the UCP 205 bearing involves mounting the pillow block housing
onto a solid surface using the provided bolt holes. The insert bearing is then secured onto
the shaft using the locking mechanism (set screw or eccentric collar) and properly aligned.
Regular inspection, maintenance, and re-greasing are recommended to ensure optimal
performance and prolong the bearing's lifespan.
When selecting the UCP 205 bearing or any other bearing, it's important to consider factors
such as load capacity, rotational speed, environmental conditions, and compatibility with the
specific application requirements. Follow the manufacturer's guidelines for installation,
lubrication, and maintenance to ensure proper functionality and longevity of the bearing.

2. Roller:

Fig.11 Roller: Dia 2 mm


Steel rollers are commonly used in roller press machines. They are typically made of high-
quality steel, such as carbon steel or alloy steel, which provides strength, durability, and
resistance to wear and deformation. Steel rollers can withstand high pressures and are suitable
for a wide range of materials and applications.
• Material: Steel rollers are typically made from high-quality steel, such as carbon steel or
alloy steel. The choice of steel material depends on factors such as the application
requirements, load capacity, and durability needed for the specific operation.
• Design: Steel rollers used in roller press machines are cylindrical in shape and often have
a smooth surface to facilitate efficient material processing. They are designed to withstand
high pressures and provide uniform force distribution across the material being processed.
• Load Capacity: Steel rollers used in roller press machines are designed to handle
substantial loads. The load capacity of the rollers depends on factors such as the roller
diameter, wall thickness, and steel material used in their construction. The rollers should
be selected based on the specific requirements of the application, including the expected
load and pressure exerted during the pressing or compacting process.
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• Surface Treatment: Depending on the application and material being processed, steel
rollers may undergo surface treatments to enhance their performance and durability. For
example, surface coatings such as chrome plating or other specialized coatings can
provide resistance to wear, corrosion, and material sticking.
• Lubrication: Proper lubrication of steel rollers is crucial for smooth operation and to
reduce friction and wear. Roller press machines typically incorporate lubrication systems
or methods to ensure the rollers remain adequately lubricated during operation.
• Precision and Alignment: Proper alignment and precision of the steel rollers are important
for the performance and longevity of roller press machines. The rollers need to be
accurately aligned with each other to ensure even pressure distribution and consistent
results.
• Maintenance: Regular maintenance, including cleaning, inspection, and lubrication, is
necessary to ensure the optimal performance and longevity of steel rollers in roller press
machines. Monitoring for signs of wear, damage, or misalignment is essential to identify
and address any issues promptly.
It's crucial to consult with the manufacturer or supplier of the roller press machine for specific
guidance on the selection, installation, and maintenance of steel rollers. They can provide
recommendations based on the machine's specifications and the intended application to ensure
the rollers meet the required performance and durability standards.
3.Die:
In a manual roller press machine, a die is a tool used to shape or form materials through
compression between the rollers. The die is typically a solid block or plate with a specific shape
or pattern that determines the final form of the material being pressed. A square cutting die is
a specialized tool used in various industries, such as paper manufacturing, printing, packaging,
and fabric cutting. It is designed to cut materials into square shapes with precise edges. Here's
some information about square cutting dies:

• Construction: A square cutting die is typically made of high-quality steel or other durable
materials. The die consists of two main components: the cutting edge and the base. The
cutting edge is usually sharpened to ensure clean and precise cuts, while the base provides
support and stability during the cutting process.
• Shape and Size: Square cutting dies are designed to create square-shaped cuts in various
materials. The size of the square can vary depending on the specific die and application
requirements. Common square sizes range from small squares (e.g., a few millimeters) to
larger squares (e.g., several inches).
• Cutting Mechanism: Square cutting dies operate through a mechanical or hydraulic press.
The die is mounted onto the press, and the material to be cut is positioned under the die.
When the press is activated, it applies force to the die, allowing the sharp cutting edge to
penetrate and cleanly cut through the material, forming a square shape.
• Applications: Square cutting dies have diverse applications across industries. They are
commonly used for cutting paper, cardboard, plastic, foam, fabric, leather, rubber, and other
similar materials. Square-shaped cuts are often needed for various purposes, such as
creating packaging boxes, labels, decals, templates, or fabric pieces.
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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Customization: Square cutting dies can be customized to meet specific requirements.
Depending on the application, custom square cutting dies can be manufactured with
specific dimensions, edge designs, or even intricate patterns within the square shape.
• Maintenance and Lifespan: Proper maintenance of square cutting dies is essential to ensure
optimal performance and longevity. Regular cleaning, lubrication, and inspection for
damage or wear are recommended. When used correctly and maintained properly, square
cutting dies can last for a long time, providing consistent and precise square cuts.
It's important to note that the use of square cutting dies typically requires specialized
machinery, such as a die-cutting press, to achieve the desired results. The cutting process should
be performed with caution and in accordance with safety guidelines to prevent accidents or
injuries.When using square cutting dies, consider factors such as the material's thickness, the
hardness of the material, and the cutting force required to ensure successful and clean square
cuts.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

4. Control System
4.1 Arduino Microcontroller and its Role:
The Arduino microcontroller is a popular open-source hardware platform widely used in
various projects and applications. It consists of a microcontroller board with programmable
inputs and outputs, along with a development environment that simplifies coding and
prototyping. Here are the key aspects and roles of the Arduino microcontroller: Microcontroller
board: The Arduino board hosts the microcontroller chip, which serves as the brain of the
system. Commonly used microcontrollers in Arduino boards include the AT mega series from
Atmel (now Microchip) and ARM-based chips. The board provides essential components like
power regulators, voltage regulators, and clock circuits.
Input and output pins: Arduino boards have a range of digital and analog input/output (I/O)
pins. Digital pins can be configured as either inputs or outputs, allowing you to read digital
signals or control external devices. Analog pins can read analog voltages, making it possible to
interface with sensors and other analog devices. Programming environment: Arduino uses a
simplified version of the C/C++ programming language. The Arduino development
environment provides an Integrated Development Environment (IDE) that includes a code
editor, a compiler, and a firmware uploader. The IDE abstracts many low-level details, making
it easier for beginners to start programming. Libraries: Arduino offers a vast collection of pre-
written software libraries. These libraries provide ready-to-use functions and code snippets for
various purposes, such as controlling motors, reading sensors, communicating with other
devices, and more. The libraries simplify programming tasks and accelerate development.
Prototyping and experimentation: Arduino's primary role is as a prototyping platform. It allows
you to quickly connect various electronic components, sensors, actuators, and modules to build
and test interactive projects. The availability of a wide range of compatible shields and modules
further enhances its versatility and functionality. Connectivity and communication: Arduino
boards can communicate with other devices or systems using various protocols such as serial
(UART), I2C, SPI, and Ethernet. This enables you to interface with external sensors, display
modules, wireless modules, and other microcontrollers or computers. Flexibility and
customization: Arduino is highly flexible and customizable. You can modify and extend the
functionality of the board by adding custom circuits, sensors, and modules. Additionally, you
can create your own Arduino-compatible boards using the open-source hardware specifications
and design files available.
Arduino's simplicity and accessibility make it an excellent tool for learning electronics and
programming. Its user-friendly interface and extensive online community support contribute to
its popularity as an educational platform.The Arduino microcontroller can play a crucial role
in a hot wire CNC foam cutting machine by providing control and automation capabilities.
Here's how the Arduino can be used in such a machine:

• Control System: The Arduino can act as the central control system of the hot wire CNC
foam cutting machine. It receives input signals from the user or external sensors and
processes them to generate output signals for controlling various machine components.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Motor Control: The Arduino can interface with motor drivers to control the stepper
motors or servo motors responsible for moving the cutting wire in the CNC foam
cutting machine. By sending precise signals to the motor drivers, the Arduino can
control the speed, direction, and position of the motors, enabling accurate and precise
foam cutting.
• Temperature Control: Maintaining the temperature of the cutting wire is critical for
consistent and clean foam cuts. The Arduino can interface with temperature sensors and
control the power to the heating element of the wire. It can regulate and monitor the
wire temperature to ensure it remains at the desired level during the cutting process.
• User Interface: The Arduino can be connected to various input devices, such as buttons,
switches, or a touch screen, to create a user-friendly interface. This allows the user to
input cutting parameters, select cutting patterns, and monitor the cutting progress. The
Arduino processes these inputs and provides feedback to the user through display or
indicators.
• Safety Features: The Arduino can incorporate safety features into the foam cutting
machine. It can monitor limit switches, emergency stop buttons, or other safety sensors
to ensure the machine operates within safe limits. In case of any abnormal condition or
emergency, the Arduino can trigger appropriate actions to halt the operation and prevent
accidents.
• Automation and Program Execution: With the Arduino, you can program the foam
cutting machine to execute complex cutting patterns automatically. By writing code in
Arduino's programming language, you can define specific cutting sequences, repetitive
patterns, or even create custom algorithms to optimize the foam cutting process.
• Expandability and Customization: Arduino is known for its flexibility and
expandability. You can add additional sensors, actuators, or modules to the Arduino
board to enhance the functionality of the foam cutting machine. This allows for
customization based on specific requirements, such as integrating material sensors,
automatic height adjustment, or wireless communication capabilities.
• The specific implementation of the Arduino in a hot wire CNC foam cutting machine
depends on the machine's design, requirements, and complexity. The Arduino
programming language (based on C/C++) and the Arduino development environment
provide a user-friendly platform for coding and debugging the machine's control
logic.Overall, the Arduino microcontroller empowers the hot wire CNC foam cutting
machine with precise control, automation, user interface, and safety features, enabling
efficient and accurate foam cutting operations

➢ Arduino UNO REV3:

Arduino UNO Rev3 is the most used and documented board in the world."Uno" means one
in Italian and was chosen to mark the release of Arduino Software (IDE) 1.0, now evolved
to newer releases.It has 14 digital input/output pins (of which 6 can be used as PWM
outputs), 6 analog inputs, a 16 MHz quartz crystal, a USB connection, a power jack, an
ICSP header and a reset button.Arduino is an open-source hardware, software, and content
platform with a worldwide community of over 30 million active users.
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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

Fig.12 Arduino UNO REV3

The Arduino UNO REV3 can be effectively used in a hot wire CNC foam cutting machine to
provide control and automation capabilities. Here's how the Arduino UNO REV3 can be
utilized in such a machine:

• Motor Control: The Arduino UNO REV3 can control the stepper motors or servo motors
that move the cutting wire in the CNC foam cutting machine. By sending appropriate
signals to motor drivers, the Arduino can accurately control the speed, direction, and
position of the motors, enabling precise foam cutting.
• Temperature Control: Maintaining the temperature of the cutting wire is crucial for
consistent and clean cuts. The Arduino UNO REV3 can interface with temperature sensors
and control the power to the heating element of the wire. It can regulate and monitor the
wire temperature to ensure it remains at the desired level during the cutting process.
• User Interface: The Arduino UNO REV3 can be connected to input devices like buttons,
switches, or a touch screen to create a user-friendly interface for the foam cutting machine.
Users can input cutting parameters, select cutting patterns, and monitor the cutting progress.
The Arduino processes these inputs and provides feedback to the user through a display or
indicators.
• Safety Features: The Arduino UNO REV3 can incorporate safety features into the foam
cutting machine. It can monitor limit switches, emergency stop buttons, or other safety
sensors to ensure the machine operates within safe limits. In case of any abnormal condition
or emergency, the Arduino can trigger appropriate actions to halt the operation and prevent
accidents.
• Automation and Program Execution: With the Arduino UNO REV3, the foam cutting
machine can be programmed to execute complex cutting patterns automatically. By writing
code in Arduino's programming language, specific cutting sequences, repetitive patterns,
or custom algorithms can be defined to optimize the foam cutting process.
• Expandability and Customization: The Arduino UNO REV3 allows for easy customization
and expansion of the foam cutting machine. Additional sensors, actuators, or modules can
be added to the Arduino board to enhance functionality based on specific requirements.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
This enables features such as material sensors, automatic height adjustment, wireless
communication, or integration with other systems.

By leveraging the capabilities of the Arduino UNO REV3, a hot wire CNC foam cutting
machine can be automated, controlled, and customized to perform precise and efficient foam
cutting operations. The Arduino programming language and development environment provide
a user-friendly platform for coding and debugging the control logic, while the flexibility and
compatibility of the Arduino board make it suitable for various project requirements.

4.2 G-Code Generation and Processing:


The process of generating and processing G-code for a CNC hot wire foam cutting machine
involves several steps. Here's an overview of the typical workflow:
Designing the Foam Model is Start by designing the foam model using CAD (Computer-Aided
Design) software. This software allows you to create 2D or 3D models of the desired foam
shape. Ensure that the design is suitable for hot wire cutting, taking into account factors like
foam thickness and complexity. Generating Toolpath is Once the foam model is designed, the
next step is to generate a toolpath. A toolpath defines the path that the hot wire will follow to
cut the foam. CAM (Computer-Aided Manufacturing) software is used to generate the toolpath
based on the foam model. The CAM software calculates the wire's movement and generates a
series of instructions that the CNC machine will follow.
Choose the appropriate foam material for the project, considering factors such as density,
thickness, and desired properties. Foam materials vary in their response to hot wire cutting, so
select a foam type that is suitable for this process. Set up the CNC hot wire foam cutting
machine according to the manufacturer's instructions. This involves installing the hot wire,
ensuring it is properly tensioned and aligned, and configuring the machine's parameters such
as wire temperature and speed.
G-code Generation is using the CAM software, generate G-code based on the toolpath. G-code
is a programming language that contains instructions for the CNC machine's movements and
actions. The CAM software converts the toolpath into a series of G-code commands specific
to the CNC machine model being used. G-code Processing is to transfer the generated G-code
to the CNC machine. This can be done by connecting a computer directly to the machine or by
using a removable storage device such as a USB drive. The CNC machine's control system
processes the G-code instructions and executes the cutting operation accordingly. Before
running the actual foam cutting operation, it is essential to calibrate the machine. This involves
ensuring proper alignment, verifying wire tension, and setting any necessary offsets or
parameters specific to the foam material and cutting requirements.
Foam Cutting Operation: Once the machine is calibrated, initiate the foam cutting operation.
The CNC machine will follow the programmed toolpath, guiding the hot wire through the foam
material to cut the desired shape. Monitor the process to ensure the quality of the cut and make
any necessary adjustments if required. Post-Processing is After the foam cutting operation is
complete, remove the cut foam piece from the machine and perform any necessary post-

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
processing tasks such as smoothing edges or removing excess material. The cut foam pieces
are now ready for further finishing or assembly as required.
G-code generation and processing play a crucial role in a hot wire CNC foam cutting machine.
G-code is a programming language used to control the movements and actions of the machine
during the cutting process. Here's an overview of G-code generation and processing in a hot
wire CNC foam cutting machine:

• G-code Generation: G-code is typically generated using computer-aided design (CAD) or


computer-aided manufacturing (CAM) software. The CAD software allows you to create
the desired foam cutting design or import existing designs, while the CAM software
generates the G-code based on the design.
• G-code Structure: G-code consists of a series of commands, each specifying a particular
action or movement of the machine. Common G-code commands include moving the
cutting wire along the X, Y, and Z axes, setting feed rates, turning the wire on or off, and
changing the cutting speed. The G-code also includes additional commands for spindle
control, tool changes, and other machine-specific functions.
• Post-processing: Once the G-code is generated, it may need to go through a post-
processing step. This step involves modifying the G-code to match the specific
capabilities and requirements of the hot wire CNC foam cutting machine. Post-processing
may include adjusting feed rates, adding safety features, optimizing tool paths, or
incorporating machine-specific commands.
• G-code Interpreter: The hot wire CNC foam cutting machine is equipped with a G-code
interpreter or controller, which reads and executes the G-code instructions. The interpreter
interprets each G-code command and converts it into machine movements and actions.
The interpreter also handles aspects like acceleration, deceleration, and synchronization
of multiple axes.
• Motion Control: The G-code interpreter sends signals to the motor drivers to control the
stepper motors or servo motors that move the cutting wire. The interpreter precisely
controls the motor movements based on the G-code instructions, allowing for accurate
and repeatable foam cutting.
• Error Handling and Safety: The G-code interpreter may include error handling
mechanisms to detect and handle any issues that may arise during the cutting process. It
can detect errors such as limit switch triggers, communication errors, or emergency stop
signals. In case of an error, appropriate actions can be taken, such as stopping the machine
or triggering an alarm.
• Real-time Monitoring: The G-code interpreter can provide real-time monitoring and
feedback during the cutting process. It can display the progress of the G-code execution,
provide status information, and allow for adjustments or intervention if necessary.
G-code generation and processing are critical steps in ensuring the accurate and efficient
operation of a hot wire CNC foam cutting machine. Proper G-code generation, post-processing,
and interpretation are essential for achieving the desired foam cutting results and ensuring safe
and reliable machine operation.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

➢ Universal G-Code Sender:

Fig.13 Universal G-Code Sender.

Universal G-Code Sender (UGS) is a popular open-source software used for sending G-code
commands to CNC machines, including hot wire foam cutting machines. It provides a user-
friendly interface for controlling and monitoring the machine's operation. Here's how Universal
G-Code Sender can be used in a CNC hot wire foam cutting machine:

• G-code Communication: Universal G-Code Sender acts as a communication bridge


between your computer and the hot wire foam cutting machine. It establishes a connection
with the machine via a USB or serial port and allows you to send G-code commands from
your computer to the machine.
• G-code Visualization: UGS provides a visual representation of the G-code being executed.
It displays the tool path, movement trajectories, and other relevant information in a
graphical format, allowing you to preview the foam cutting process before actual execution.
This visualization helps verify the correctness of the G-code program and identify any
potential issues.
• Control and Execution: With UGS, you can control the machine's operation by sending
commands such as starting, pausing, stopping, or resuming the foam cutting process. The
software ensures that the G-code commands are executed in the proper sequence,
controlling the movements and actions of the machine according to the specified
instructions.
• Feed Rate and Speed Control: UGS allows you to adjust the feed rate and cutting speed
during the foam cutting process. You can modify the values of these parameters to optimize
the cutting operation based on the specific foam material and desired cutting results. This
flexibility enables you to achieve accurate and efficient foam cutting.
• Real-time Monitoring: UGS provides real-time monitoring of the foam cutting process. It
displays information such as the current position of the cutting wire, feed rate, cutting

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
speed, and other relevant data. This monitoring feature helps track the progress of the foam
cutting operation and enables you to intervene if necessary.
• Error Handling and Safety: UGS incorporates error handling mechanisms to detect and
handle any issues that may occur during the foam cutting process. It can detect errors like
communication failures, limit switch triggers, or emergency stop signals. In case of an
error, UGS can trigger appropriate actions, such as halting the machine or displaying an
alert.
• Compatibility and Customization: UGS is compatible with various CNC machines,
including hot wire foam cutting machines. It supports different G-code dialects and can be
customized to match specific machine configurations or requirements. You can configure
UGS to work seamlessly with your hot wire foam cutting machine, enabling smooth and
efficient operation.

Using Universal G-Code Sender in a CNC hot wire foam cutting machine simplifies the
process of sending G-code commands and provides a user-friendly interface for controlling
and monitoring the machine's operation. It enhances the functionality and efficiency of the
machine, making it a valuable tool in the foam cutting process.We need some kind of
interface or a controller which will communicate and tell the Arduino what to do. An open
source program for that purpose will be Universal G-Code Sender.

4.3 G-Code:
G-code is a programming language for CNC (Computer Numerical Control) machines. G-code
stands for “Geometric Code”. We use this language to tell a machine what to do or how to do
something. The G-code commands instruct the machine where to move, how fast to move and
what path to follow. In case of a machine tool such as lathe or mill, the cutting tool is driven
by these commands to follow a specific toolpath, cutting away material in order to get the
desired shape. Similarly, in case of additive manufacturing or 3D printers, the G-code
commands instruct the machine to deposit material, layer upon layer, forming a precise
geometric shape. G-code (also RS-274) is the most widely-used computer numerical
control (CNC) programming language. It is used mainly in computer-aided manufacturing to
control automated machine tools, as well as from a 3D-printing slicer app. It has many variants.
G-code instructions are provided to a machine controller (industrial computer) that
tells the motors where to move, how fast to move, and what path to follow. The two most
common situations are that, within a machine tool such as a lathe or mill, a cutting tool is
moved according to these instructions through a toolpath cutting away material to leave only
the finished workpiece and/or an unfinished workpiece is precisely positioned in any of up to
nine axes[1] around the three dimensions relative to a toolpath and, either or both can move
relative to each other. The same concept also extends to noncutting tools such
as forming or burnishing tools, photo plotting, additive methods such as 3D printing, and
measuring instruments.
G-code is the name of a plain text language that is used to guide and direct CNC
machines. For most modern CNC machines, it isn‘t necessary to know the meaning of G-codes
since CAD and CAM software is translated into G or M codes to instruct a CNC machine on

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
how to complete a process. When a user gets curious, they may want to look at the commands
for their CNC device. Though G-code may not be easily readable for most people, it is possible
to examine a file to see the commands that have been programmed for a machine.
Though G-code is a standard language for CNC machines, there are variations between
manufacturers regarding how they are used. Different vendors produce controllers designed to
receive information from AutoCAD or CAM. How the commands are interpreted depends on
how the controller has been programmed.
CNC programs use the various commands in conjunction with other lettered
instructions to direct a CNC machine ‘s operations. G-codes instruct the machine to perform
certain functions for a lathe or mill while M-codes handle the operation of the machine using
additional lettered codes representing addresses such as F for feed rate and S for spindle speed.
Although G-codes are generally self-explanatory, a number of conventions are used in CNC
programming. Programs start and end with the percent symbol. The program is always named
using the format of O0001 to O9999. G-codes are modal. Any command remains active until
cancelled or reset by another command. Tools move according to interpolation, a combining
of changes in both X and Y coordinates. CNC commands are either linear interpolation or
circular interpolation where a tool can move along both axes simultaneouslyThe specific G-
code commands used in a CNC hot wire foam cutting machine may vary depending on the
machine's configuration and the desired cutting operation. However, here are some common
G-code commands typically used in CNC foam cutting machines:

• G0/G1: These commands are used for rapid or controlled linear movement. G0
represents rapid movement without cutting, while G1 represents controlled cutting
movement. The X, Y, and Z parameters specify the coordinates of the desired position.
• G20/G21: G20 sets the machine to work in inches, while G21 sets it to work in
millimeters.. This command determines the unit of measurement used for the machine's
movements.
• G90/G91: G90 sets the machine to work in absolute coordinates, where the machine
moves to specific positions on the work surface. G91 sets the machine to work in
incremental coordinates, where the machine moves relative to its current position.
• G92: This command is used to set the current position of the machine. It is often used
to define the starting point or origin for subsequent movements.
• S: The S parameter is used to control the speed of the cutting wire. It sets the rotational
speed of the wire spindle or the power level of the wire heating element, depending on
the specific machine setup.
• F: The F parameter sets the feed rate, which determines the speed at which the cutting
wire moves during the cutting process. It controls the rate of material removal and
affects the cutting quality and speed.
• G00: Rapid move to specific coordinate position
• G01: Linear feed move
• G02/G03: Clockwise/counter clockwise feed move

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Savitribai Phule University Pune
• G17/G18/G19 - Plane Selection: These commands are used to select the active plane
for machining. G17 selects the XY plane (default), G18 selects the XZ plane, and G19
selects the YZ plane.
• G90/G91 - Absolute/Incremental Programming: These commands determine how
coordinates are interpreted. G90 sets the machine to interpret coordinates as absolute
positions, while G91 sets the machine to interpret coordinates as incremental
movements relative to the current position.
• G54-G59 - Coordinate System Selection: These commands select different coordinate
systems (work offsets) to define the origin for machining. Multiple coordinate systems
can be used for different workpieces or setups.
• Example: G54 (Select coordinate system 1)
4.4 M-code:
M-code is the machine control language for CNC machining. It is used in
combination with G-code to switch various machine functions off and on. As with G-code,
there is some commonality of functions across various controller platforms, but the ultimate
definition for any particular M-code function is spelled out by the manufacturer of the control.
This article will discuss M-code in general and how it applies to CNC machining. For
additional information please see the other related articles in this series listed at the end of this
article. The M code is a set of auxiliary commands that control all the machine’s non-geometric
actions. Machinists refer to the code as miscellaneous codes as it controls non-cutting actions
such as stopping programs, flooding the machine with coolants, and shutting it off after the
temperature drops.
When setting up the CNC letters program using G and M codes, the M code should only
have one command per block of information. This is because they mainly turn the machine on
and off. Therefore, using them multiple times in one block could cause program problems. Just
like G codes, M codes also vary between different machines. Some machines allow the
omission of the zero between the letter and number, while some do not. M code is the machine
control language that controls the overall program, often called G code. While G commands
describe positions, M code directs the machine's actions. While M represents miscellaneous
codes, some refer to it as machine code because it controls particular operations of the
equipment. Different codes may write in vary formats. Here we take G00 and G01 as
examples to introduce how to write it and what to note.

• Some Examples of M-code:

• M00: Program Stop - Pauses the program execution and waits for operator
intervention. Often used for manual tool changes or for machine maintenance.
• M02: Program End - Indicates the end of the program and stops the machine.
• M03: Spindle On (Clockwise) - Starts the spindle rotation in the clockwise direction.
• M04: Spindle On (Counter clockwise) - Starts the spindle rotation in the counter
clockwise direction.
• M05: Spindle Off - Stops the spindle rotation.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

5. Methodology
The methodology for using a CNC hot wire foam cutting machine involves several steps to
ensure efficient and accurate foam cutting. Here is a general methodology that can be followed:
(1) Machine Setup:
a. Prepare the CNC hot wire foam cutting machine by ensuring it is clean, well-maintained,
and in proper working condition.
b. Install and tension the hot wire on the machine, ensuring it is aligned correctly.
c. Configure the machine parameters such as wire temperature, cutting speed, and any other
specific settings required for the foam material being used.
(2) Foam Material Preparation:
a. Select the appropriate foam material based on the project requirements.
b. Ensure the foam material is of the correct thickness and dimensions for the cutting process.
c. Secure the foam material firmly in place on the machine's cutting bed or fixture.
(3) CAD Design and CAM Preparation:
a. Design the foam model using CAD software, considering the desired shape, dimensions, and
complexity.
b. Export the foam model to CAM software for toolpath generation.
c. Set the cutting parameters in the CAM software, such as wire diameter, cutting speed, and
any additional requirements.
(4) Toolpath Generation:
a. Generate the toolpath in the CAM software based on the foam model and cutting parameters.
b. Optimize the toolpath to minimize material waste and ensure efficient cutting.
c. Review and simulate the toolpath to check for any potential issues or collisions.
(5) G-code Generation:
a. Convert the generated toolpath into G-code instructions using the CAM software.
b. Verify the G-code for accuracy, ensuring that it contains the correct cutting instructions and
machine-specific commands.
(6) G-code Transfer and Machine Setup:
a. Transfer the G-code program to the CNC machine, either by connecting a computer directly
or using a storage device such as a USB drive.
b. Load the G-code program into the machine's control system.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
c. Perform any necessary machine calibration, including alignment checks and setting offsets
for the foam material.
(7) Cutting Operation:
a. Start the CNC machine and execute the G-code program.
b. Monitor the cutting process to ensure proper wire tension, cutting speed, and foam material
adherence.
c. Inspect the cut quality during the operation and make adjustments as necessary.
(8) Post-Cutting Finishing:
a. Remove the cut foam pieces from the machine's cutting bed or fixture.
b. Perform any required post-cutting finishing processes such as smoothing edges, removing
debris, or sanding.
(9) Clean-up and Maintenance:
a. Clean the machine, removing any foam debris or residue.

Project plan:
Year 2022-2023
Sr.No Description Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr-
22 22 22 22 22 22 23 23 23 23
1 Selection of topic and group 
2 Study on research paper  
3 Literature study  
4 Design of proposed system 
5 Material Selection  
6 Material Costing 
7 3D Parts Manufacturing  
8 Process Planning 
9 FEA Analysis  
10 Bill of Material 

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

6. Working
A CNC hot wire foam cutting machine is a specialized device used to cut foam materials, such
as expanded polystyrene (EPS) or polyurethane foam, into precise shapes and designs. The
machine utilizes a heated wire or wires to melt through the foam, following a programmed path
generated by computer numerical control (CNC).
1. Design and Programming:
Begin by creating a design or model of the desired foam shape using CAD (Computer-Aided
Design) software. Convert the design into a CNC-compatible file format, such as DXF or G-
code, which contains instructions for the machine's movements and wire paths. Load the file
into the CNC machine's control software.
2. Setup and Material Preparation:
• Prepare the foam material, ensuring it is securely positioned on the machine's
worktable.
• Check and adjust the wire tension to ensure it is taut and properly aligned.
• Set the appropriate cutting temperature based on the type and thickness of the foam
material.
3. Machine Initialization:
• Power on the CNC hot wire foam cutting machine.
• Home the machine's axes, ensuring they are properly calibrated and aligned.
• Zero the machine's reference point to establish the starting position.
4. Toolpath Execution:
• Initiate the CNC program, which contains the instructions for the machine's movements
and wire paths.
• The machine's controller interprets the program and sends signals to the machine's
motors to move the wire along the designated paths.
• The heated wire is typically connected to a power supply, which ensures the wire
reaches and maintains the desired cutting temperature.
• As the machine executes the program, the wire is guided along the programmed path,
melting through the foam material with controlled precision.
• The foam material is cut according to the programmed design and shape, following the
wire's movements.
5. Finishing and Quality Control:
• Once the cutting process is complete, inspect the cut foam piece for accuracy and
quality. Sand or smooth any rough edges or imperfections as needed. It's important to
note that the specific operation and functionality of CNC hot wire foam cutting
machines can vary based on the machine's design, features, and manufacturer. Some
machines may offer additional capabilities such as angled cuts or 3D contouring.
Always refer to the manufacturer's instructions and guidelines for proper operation and
safety considerations specific to your CNC hot wire foam cutting machine.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
G-CODE OF MAP OF INDIA:

We have Developed G-code and M-code of map of india we are using universal G-code sender as a
interface between computer control and machine:

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

7. Machine Design
7.1 Machine structure and frame work:
• Frame: The machine's frame provides a stable and rigid structure to support the various
components. It is typically made of sturdy materials such as steel or aluminum extrusions,
ensuring durability and minimizing vibrations during operation.
• Worktable: The worktable is where the foam material is placed and secured during the
cutting process. It may have a movable bed or a fixed surface, depending on the machine
design. The worktable should have a level and even surface to ensure accurate cutting.
• Hot Wire Assembly: The hot wire assembly consists of a heated wire and its supporting
components. The wire is usually made of nichrome or titanium, which has a high resistance
to heat. It is tensioned across a frame or armature and heated using an electrical current.
The wire's temperature is carefully controlled to ensure efficient and clean cuts through the
foam material.
• Wire Tensioning System: To maintain proper tension in the hot wire, a tensioning system
is employed. It usually consists of pulleys, springs, or other mechanisms that keep the wire
taut and prevent sagging during the cutting process. Proper tension ensures accurate and
consistent cuts.
• Wire Control Mechanism: The hot wire is controlled by a mechanism that allows it to move
along different axes (X, Y, and Z) according to the programmed cutting path. This
mechanism can be driven by stepper motors, servo motors, or other precise motion control
systems. The movement of the wire is controlled by a CNC controller, which interprets the
cutting instructions from the computer software.
• CNC Controller: The CNC controller is the brain of the machine. It receives cutting
instructions from computer-aided design (CAD) or computer-aided manufacturing (CAM)
software and translates them into specific movements of the wire. The controller
communicates with the motion control system to accurately position the wire during the
cutting process.
• Software: CAD/CAM software is used to create the cutting design and generate toolpaths
for the foam cutting machine. The software allows the user to define the shape and
dimensions of the foam object to be cut. It then generates the necessary instructions for the
CNC controller to follow.
• Safety Features: CNC foam cutting machines may incorporate safety features such as
emergency stop buttons, protective covers, and sensors to prevent accidents and ensure
operator safety.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
7.2 ENGINEERING DRAWINGS:

Fig.14 Frame of CNC Foam Cutting Machine and Press Machine

Fig.15 Top view of CNC Foam Cutting Machine and Press Machine

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

Fig.16 Right hand side view CNC Foam Cutting Machine and Press Machine

Fig.17 Front View CNC Foam Cutting Machine and Press Machine

Fig.18 Right Angle View CNC Foam Cutting Machine and Press Machine

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
7.3 Mechanical components selection and Frame work:
When it comes to selecting mechanical components for a CNC hot wire foam cutting machine,
there are several factors to consider, such as the machine's size, cutting requirements, accuracy
needed, and budget. Here are some commonly used mechanical components and considerations
for their selection and assembly:
Linear Guides: Linear guides provide smooth and precise linear motion for the machine's
axes. They come in various types, such as ball screws, linear bearings, or profiled rail systems.
Factors to consider when selecting linear guides include load capacity, accuracy, rigidity, and
backlash. It's important to choose guides that can handle the weight of the cutting wire
assembly and provide the required precision for your cutting application.
Motors: Motors are responsible for driving the linear motion of the cutting wire assembly.
Stepper motors and servo motors are commonly used in CNC machines. Stepper motors are
cost-effective and provide precise positioning, while servo motors offer higher speed and
torque capabilities. Consider the required torque, speed, and control accuracy when selecting
motors, ensuring they are compatible with the chosen linear motion system.
Motion Control System: The motion control system consists of motor drivers and controllers
that interpret the instructions from the CNC controller and accurately move the cutting wire
assembly. Select motor drivers and controllers that are compatible with the chosen motors and
offer the required resolution and communication capabilities.
Power Transmission Components: Power transmission components, such as timing belts,
pulleys, and gears, transmit the rotational motion from the motors to the cutting wire assembly.
These components should be selected based on the required torque transmission, speed, and
backlash considerations.
Wire Tensioning Mechanism: The wire tensioning mechanism is crucial to maintain proper
tension in the cutting wire. It may involve pulleys, springs, or other tensioning devices.
Consider the required tensioning force and adjustability when selecting the components for the
wire tensioning mechanism.
Frame and Supports: The frame provides the structure and stability for the machine. It should
be rigid enough to minimize vibrations during cutting. Select materials such as steel or
aluminium extrusions that offer strength and durability. Ensure the frame design allows easy
access for maintenance and adjustments.
Fasteners and Hardware: Select appropriate fasteners and hardware, such as screws, nuts,
and brackets, for assembling the various components securely. Consider factors like material
strength, corrosion resistance, and compatibility with the chosen frame and components.
Safety Features: Incorporate safety features like emergency stop buttons, protective covers,
and sensors to ensure operator safety. Select components that meet safety standards and provide
reliable protection during machine operation.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
7.4 Cutting Tool Integration:
Hot Wire Selection: Choose a suitable hot wire material based on your cutting requirements.
Common options include nichrome and titanium wires, which have high heat resistance and
durability. The wire diameter should be selected based on the desired cut width and the foam
material's thickness.
Wire Mounting: Mount the hot wire securely in the cutting assembly. The wire is typically
tensioned across a frame or armature, which ensures its stability during the cutting process.
The wire mounting mechanism should allow easy adjustment of tension and replacement of
the wire when necessary.
Wire Heating System: The hot wire needs to be heated to a precise temperature for effective
cutting. The heating system usually consists of a power supply, temperature controller, and wire
connection points. The power supply provides the electrical current required to heat the wire,
while the temperature controller ensures accurate and consistent temperature control. The wire
should be properly connected to the power supply, and the electrical connections should be
secure and insulated.
Wire Control and Positioning: The hot wire's position and movement are controlled by the
machine's CNC controller and motion control system. The CNC controller interprets the cutting
instructions and sends commands to the motion control system to accurately position and move
the wire along the desired cutting path. The integration of the cutting tool with the CNC
controller involves configuring the appropriate axes, motion parameters, and programming the
cutting path.
Wire Cooling and Cleaning: During cutting, the hot wire may accumulate debris or foam
residue, which can affect cutting quality. Implement a wire cooling and cleaning system to keep
the wire clean and prevent excessive heat buildup. This can be achieved using air blowers or
compressed air to blow away debris and cool the wire during cutting pauses or tool changes.
Safety Considerations: The integration of the cutting tool should also include safety features.
Install protective covers or shields around the cutting area to prevent accidental contact with
the hot wire. Implement emergency stop buttons or safety interlocks to halt the machine's
operation in case of any safety concerns.
Calibration and Testing: Once the cutting tool is integrated, perform calibration and testing to
ensure its proper alignment and functionality. Verify that the wire is tensioned correctly, the
temperature control system is functioning accurately, and the wire follows the programmed
cutting path precisely.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

8. Electrical System

1. Stepper Motor Nema 17 Bipolar 40mm 64oz.in(45Ncm) 2A

Fig.19 Stepper Motor

The Nema 17 stepper motor is a commonly used type of stepper motor in various applications,
including CNC machines, 3D printers, robotics, and more. Here is some information about the
Nema 17 bipolar stepper motor with the specifications you provided:

• Size: The "Nema 17" designation refers to the motor's standard mounting dimensions,
with a faceplate measuring 1.7 x 1.7 inches (43.18 x 43.18 mm). This size is widely
used and offers a good balance between torque and physical dimensions.
• Bipolar Configuration: The Nema 17 bipolar stepper motor has two coils (windings)
and requires a bipolar stepper motor driver to control its operation. Bipolar stepper
motors offer higher torque compared to unipolar stepper motors but require a more
complex driver circuit.
• Holding Torque: The specified holding torque is 64 oz.in (45 Ncm). Holding torque is
the maximum torque that the motor can produce when stationary, with both coils
energized. It is an indication of the motor's ability to hold a position under load.
• Current Rating: The motor has a current rating of 2A. The current rating determines the
amount of current that can flow through each coil. It is crucial to match the motor's
current rating with the driver's current output capability to ensure proper operation and
prevent overheating.
• Steps per Revolution: The Nema 17 stepper motor typically has a step angle of 1.8
degrees per full step, resulting in 200 steps per revolution. This step resolution can be
further divided using microstepping techniques to achieve smoother motion and higher
precision.
• Wiring: The Nema 17 bipolar stepper motor has four wires, two for each coil. The coils
are typically wired in series or parallel, depending on the desired torque and driver
configuration.
• Driver Compatibility: To drive the Nema 17 bipolar stepper motor, you would need a
stepper motor driver capable of providing sufficient current and voltage to the motor
while properly controlling the sequence and timing of the coil energization.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
It's important to note that the performance and specifications of a stepper motor can vary
depending on the manufacturer and specific model. Therefore, it's recommended to refer to the
manufacturer's datasheet or documentation for precise specifications and wiring instructions
for your particular Nema 17 stepper motor model.

• Electrical Specification-

• Manufacturer Part Number: 17HS16-2004S


• Motor Type: Bipolar Stepper
• Step Angle: 1.8 deg.
• Holding Torque: 45Ncm(63.7oz.in)
• Rated Current/phase: 2A
• Phase Resistance: 1.1ohms
• Inductance: 2.6mH+/-20%(1KHz)

2. A4988 driver board

Fig.20 Driver board

A4988 driver board widely used in stepper motors /3D printer/CNC/engraving


machines/Supported 3d printers. A4988 is a complete microstepping motor driver with built-
in translator for easy operation.This stepper motor driver lets you to operate bipolar stepper
motors in full-, half-, quarter-, eighth-,and sixteenth-step modes, with an output drive capacity
of up to 35 V and 2 A. The translator is the key to the easy implementation of the A4988.
Simply inputting one pulse on the STEP input drives the motor one microstep. The A4988 is a
popular stepper motor driver board commonly used in various applications, including CNC
machines, 3D printers, and robotics. Here is some information about the A4988 driver board:

• Motor Compatibility: The A4988 driver board is designed to drive bipolar stepper motors,
including Nema 17 motors, which have two coils. It is not compatible with unipolar stepper
motors.
• Microstepping: The A4988 driver board supports microstepping, allowing for smoother
and more precise motion control. It can provide full-step, half-step, quarter-step, eighth-

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
step, sixteenth-step, or even higher microstepping resolutions, depending on the
configuration.
• Current Control: The A4988 driver board provides adjustable current control to regulate
the current flowing through the stepper motor coils. It has a built-in potentiometer to adjust
the current limit, allowing you to optimize the motor's performance and prevent
overheating.
• Step/Direction Control: The A4988 driver board uses step and direction control signals to
control the motion of the stepper motor. It accepts pulse signals on the step pin to move the
motor in discrete steps and direction signals on the direction pin to determine the rotation
direction.
• Voltage and Power Supply: The A4988 driver board typically operates with a supply
voltage between 8V and 35V. The driver board has built-in voltage regulation to provide
the necessary voltage levels for driving the stepper motor coils. It requires a separate power
supply to provide the voltage and current required by the stepper motor.
• Thermal Protection: The A4988 driver board incorporates thermal protection, which
monitors the temperature of the driver chip. If the temperature exceeds a certain threshold,
the driver will automatically reduce the current to prevent overheating and protect the
board.
• Arduino Compatibility: The A4988 driver board can be easily interfaced with
microcontrollers such as Arduino. It uses step and direction signals to control the motor,
making it compatible with the standard stepper motor libraries and programming examples
available for Arduino.
• Heat Sink: To dissipate heat generated during operation, the A4988 driver board often
requires a heat sink to be attached to the driver chip. The heat sink helps in maintaining the
optimal temperature and ensures reliable performance.

It's important to consult the datasheet and documentation specific to your A4988 driver board
for precise wiring instructions, current limit settings, and other technical details. The A4988
driver board is a widely used and well-documented stepper motor driver that provides a cost-
effective solution for driving bipolar stepper motors.

• Features-

• Thermal shutdown circuitry


• 3.3 and 5 V compatible logic supply
• Thermal shutdown circuitry
• five optional step mode: full, 1/2, 1/4, 1/8 and 1/16

• Specifications-

• Low RDS (ON) outputs


• Automatic current decay mode detection / selection
• Mixed with slow current decay modes
• Synchronous rectification for low power dissipation
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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
3. HiLetgo A4988 V3 Engraver Drive Shield

Fig.21 Engraver Drive Shield

The HiLetgo A4988 is a commonly available A4988 stepper motor driver module produced by
the HiLetgo brand. The A4988 module is a compact and versatile motor driver board that is
widely used in various DIY projects, including 3D printers, CNC machines, robotic systems,
and more. Here are some key features and details about the HiLetgo A4988 module:

• Stepper Motor Control: The HiLetgo A4988 module is designed to control bipolar stepper
motors, which have two coils. It can handle motor currents of up to 2A per coil, allowing
it to drive a wide range of stepper motors, including Nema 17 motors.
• Microstepping Support: The A4988 module supports up to 1/16 microstepping resolution,
which enables smoother and more precise motor movements compared to full stepping.
Microstepping allows for finer control over the stepper motor and can help reduce noise
and vibrations.
• Adjustable Current Limit: The module includes a potentiometer that allows you to adjust
the current limit to match the specific requirements of your stepper motor. Properly setting
the current limit is essential to prevent overheating and ensure optimal motor performance.
• Step/Direction Control: The A4988 module uses step and direction control signals to
command the stepper motor's movement. The step signal triggers each step movement, and
the direction signal determines the rotation direction.
• Thermal Protection: The module has built-in thermal protection that monitors the
temperature of the chip. If the temperature exceeds a certain threshold, the module will
automatically reduce the current to prevent overheating and protect the driver.
• Voltage and Power Supply: The HiLetgo A4988 module operates within a voltage range of
8V to 35V. It requires a separate power supply to provide the necessary voltage and current
to the stepper motor.
• Heat Sink Compatibility: Like most A4988 modules, the HiLetgo A4988 may benefit from
the addition of a heat sink to dissipate heat generated during operation. A heat sink can help
maintain a safe operating temperature and improve the overall reliability of the module.
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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• The HiLetgo A4988 module is compatible with microcontrollers such as Arduino, making
it easy to integrate into projects and control stepper motors using standard Arduino libraries
and programming.

• Each road stepper motors only need two IO ports


• This expansion board as a driver expansion board, can be used for engraving machines,
3D printers.
• PWM Spindle and direction pins. 4-Axis support. Runs on 12-36V DC
• It is a total of four slots, can drive four A4988 stepper motor. Each road stepper motors
only need two IO ports. In other words, six IO ports can be well managed three stepper
motors. Very convenient to use.
• Stepper motor wiring as follows: 2A, 2B is a group (red, green), 1A, 1B is a group
(blue, yellow), if want to change direction, can be change the position of one group ,
for example 2A, 2B mutually exchanged.

• Product Description-

• Microcontroller Microchip ATmega328P


• Operating Voltage 5V
• USB Standard Type B
• Digital I/O Pins 14
• PWM Digital I/O Pins 6
• Analog Input Pins 6
• Flash Memory 32 KB
• SRAM 2 KB
• EEPROM 1 KB
• Clock Speed 16 MHz

4. DC voltage regulator

Fig.22 DC voltage regulator


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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

In a CNC hot wire foam cutting machine, a DC voltage regulator is typically used to provide a
stable and regulated voltage to various components and subsystems. Here are some common
types of DC voltage regulators that may be used in a CNC hot wire foam cutting machine:

• Linear Voltage Regulator: Linear voltage regulators, such as the LM317 or LM7805, are
commonly used for low-power applications in CNC machines. They provide a fixed output
voltage and are relatively simple to use. However, they are less efficient and generate heat
when there is a significant voltage drop between the input and output.
• Switching Voltage Regulator: Switching voltage regulators, like the LM2596 or DC-DC
buck converters, are more efficient and suitable for higher power applications in CNC
machines. They use a switching mechanism to regulate the output voltage and are capable
of handling higher current loads. Switching regulators are more complex but offer
improved efficiency and better heat dissipation.
• Adjustable Voltage Regulator: Adjustable voltage regulators, such as the LM317, LM338,
or LM350, allow you to set the desired output voltage by adjusting the feedback resistors.
These regulators provide flexibility in choosing the output voltage based on the specific
requirements of the CNC hot wire foam cutting machine.

The specific choice of DC voltage regulator will depend on the power requirements, voltage
levels, and efficiency considerations of the CNC machine. It's important to ensure that the
voltage regulator can handle the required current and provide a stable output voltage to power
various components, including the stepper motor drivers, microcontroller, control circuitry, and
any other subsystems in the machine.

When selecting a DC voltage regulator, consider factors such as input voltage range, output
voltage range, maximum current rating, efficiency, thermal considerations, and any specific
requirements of the components in the CNC hot wire foam cutting machine. Always refer to
the datasheet and manufacturer specifications for proper usage guidelines and to ensure
compatibility with your specific application.It is made of electronic accessories, nickel
plating on surface(anti-oxidatioan), inner conductor: pure copper.it is long lasting and durable
for you to use.A heat sink is added to make the module better, and a large area of copper and
dense vias enhance heat dissipation. it has current limiting, short circuit and over temperature
protection. Input voltage is about dc4-40v (try not to exceed 38V as input).Output voltage is
about 1.25-36V continuously adjustable. Output current is about 0-8A, recommended for use
within 4.5A High conversion efficiency up to 94%. It can reach up to 8A 200W high power,
high efficiency and low ripple with power indicator. In addition to the current limiting and
voltage regulation step-down function. High reliability, strong vibration resistance, good
electromechanical performance.This module can be applied to the buck field where the input
voltage is higher than the output voltage, such as battery, power transformer, DIY adjustable
power supply, and so on. The output current is up to 8A.Need to add fan when using long-
term work recommendations within 5A!

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Specifications-

• Product name: DC voltage regulator


• Voltage regulation: PWM modulation
• Input voltage: DC4-40V
• Output range: DC1.25-36V
• Current: 8A
• Power: 200w
• Conversion efficiency: 94%
• Switching frequency: 180KHz
• Appearance size: 61*41*27mm

5. URBEST AC 250V 5A SPDT

Fig.23 Single Pole Double Throw

The URBEST AC 250V 5A SPDT (Single Pole Double Throw) relay can also be used in a hot
wire CNC foam cutting machine for similar purposes as mentioned earlier. Here's some
information about the URBEST AC 250V 5A SPDT relay:

• SPDT Configuration: Like other SPDT relays, the URBEST AC 250V 5A relay has three
terminals - a common terminal (COM), a normally open terminal (NO), and a normally
closed terminal (NC). It allows the switching of a single input to either of the two output
paths
• Voltage and Current Ratings: The URBEST AC 250V 5A SPDT relay is rated for a
maximum voltage of 250V AC and a maximum current of 5A. This means it can handle up
to 5A of current flowing through the relay contacts when switched.
• Coil Control: The relay is controlled by an input coil that requires a specific voltage to
activate the switching mechanism. The coil voltage is typically lower than the voltage being
switched by the relay contacts. The coil is energized to switch the relay from its normally
open or normally closed state.
• Application in CNC Foam Cutting Machine: In a hot wire CNC foam cutting machine, the
URBEST AC 250V 5A SPDT relay can be used to control various aspects of the machine's
operation. It can be utilized to control power to the hot wire, switch between different
modes or configurations, or control the movement of the cutting wire.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Safety Considerations: As with any electrical component, it's crucial to follow safety
measures when using the URBEST AC 250V 5A SPDT relay in a CNC foam cutting
machine. Ensure proper insulation, grounding, and protection against short circuits or
overloads. Adhere to proper wiring practices and consult with a qualified electrician or
engineer to ensure safe integration into the CNC foam cutting machine.

Always consult the manufacturer's specifications and documentation for specific guidelines,
wiring instructions, and precautions related to the URBEST AC 250V 5A SPDT relay.
Additionally, it is recommended to seek professional guidance to ensure the proper installation
and safe operation of the relay in your CNC foam cutting machine.

• Specifications-

• Product Name : Micro Switch;Voltage & Current : AC 250V 5A;Poles :


SPDT;Contact Type : 1NO + 1NC
• Action Type : Momentary;Actuator Type : Roller Lever Arm;Terminal Type : 3-
Pin Terminals;Overall Size : 20 x 6.5 x 13.5mm / 0.79" x 0.26" x 0.53" Mounting
Hole Dia. : 2mm / 0.08";Mounting Hole Spacing : 9.5mm / 0.37";Pin Pitch : 7.2 x
9mm / 0.28" x 0.35"
• Lever Arm Size : 17.5 x 4mm / 0.69" x 0.16" (L*W);Roller Size : 5 x 3mm / 0.2"
x 0.12" (D*T);Material : Plastic, Metal
• Color : Black, Silver Tone;Total Weight : 24g;
• Need : 10 x Micro Switches

6. LEDMO 12V 5A 60W Power Supply Adapter

Fig.24 Adapter

The LEDMO 12V 5A 60W Power Supply Adapter is a power supply unit commonly used to
provide stable and regulated power to various electronic devices and components. In the
context of a hot wire CNC foam cutting machine, this power supply adapter can be used to
power different components that require a 12V DC power source. Here's some information
about the LEDMO 12V 5A 60W Power Supply Adapter:

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Voltage and Current Ratings: The LEDMO power supply adapter provides a regulated
output voltage of 12V DC. It has a maximum output current of 5A, which means it can
deliver up to 5 amps of current to the connected devices.
• Power Output: The power supply adapter has a maximum power output of 60W. This power
rating indicates the maximum amount of power the adapter can provide to the connected
devices without exceeding its capacity.
• Input Voltage: The LEDMO power supply adapter is designed to work with a wide range
of input voltages, typically ranging from 100V to 240V AC. This flexibility allows it to be
used with different power systems around the world.
• Connector Type: The power supply adapter is typically equipped with a standard DC barrel
connector, which is a common connector type used in many electronic devices. The specific
size and polarity of the connector may vary, so it's important to ensure compatibility with
the devices you intend to power.
• Protection Features: The LEDMO power supply adapter usually includes built-in protection
features such as overcurrent protection, overvoltage protection, and short circuit protection.
These safeguards help protect the connected devices and the power supply itself from
potential damage or malfunctions.
• Application in CNC Foam Cutting Machine: The LEDMO 12V 5A 60W Power Supply
Adapter can be used in a hot wire CNC foam cutting machine to power various components
that require a 12V DC power supply. This may include stepper motor drivers, control
circuits, microcontrollers, LED lighting, cooling fans, and other electronic components.
• When using the LEDMO power supply adapter or any power supply unit, it is important to
ensure that the power supply can provide sufficient current and voltage for all the
components in the CNC foam cutting machine. Also, ensure that the total power
requirements of the components do not exceed the power supply's rated capacity.
• Always follow the manufacturer's instructions, guidelines, and safety precautions provided
with the LEDMO power supply adapter to ensure proper and safe operation in your CNC
foam cutting machine.
• LED power supply widely used for LED strip lights, and any 12V DC led lights
• New upgraded Low fever & No Noise | Full Wattage 60 W | Long Lifespan
• Easy installation, save time and more securer cable connection(4.92ft)no hard wiring, no
soldering, no electrician or electrical experience required. Includes output cable with a
standard 5.5 x 2.1mm DC jack (positive tip) for connecting to your strip, controller, or
dimmer
• Full protection of over Voltage, over Current, short Circuits and over temperature
• 5 year warranty, UL Listed(number: E488794), CE and FCC. High quality commercial
grade AC to DC power supply adapter.

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D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

Chapter .9

Design Software Analysis

• Heat Transfer Model

Temperatures transferred to the plastic foam by conduction from the hot-tool can be
calculated via the nonlinear transient thermal finite element equation. The following
sections describe the temperature-dependant material properties of the foam and the time
dependant heat loads embedded in equation. Also described in this section are the
assumptions, elements and mesh management used in the simulations.

• Assumptions

A number of assumptions have been made in developing the finite element model,
including. The temperature distribution across the centreline is assumed symmetrical. The
foam material is isotropic and homogeneous. Thermal expansion is negligible; therefore,
the model geometry is constant. Moving foam work piece Planes of symmetry Static hot-
wire or hot-ribbon The conductivity of the foam is low and therefore heat transfer on the
surfaces far away from the wire is negligible. The surfaces can be treated as adiabatic.
The hot-tool is perfectly surrounded by foam at all times; therefore, conduction is the only
mode of heat transfer. Thermal degradation of the PS plastic at temperatures over 400°C is
assumed negligible.

The kerf width is represented by the maximum width of the isotherm at the temperature at
which the cells collapse. A value of 160°C was adopted from literature.
These assumptions allow the model to be made half the size, using symmetry to reduce the
number of elements required. The main assumption in the model is that the hot-tool is
always surrounded by foam. This inevitably leads to more heat being conducted into the
foam than if an air gap were surrounding a portion of the cutting element. This effect is
somewhat balanced by the fact that the conductivity of air is relatively close to that of EPS
and XPS (e.g., conductivity of air at 100°C = 0.031 W/mK and the conductivity of XPS at
100°C = 0.032 W/mK). Also, the radiated energy from the hot-tools is approximately 1%
and can be assumed negligible.

It is expected that the FEA results will depart from experimental data for high energy cuts
as the air gap surrounding the wire increases. Thermal degradation of the PS has also been
ignored for two main reasons; firstly, the cutting tool temperature is rarely over 400°C and
therefore has no effect on the majority of cases, and secondly it greatly simplifies the model
and reduces computing time. Because thermal degradation of PS is an endothermic
reaction, ignoring it will result in higher temperatures in the foam and larger recorded kerf
widths when compared to experimental data.

52
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
A heat transfer model for a hot wire CNC foam cutting machine involves understanding
the different modes of heat transfer that occur during the cutting process. The main modes
of heat transfer involved in this context are conduction, convection, and radiation. Here's a
brief overview of each:

Conduction: Conduction is the transfer of heat through direct contact between materials.
In the case of a hot wire foam cutting machine, conduction occurs when the heated wire
comes into contact with the foam material. The heat from the wire is transferred to the foam
through direct contact, causing the foam to soften and melt.Factors that influence
conduction include the thermal conductivity of the foam material, the temperature gradient
between the wire and the foam, and the contact area between the wire and the foam.

Convection: Convection is the transfer of heat through the movement of fluids, such as air
or gases. In a hot wire foam cutting machine, convection plays a role in the heat transfer
process as air circulates around the heated wire and the foam material.

Factors that influence convection include the velocity of the air, the temperature difference
between the wire/foam and the surrounding air, and the surface area of the wire and foam
exposed to the airflow.

Radiation: Radiation is the transfer of heat through electromagnetic waves. In the context
of a hot wire foam cutting machine, radiation occurs when the heated wire emits thermal
radiation that is absorbed by the foam material.

Factors that influence radiation include the temperature of the wire, the emissivity of the
wire and foam material, and the distance between the wire and the foam.Developing a
comprehensive heat transfer model for a hot wire CNC foam cutting machine requires
considering the specific geometry of the machine, the thermal properties of the materials
involved (such as the foam and the wire), the heat generation by the wire, and the
surrounding environmental conditions.Numerical methods, such as finite element analysis
(FEA) or computational fluid dynamics (CFD), can be used to simulate and analyze the
heat transfer processes in a hot wire foam cutting machine. These methods allow for a
detailed understanding of the temperature distribution, heat fluxes, and other heat transfer
parameters within the system.It's important to note that the complexity and accuracy of the
heat transfer model will depend on the specific requirements and level of detail needed for
the analysis.

53
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
Software Analysis:

• Meshing in Ansys-

Fig.25 Meshing in Ansys

• Fixed Support-

Fig.26 Fixed Support

54
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Load Applied on Structure-

Fig.27 Load Applied on Structure

• Structural Analysis Stress Result-

Fig.28 Structural Analysis Stress Result

55
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

10.Testing and Evaluation

10.1 Functional Testing of machine components:


Functional testing of machine components is crucial to ensure the proper operation and
performance of a CNC hot wire foam cutting machine. Here are some key machine components
and suggested functional tests for each:

• Control System:
Verify the control panel functionality, including buttons, switches, and indicators. Test the
homing sequence to ensure proper axis alignment. Validate the control system's response to
emergency stop commands. Check the communication between the control software and the
machine.

• Wire Tensioning System:


Confirm the wire tension adjustment mechanism is working correctly. Test the wire tensioning
system's ability to maintain consistent tension during cutting. Assess the wire tensioning
system's response to changes in cutting speed.

• Cutting Wire:
Verify the wire installation and alignment. Perform a trial cut to ensure the wire heats up
properly and maintains its temperature. Test the wire's stability during cutting and its ability to
follow programmed paths accurately.

• Axis Movement:
Verify the movement of each axis (X, Y, Z) according to the control commands. Test the axis
movement range to ensure it matches the machine specifications. Assess the smoothness and
accuracy of axis movements by running test patterns.

• Safety Features:
Test emergency stop functionality to ensure immediate machine shutdown. Validate the
response of safety sensors, such as limit switches and interlocks. Check the effectiveness of
safety mechanisms for wire breakage or wire entanglement.

• Heating and Temperature Control:


Monitor and measure the wire temperature during cutting to ensure it remains within the
desired range. Test the temperature control system's ability to maintain consistent wire
temperature.

• Material Handling System (if applicable):


Test the material clamping and positioning mechanisms for secure and accurate material
placemen. Verify the functionality of material feeding systems, if present.

56
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
• Peripheral Systems (e.g., dust extraction, cooling):
Verify the proper functioning of peripheral systems, such as dust extraction systems or cooling
mechanisms. Test their ability to effectively remove foam dust and maintain a safe operating
environment.
During functional testing, document any observed issues, malfunctions, or deviations from
expected performance. These tests help ensure that the machine components are functioning as
intended, identify any potential issues early on, and allow for adjustments, repairs, or
maintenance as needed. Always follow the manufacturer's guidelines and safety precautions
when conducting functional tests.

• Wire Temperature and Current Table:


Wire Temperature
Current (A)
(oC)
0.5 29
1.0 45
1.5 66
2.0 98
2.5 125
2.6 167
2.8 148
2.9 158
Table.1 Wire Temperature and Current

• Wire Temperature And Time During Cutting :

Time (sec) Wire Time (sec) Wire


Temperature Temperature
(oC) (oC)
0 317 11 283
1 314 12 280
2 307 13 289
3 304 14 297
4 303 15 295
5 300 16 267
6 296 17 275
7 293 18 275
8 288 19 271
9 280 20 273
10 278 21 276

Table.2 Wire Temperature And Time During Cutting

57
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
10.2 Observation and Calculation:
• Stepper Motor Selection calculations-
• Mass of components including spindle(approx.): 4Kg
• Fm = 4x9.81 = 39.24N • Frictional Force
• Ft = μ*Fm = 0.2x39.24 =7.848N
• Force required for pushing the wire into work piece for machining Fc = 20N(approx.)
• Total Force: FT = Fm+ Ft+ Fc = 39.24+7.848+20 = 67.088N

Temperature Voltage Current Resistance


(oC) (Volts)±0.005 (Amperes)±0.005

23 (Room temp) 0 0 0
50 0.39 0.46 0.858
100 0.7 0.72 0.972
150 0.9 0.93 0.968
200 1.1 1.14 0.965
250 1.71 1.4 1.22
300 1.65 1.67 0.988
350 1.79 1.8 0.994
400 2.02 2.02 1
450 2.4 2.15 1.12
500 2.32 2.31 1
550 2.55 2.52 1.01
600 2.66 2.64 1.01

650 2.73 2.71 1.01


700 2.9 2.86 1.01
750 3.05 3.01 1.01
800 3.24 3.2 1.01
850 3.62 3.58 1.01
900 3.91 3.86 1.01
950 4.12 4.15 0.993

58
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune
➢ Thermal Plastic Foam Cutting

This section provides an overview of plastic foam cutting (PFC). It begins with information
about polystyrene foams and their manufacture, followed by the PFC process and a brief
description of the thermomechanical mechanisms involved in the process.

Metal Build
Starch Metal Plastic Photopolym Plasti Photopolym
Plastic, Materi
Plaster, Plastic, Paper, ers cs ers
Wood, al
Complexi Excelle Very
Fair Fair Good Fair Poor
ty nt good
Excelle Very
Accuracy Fair Fair Good Fair Excellent
nt good
Very Modera
Cost High Low Very high Low Low
high te
Build Excelle Excelle
Good Poor Excellent Poor Excellent
Size nt nt
Averag Very Very
Speed Poor Good Average Excellent
e good good
SLA FDM Inkjet 3DP SLS LOM SRP
RP
Property
Process

59
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

11.Result and Conclusion


11.1 Result:
The result of a hot wire CNC foam cutting machine is the precise cutting and shaping of foam
materials according to the programmed design. The machine uses a heated wire, typically made
of nichrome or a similar material, to melt and cut through the foam material. The foam material
can be expanded polystyrene (EPS), extruded polystyrene (XPS), or other types of foam.The
hot wire CNC foam cutting machine offers several advantages and produces several results,
including:
• Precision: The machine can precisely cut intricate shapes, curves, and angles in foam
materials. It follows the programmed design with high accuracy, allowing for consistent
and precise cuts.
• Efficiency: The CNC foam cutting machine automates the cutting process, enabling
faster and more efficient production compared to manual cutting methods. It can
produce a large number of identical foam pieces quickly.
• Versatility: The machine can handle a wide range of foam thicknesses and densities. It
can cut foam blocks or sheets into various shapes and sizes, depending on the design
specifications.
• Smooth and Clean Cuts: The hot wire melts through the foam material, resulting in
smooth and clean cuts without rough edges or burrs. This ensures a professional and
finished appearance of the cut foam pieces.
• Reproducibility: The CNC foam cutting machine allows for the easy reproduction of
designs. Once a design is programmed, it can be replicated consistently, ensuring
uniformity in the produced foam pieces.
• Customization: The machine offers flexibility in terms of design customization. It can
cut foam materials into unique shapes and sizes, catering to specific project
requirements or customer preferences.
Overall, the result of using a hot wire CNC foam cutting machine is the production of
accurately cut foam pieces with precision, efficiency, and versatility. These foam pieces can be
used in various applications, such as packaging, insulation, architectural models, props,
signage, and more.

60
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

11.2 Conclusion :
In conclusion, the hot wire CNC foam cutting machine is a valuable tool that offers precise
and efficient cutting of foam materials. It combines the use of a heated wire and computer-
controlled movements to create intricate and accurate cuts in foam blocks or sheets.
The hot wire CNC foam cutting machine provides several advantages. It allows for the
automation of the cutting process, which increases productivity and reduces manual labor.
The machine can cut complex shapes and designs with high precision, ensuring consistent
results. It offers versatility in terms of foam thicknesses, densities, and customization options.
Throughout the project, careful consideration should be given to the selection and assembly
of the machine's components, such as the frame, stepper motors, hot wire system, and control
electronics. Programming the machine with appropriate cutting paths and designs is also
crucial.
Safety measures should be implemented to protect operators and ensure the safe operation of
the machine. Regular maintenance and calibration of the machine are important to maintain
its performance and accuracy.The hot wire CNC foam cutting machine finds applications in
various industries, including packaging, insulation, model making, signage, and more. It
provides a cost-effective solution for producing foam parts with precision and efficiency.
In summary, the hot wire CNC foam cutting machine is a valuable asset for foam fabrication.
It offers precise cutting, automation, versatility, and customization options. With proper
assembly, programming, and maintenance, it can be a reliable tool for foam cutting
operations in a wide range of industries.

61
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)
Savitribai Phule University Pune

12. References

1. Bortner, Dr. Larry. "Temperature Dependence of Resistance." Temperature Dependence


of Resistance. Web. 12 Jan. 2014. Contains equations and information about resistance
and temperature.
2. "Dependence of Resistance on Temperature." Boundless. Boundless, n.d. Web. 6 Nov.
2013. < https://www.boundless.com/physics/electric-current-and-resistance/resistance-
and-resistors/dependence-of-resistance-on-temperature/> Useful for learning about
resistivity.
3. Giancoli, Douglas C. Physics: Principles with Applications. 3rd ed. New Jersey:
Pearson, 2009. Print. A good resource in general and for learning about Ohm's Law.
4. Kuphdalt, T.R. "Temperature coefficient of resistance." Fundamentals of Electrical
Engineering and Electronics, 1 Dec. 2010. Web. 1 Jan. 2014.
<http://www.vias.org/feee/conduct_07.html> Contains good information about the
temperature coefficient of resistance and contains a nice diagram.
5. Kwan, Harvey. "Resistivity of Nichrome." The Physics Factbook. Glenn Elert, 2007.
Web. 6 Nov. 2013. <http://hypertextbook.com/facts/2007/HarveyKwan.shtml>
Contains information about the properties of Nichrome.
6. "Resistance." The Physics Classroom. The Physics Classroom, 2013. Web. 6 Nov. 2013.
<http://www.physicsclassroom.com/class/circuits/Lesson-3/Resistance> A resource
about resistance and what variables affect it.

62
D.Y. PATIL INSTITUTE OF ENGINEERING AND TECHNOLOGY, AMBI, B.E. (MECHANICAL)

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