ABSTRACT

The rapid growth of technology has improved the use and use of computer-based
manufacturing systems to a large extent, but the cost is considerable. The manufacturing
concept of a low cost CNC router is put forward to reduce the cost and complexity of a
computerized manufacturing system. This project discusses the development of low-cost
CNC routers that can perform 5-axis interpolation at the same time. By combining standard
PC interfaces with CNC-based control systems, the cost is achieved in Mach 3-based
embedded systems. The system also contains an offline G code Analyzer, which is then
interpreted from the USB on the controller.

The system adopts enhanced software and reduces computer expenditures to control the 5-
axis CNC machine. The main idea of the design of this device is to target small industries and
increase annual production. Grinding machines are actually machines used for processing
metal, wood and other solids. The computer milling machine has two directions, portrait or
landscape, and the material is divided according to the previously mentioned design. In 5 axis
CNC Vertical Milling machine, the tool/table moves in 5 ways. Fast cycle times, ease of
setup reduction of work, flexibility and quality finish make 5 machining axle ideal for
manufacturing complex parts such as turbines, curved holes and impeller that can only
produce 5 axis milling machines.

Vertical Milling machines are more suitable for composite angle milling, conventional
milling fixture drilling, drilling, and desktop computers. Ideal for small pieces of production
rooms, workshops and technical school demonstrations. 5 CNC axles are designed with three
ball screws for three pan shafts and five stepper motors to control each of the five axes. These
main components come from the market and serve as a basis for the design of the rest of the
ingredients. In order to establish seamless integration and verify the process design of 100%
machine parts, PRO-E was adopted before manufacturing parts of the machine. Aluminum
alloy, T-condition has low cost, corrosion resistance and other characteristics. We have
designed 5 axis manufacturing using vertical milling machine using PLC control unit using
"Software design program Mach 3 milling machine ". Due to the accuracy of some
components, the design and testing of the machines passed the infant mortality stage, and
after the necessary adjustments, it now works well. The volume of work to be manufactured
on this machine is limited by the size of the base block (115x160) mm. These soft materials
are compatible with low power stepper motors. The performance of 5-axis CNC mill at the
top of the manufacturing table is completely satisfactory.
 CONTENTS
1 SYNOPSIS........................................................................................................................................................

1.1 INTRODUCTION...................................................................................................................................

1.2 AUTOMATIC TOOL CHANGER (ATC)..................................................................................................

2 LITERATURE REVIEW.......................................................................................................................................

2.1 ATC ON VERTICAL MILLING.................................................................................................................

2.2 TYPES OFMILLING MACHINES.............................................................................................................

2.2.1 VERTICAL MILLING MACHINE................................................................................................................

2.2.2 HORIZONTAL MILLING MACHINE..........................................................................................................

2.3 MILLING PROCESSES............................................................................................................................

2.4 COMPUTER NUMERICAL CONTROL (CNC).........................................................................................

2.4.1 MAINCONSTITUENTS OF CNC:............................................................................................................

2.4.2 PROGRAM OF COMMANDS:...............................................................................................................

2.4.3 MACHINE CONTROL UNIT (MCU):.......................................................................................................

2.4.4 PROCESSING EQUIPMENT:..................................................................................................................

2.5 DIFFERENT TYPES OF CNCS:...............................................................................................................

2.6 AXIS MACHINE MACHINING CENTERSCONFIGURATION:..................................................................

2.6.1 TTTRR CONFIGURATION:.....................................................................................................................

2.6.2 RRTTT CONFIGURATION:.....................................................................................................................

2.6.3 RTTTR CONFIGURATION:.....................................................................................................................

3 DESIGN CONDITIONS....................................................................................................................................

3.1 DESIGN CONDITIONS OF ATC FOR 5 AXIS CNC MILLING MACHINE...................................................

3.2 DESIGN CHARACTERISTICS................................................................................................................

3.3 MATERIAL USED IN THE MANUFACTURING......................................................................................

3.3.1 ALUMINIUM........................................................................................................................................

4 CALCULATIONS..............................................................................................................................................

4.1 MILLING MACHINE CALCULATIONS...................................................................................................

4.1.1 METAL REMOVAL RATE.......................................................................................................................

2
 4.1.2 FEED PER TOOTH.................................................................................................................................

4.1.3 CUTTING SPEED...................................................................................................................................

4.1.4 NUMBER OF TEETH OF CUTTER..........................................................................................................

4.1.5 POWER AT THE CUTTING TOOL...........................................................................................................

4.1.6 POWER AT THE MOTOR......................................................................................................................

4.1.7 THRUST FORCE....................................................................................................................................

4.1.8 MOTOR TORQUE.................................................................................................................................

5 COMPUTER AIDED DESIGN...........................................................................................................................

5.1 OVERVIEW.........................................................................................................................................

5.2 CAD SOFTWARE.................................................................................................................................

5.3 CAD MODELING.................................................................................................................................

5.4 PLANNING OF DESIGN.......................................................................................................................

5.5 DESIGN CONCEPTS............................................................................................................................

5.6 PARTS MODELING.............................................................................................................................

5.7 DESIGNING IN PRO ENGINEER...........................................................................................................

6 FEM Structural Analysis.................................................................................................................................

6.1 OVERVIEW.........................................................................................................................................

6.2 ANSYS SOFTWARE.............................................................................................................................

6.3 FEM ANALYSIS...................................................................................................................................

6.4 ANALYSIS CONCEPTS.........................................................................................................................

6.5 ANALYSIS SYSTEMS............................................................................................................................

6.5.1 GEOMETRY..........................................................................................................................................

6.5.2 ENGINEERING DATA............................................................................................................................

6.6 MESHING...........................................................................................................................................

6.7 FORCES..............................................................................................................................................

6.8 SOLUTION..........................................................................................................................................

6.9 CNC WORKTABLE..............................................................................................................................

6.9.1 MESHING............................................................................................................................................

3
 6.9.2 FORCES................................................................................................................................................

6.9.3 TOTAL DEFORMATION........................................................................................................................

6.9.4 EQUIVALENT STRESS...........................................................................................................................

7 PARTS MANUFACTURING &MECHANICALASSEMBLY....................................................................................

7.1 PARTS MANUFACTURING..................................................................................................................

7.2 T-SLOT TABLE....................................................................................................................................

7.2.1 SIDE AND SURFACE MILLING OPERATION...........................................................................................

7.2.2 SLOTTING OPERATION........................................................................................................................

7.2.3 DRILLING OPERATION.........................................................................................................................

7.3 FIXTURE.............................................................................................................................................

7.4 AB AXES CONNECTOR........................................................................................................................

7.5 BALL SCREW SUPPORT......................................................................................................................

7.6 BALL SCREWS....................................................................................................................................

7.6.1 ADVANTAGES AND DISADVANTAGES OF BALL SCREWS......................................................................

7.6.1.1 ADVANTAGES OF BALL SCREWS............................................................................................50

7.6.1.2 DISADVANTAGES OF BALL SCREWS.......................................................................................51

7.6.1.3 PARAMETERS OF BALL SCREWS............................................................................................51

7.6.1.3.1 PITCH...............................................................................................................................51

7.6.1.3.2 BULLETS...........................................................................................................................51

7.6.1.3.3 AXIS YARN........................................................................................................................51

7.6.1.3.4 THREAD ANGLE................................................................................................................51

7.7 BUSHING...........................................................................................................................................

7.8 BEARINGS..........................................................................................................................................

7.8.1 BALL BEARING.....................................................................................................................................

7.9 COMPLETE FABRICATION..................................................................................................................

8 ELECTRONICS AND CIRCUITRY.......................................................................................................................

8.1 ELECTRONIC CONTROL SYSTEM........................................................................................................

8.1.1 PROBLEM DEFINITION.........................................................................................................................

4
 8.1.2 BASIC APPROACH................................................................................................................................

8.1.3 OBJECTIVES.........................................................................................................................................

8.1.4 MOTOR SELECTION.............................................................................................................................

8.2 STEPPER MOTOR...............................................................................................................................

8.2.1 BENEFITS OVER SERVO AND DC MOTORS...........................................................................................

8.2.2 Types of Stepper Motor......................................................................................................................

8.2.2.1 VARIABLE-RELUCTANCE........................................................................................................57

8.2.2.2 PERMANENT MAGNET..........................................................................................................58

8.2.2.3 HYBRID..................................................................................................................................58

8.2.2.4 PHASES AND POLES...............................................................................................................59

8.2.3 PHASE CURRENT WAVEFORMS...........................................................................................................

8.2.3.1 WAVE DRIVE (ONE PHASE ON)..............................................................................................60

8.2.3.2 FULL STEP DRIVE (TWO PHASES ON).....................................................................................60

8.2.3.3 HALF STEPPING.....................................................................................................................60

8.2.3.4 POSITIONAL ERROR...............................................................................................................61

8.3 STEPPER MOTOR SPECIFICATIONS....................................................................................................

8.3.1 MOTOR X Y & Z AXIS...........................................................................................................................

8.3.2 MOTOR A & B......................................................................................................................................

8.4 STEPPER MOTOR WIRES....................................................................................................................

8.4.1 STEPPER MOTOR CIRCUIT...................................................................................................................

8.5 CONTROL BOARD IMPLEMENTATION...............................................................................................

8.5.1 COMMUNICATION WITH PC...............................................................................................................

9 LIMITATIONS, RECOMMENDATIONS AND CONCLUSIONS............................................................................

9.1 Limitations.........................................................................................................................................

9.2 Recommendations............................................................................................................................

9.3 Conclusion.........................................................................................................................................

9.4 G Codes.............................................................................................................................................

10 Appendix A....................................................................................................................................................

5
 10.1 JOB 1.................................................................................................................................................

10.2 JOB 2.................................................................................................................................................

10.3 JOB 3.................................................................................................................................................

11 REFERENCES..................................................................................................................................................

6
 LIST OF FIGURES
Figure 1 5 AXIS DESKTOP CNC VERTICAL MILLING MACHINE................................................................................3

Figure 2 BASIC FIVE AXIS MILLING MACHINE [4].....................................................................................................6

Figure 3 PERIPHERAL MILLING[11]........................................................................................................................8

Figure 4 FACE MILLING [11]...................................................................................................................................8

Figure 5 CONVENTIONAL FACE MILLING [11].......................................................................................................9

Figure 6 END MILLING [11]................................................................................................................................9

Figure 7 PROFILE MILLING [11].........................................................................................................................10

Figure 8 POCKET MILLING [ 11].........................................................................................................................10

Figure 9 SURFACE CONTOURING [11]..................................................................................................................11

Figure 10 BLOCK DAIGRAM OF PROGRAMMABLE LOGIC CONTROL SYSTEM......................................................13

Figure 11 Three Axis CNC Machine [10]...............................................................................................................15

Figure 12 Five Axis CNC Machine [10].................................................................................................................15

Figure 13 COMPLETE ASSEMBLY OF MACHINE....................................................................................................20

Figure 14 T SLOT TABLE......................................................................................................................................27

Figure 15 BALL SCREW.........................................................................................................................................28

Figure 16 BALL SCREW NUT.................................................................................................................................29

Figure 17 X & Y Axis Sliding Part..........................................................................................................................30

Figure 18 ball Screw End Support Part................................................................................................................30

Figure 19 Z-Axis Ball Screw..................................................................................................................................31

Figure 20 Z-AXIS BASE 2.......................................................................................................................................31

Figure 21 XY-AXIS BASE 1.....................................................................................................................................32

Figure 22 ISOMETRIC VIEW.................................................................................................................................33

Figure 23 FRONT VIEW........................................................................................................................................35

Figure 24 SIDE VIEW............................................................................................................................................37

Figure 25 TOP VIEW.............................................................................................................................................39

Figure 26 CNC WORKTABLE................................................................................................................................43

Figure 27 MESH...................................................................................................................................................44

Figure 28 FORCES AND FIXED SUPPORT..............................................................................................................44

Figure 29 TOTAL DEFORMATION.........................................................................................................................45

Figure 30 EQUIVALENT STRESS............................................................................................................................46

Figure 31 T-SLOT TABLE.......................................................................................................................................49

Figure 32 FIXTURE...............................................................................................................................................50

Figure 33 AB CONNECTOR...................................................................................................................................51

Figure 34 Ball Screw Support...............................................................................................................................52

Figure 35 BALL SCREWS [17]................................................................................................................................53

Figure 36 BUSHING [17].......................................................................................................................................55

Figure 37 BALL BEARING [17]..............................................................................................................................56

Figure 38 COMPLETE FABRICATED MODEL..........................................................................................................57

Figure 39 CROSS-SECTIONAL DIAGRAM OF A VARIABLE RELUCTANCE MOTOR WINDING [15]...........................61

Figure 40 CROSS-SECTIONAL DIAGRAM OF A PERMANENT MOTOR WINDING [15]............................................62

Figure 41 UNIPOLAR AND BIPOLAR WOUND STEPPER MOTORS [15]..................................................................63

Figure 42 DIFFERENT PHASE CURRENT WAVEFORMS FOR STEPPER MOTOR [15]...............................................65

Figure 43 STEPPER MOTOR CONNECTOR [15].....................................................................................................66

Figure 44 STEPPER MOTOR DRIVE [15]................................................................................................................67

Figure 45 EIC 2032 [15]........................................................................................................................................68

Figure 46 EIC 4011 [15].......................................................................................................................................68

Figure 47 JOB 1....................................................................................................................................................74

Figure 48 JOB 2....................................................................................................................................................76

Figure 49 JOB 3....................................................................................................................................................78

8
 LIST OF TABLES
Table 1 DESIGN SPECIFICATIONS...........................................................................................................................5

Table 2 DESIGN SPECIFICATIONS.........................................................................................................................22

Table 3 10 T SLOT TABLE.....................................................................................................................................32

Table 4 MACHINE PERIMETER.............................................................................................................................37

Table 5 X-AXIS T SLOT TABLE PERIMETER............................................................................................................38

Table 6 X -AXIS BALL SCREW PERIMETER.............................................................................................................39

Table 7 X-AXIS STEPPER MOTOR SPECIFICATIONS...............................................................................................39

Table 8 Z-Axis SPECIFICATIONS............................................................................................................................40

Table 9 Z-AXIS BALL SCREW.................................................................................................................................41

Table 10 Z-AXIS STEPPER MOTOR SPECIFICATIONS.............................................................................................41

Table 11 Y-AXIS T SLOT TABLE SPECIFICATIONS...................................................................................................42

Table 12 BALL SCREW SINGLE START...................................................................................................................42

Table 13 Y-AXIS STEPPER MOTOR SPECIFICATIONS.............................................................................................43

Table 14 PORT ADRESSES....................................................................................................................................72

 1 SYNOPSIS

1.1 INTRODUCTION

Design and fabrication of automatic tool changer for up gradation of 5- axis

desktop CNC vertical milling machine.

1.2 AUTOMATIC TOOL CHANGER (ATC)

ATC type there are three main tool changers on the market, depending on
the arrangement of the tool box.

 tool replacement system with clamping arm.

 tool replacement system with chain machine.
 the tool replacement system and the magazine box tool replacement
system and the clamping arm in this system

there are two main elements: the magazine clip arm in this system, the disc
is supplied with the box, and contains different types of tools. it can hold
up to 32 tools. in a magazine, all the tools you need are fixed in the
magazine. programming tool on the controller, set the index in front of the
grip arm according to the program, and then grab the grip tool and perform
the action. when each tool is complete, the clamping arm placement tool
returns to the magazine.

the tasks are divided in team members so that every member give his
maximum output in their respective task. each team member worked on
separate jobs during the progress of the project. every member was in
integration with other tasks being done in correspondence by other team
members. then integration testing is done to make sure that all components
are working properly. after the test is performed successfully the whole
team would be accountable for the completion of project. after completion
of each phase a testing phase is carried out to make sure that project
operational.
 Following are the project objectives/aims:

i. To design, fabricate and test a prototype of 5 Axis CNC desktop milling

machine
ii. To study the comparison between conventional manufacturing and CNC
manufacturing
iii. To design the electronic circuitry (driving circuits) for controlling all the Axis
with the help of stepper motors.
iv. To carry out tests to verify it’s working.

Following are the problems faced during the completion of

the project

1. Design of Ball Screws

2. Design Validation
3. Fabrication and Testing of Prototype

Software which is used for designing and

design validation

 Pro-E 5 (CREO)

2
 CNC Software which is used for part
programming

 Mach 3 Mill
 The 5 Axis CNC Desktop Milling machine can be used for lab teaching and
training it can reliably be used and part programs can be run using soft
material like
a) Nylon GP 66
b) Aluminum
c) Brass
 The usage of soft material is recommended for the
machine because of low power stepper motors.

Figure 1 5 AXIS DESKTOP CNC VERTICAL MILLING MACHINE

3
 Following are the design specifications of 5Axis CNC vertical milling machine

Table 1 DESIGN SPECIFICATIONS

Area of the foundation block where work 115*160

piece has been clamped

Nominal Diameter of X, Y Axis ball 16

screws

Nominal Diameter of Z Axis ball screw 12

Length of ball screw(X axis) 580

Length of ball screw(Y axis) 480

Length of ball screw(Z axis) 160

Pitch of X and Y ball screw 4.5

Pitch of ball screw (Z axis) 3.8

Lead of each ball screw 5

No. of Start of Ball Screw Single

Rotation of A-axis -90o – +90o

Rotation of B axis 0 – 360o

Dimensions of 10 T slots Table 400*258

Height of Table 20

Maximum Height of Machine 445

Maximum Length of Machine 605

Maximum Width of Machine 590

Note*: All dimensions are in mm

4
5
 2 LITERATURE REVIEW

2.1 ATC ON VERTICAL MILLING

BOM-Saeng Riah and Wissam Park and Gordon Pitnock studied robotic mold
polishing station to control a computer and a robot controller. The space
station consists of six degrees of freedom industrial robots, mechanical and
mechanical manipulators, pneumatic grinding tools and abrasive grinding. The
plant also includes an automatic tool changer designed to replace the milling
tool, making the process completely unattended. Since death and mold
manufacture usually produce low volume, using robotic automation systems
and manual programming of serial robots using the teaching of pendants.
Improved surface quality, position angle grinding tools and part surfaces are
controlling the computer. In addition, in order to further enhance the
performance of the system; polishing pads and brackets. S1S. Balestra, A.
Bertolin and C. Bozza on the design and performance of computer-controlled
emulsion panels to develop and remove scanned nuclear emulsion membranes
in Europe System microscope. The plate changer is used for large-scale
scanning and measuring emulsions.[1]

Experience the neutrino oscillation of lab Gran Sato on a neutrino mesh beam.
Unlike other systems, it is suitable for drying and oil targets. Changing the
film requires less than 20 s and is related to the positioning of the precision
emulsion film. The final accuracy of retrieving the path coordinates after the
baseline is superior to the measurement mark. [2]

H. Ambrosio and M. Caramanoglu study the time physical objects between

thinking and production are being reduced due to the use of CAD/CAM
systems and auxiliary manufacturing.

It can also be converted to non-expendable materials, such as solid wood using

CAD/CAM systems, but only subtraction procedures, such as machines with
CNC routers. Although about 5-axis CNC router machine Affordable, wide-
purchased, more flexible 5-axis steering machines are still available as very
large small business investments. Refurbished small articulated robots can be
a cheaper alternative, but require light end effects.

Third brothers C, Pascoe M and MIHAILA.L One of the key solutions for
studying high-speed and efficient manufacturing is based on full automation of
the entire manufacturing process.

Automatic change tools involved in the manufacturing process are

implemented through an automatic tool replacement mechanism, so the non-
production time consumed is greatly reduced as the tool is replaced.
Innovative automatic changer tool, simple and compact, with any machining
center series or magazine tools can be equipped with tool magazine.

In addition, by using this mechanism to change other tools the system changes
the tool's subcomponents, such as the tool transfer mechanism and alternate
location, and replaces the mechanism for this change. Auxiliary mobility
needed to carry magazine gadgets the wait position overlaps with the time
machine, so the total time exchange of the tool uses the implement tool to
reduce the spindle.[4]

Milling is the machining method that uses rotary cutters to

takeaway material from a work piece, advancing (or feeding)
in a direction at any angle with the axis of the tool. It covers
an extensive variety of different operations and machines, on
scales from tiny individual components to massive, heavy-
duty gang milling operations. It’s one amongst the foremost of
the unremarkably used processes in industrial business and
machine retailers nowadays for machining parts to precise
sizes and shapes.

7
 Grinding could be a cutting process that uses a milling cutter
to remove material from the surface of a work piece. The
milling cutter could be a rotating cutting tool, usually with
several cutting points. Unlike drilling, where the tool is
advanced on its axis of rotation, the cutter in the milling is
usually moved perpendicular to its axis so that the cut
happens on the circumference of the cookie cutter. As the mill
cutter enters the work room, the cutting edges (flutes or
teeth) of the tool repeatedly cut out of the material, shaving
the chips from the work room with each pass. Cutting action is
shear deformation; the metal is pushed out of the work room

[4]
Figure 2 BASIC FIVE AXIS MILLING MACHINE
into small clumps that hang together to a much or lesser
extent (depending on the type of metal) to create fleas.

2.2 TYPES OFMILLING MACHINES

2.2.1 VERTICAL MILLING MACHINE

On a vertical grinding machine, the Spindle axis is tied vertically. The mold
cutter is held in spindle and rotates on axis. Spindle can usually be extended
(or tables can be raised/lowered, giving the same effect), allowing for diving
and drilling cutting. There are two subcategories of vertical mills: Factory bed
and Mill turret.

A Mill turret incorporates a stationary Spindle and therefore the table moves
both perpendicular and parallel to the Spindle axis to complete the cut. The

8
 most common example of this type is Bridgeport. Turret Mills usually have
seasonings that allow cookie cutter to be lifted and lowered in a way even to
drill the press. Machine type provides 2 cutting strategies in the vertical
direction (Z): by lifting or lowering sharply, and by moving your knees.

However, in The Bed Mill, the table moves only perpendicular to the spindle
axis, while the shaft itself moves parallel to its own axis.

Turret mills are generally regarded by some to be more versatile than both
models. However, the tower is only practical as long as the machine remains
relatively small. As the size of the machine increases, moving the knee up and
down requires considerable effort and it also becomes difficult to reach the
spiked power handle (if equipped). Therefore, the largest milling machine is
usually the type of bed.

2.2.2 HORIZONTAL MILLING MACHINE

A horizontal factory has almost the same type of x-y table, however the cutters mounted on
some horizontal milling horizontal mills also feature built in turntable that allows milling at
various angles. This feature is named as a universal table. while end mills and other types of
tools on the market to vertical mills are also used in horizontal factories, their real gains lie in
the cutters mounted in arbor, known as the side and face factories, which have a somewhat
cross-section like a circular look, but usually wider and smaller in diameter.

2.3 MILLING PROCESSES

Various milling methods done by a milling cutter may be grouped under 2 headings
peripheral milling and face milling. The cutting actions of milling cutter to perform the above
process are described below

1. PERIPHERAL MILLING
a. Cutter axis is parallel to surface being machined
b. Cutting edges on outside periphery of cutter

9
 Figure 3 PERIPHERAL MILLING [11]

2. FACE MILLING
a. Cutting axis perpendicular to the LED surface
b. Cutting edge on both ends and outer fringe Cutter

Figure 4 FACE MILLING [11]

10
3. CONVENTIONAL FACE MILLING
Cutter overhangs work on both sides

Figure 5 CONVENTIONAL FACE MILLING [11]

4. END MILLING
Cutter diameter is less than work width, so a slot is cut into part

Figure 6 END MILLING [11]

11
5. PROFILE MILLING
Form of end milling in which the outside periphery of a flat part is cut

Figure 7 PROFILE MILLING [11]

6. POCKET MILLING
Another form of end milling used to mill shallow pockets into flat parts

Figure 8 POCKET MILLING [11]

12
7. SURFACE CONTOURING
Ball nose cutter is fed back and forth across the work along a curvilinear path
at close intervals to create a three dimensional surface form

Figure 9 SURFACE CONTOURING [11]

13
2.4 COMPUTER NUMERICAL CONTROL (CNC)

Digital/Numeric control (NC) is a type of programmable automation where

processing equipment is controlled using different numbers, letters, and
symbols. They are encoded in an acceptable format by the colleague for the
hint program schema for a specific piece of work or assignment. After you
change the task, the hint program changes. The application of NC technology
is divided into two broad categories:

1. Machine tool applications such as drilling, milling, turning

and other metal work
2. Non-machine applications tool such as assembly and
inspection.

The position of the tool is driven by the motor through a series

of gears to lower the pace in order to produce extremely
precise motion, or to drive a direct stepper or servo motor in a
modern design. As long as the troops remain small enough to
look bad, the control of the open ring will work.

On commercial metal machines, closed-loop control is

standard and requires the required accuracy, speed and
redundancy. CNC milling is a specific form of computer-
controlled CNC (CNC) machining. Grinding itself is a machining
method similar to drilling and cutting, capable of performing
many operations by cutting and drilling machines. As with
drilling, milling uses a rotating cylindrical cutting tool.
However, the tools in the milling machine can move along
multiple axes and can generate various shapes, openings, and
holes.

In addition, the work piece usually moves on the milling tool in

multiple directions, unlike the movement of a drilling shaft. X
and Y set the horizontal movement of the work piece (forward,
backward, and side by side at a flat level). Z indicates vertical
or up and down movement. Most machines offer three to five
axes, providing at least X, Y and Z axes.

Advanced machines, such as 5-axis milling centers, require

CAM programming for optimal performance due to the

14
extremely advanced engineering involved in machining
modes.

15
2.4.1 MAINCONSTITUENTS OF CNC:
The computer-aided manufacturing system consists of three basic components:

The procedure is explained

Machine Control Unit

Processing equipment

The program is fed into the console, indicating the processing equipment accordingly.

2.4.2 PROGRAM OF COMMANDS:

 The program of instructions is the detailed step by step
commands that direct the processing equipment.

Processing
Program of Machine
Equipment
instruction control unit

Figure 10 BLOCK DAIGRAM OF PROGRAMMABLE LOGIC CONTROL SYSTEM

 The commands refer to the position of the machine tool

spindle with respect to the worktable on which the part is fix.
 They also include the selection of spindle speeds, cutting tools
and other functions.
 The program is coded on a suitable medium for submission to
the machine control unit.

16
2.4.3 MACHINE CONTROL UNIT (MCU):
The MCU consists of electronic and control equipment for reading and
interpreting assistance programs and converting them into mechanical
procedures for equipment tools or other processing equipment.

2.4.4 PROCESSING EQUIPMENT:

Ingredients that do useful work

In the most common example, NC processing instance handling instance.

Includes nightstand and spindles, as well as engines and controls derived from them.

2.5 DIFFERENT TYPES OF CNCS:

On the basis of degree of freedom (DOFs) CNCs are divided

into following

1. 3-Axis CNC
2. 4-Axis CNC
3. 5-Axis CNC

In these configurations there are three translational Axis while

remaining are rotational Axis. Up to 10 Axis are possible but
due to their complexity and stability issues they are not
commonly used. As the no. of DOFs are increased the system
algorithm to reach specific point become complex this may
lead turn wanted program interference and conjunctions.

17
Figure 11 Three Axis CNC Machine [10]

Figure 12 Five Axis CNC Machine [10]

18
2.6 AXIS MACHINE MACHINING
CENTERSCONFIGURATION:

In 5 Axis milling CNCs there are 3 translational Axis and 2 rotational Axis.
The configuration of these rotational Axis differs for different usages.
Theoretically there are 2n-1 = 16 possibilities. But most of these
possibilities have some stability issues and for sake of simplicity rotation
is associated either with tool post or with work bench.

Due to these reasons, configurations are as follows:

 TTTRR
 RRTTT
 RTTTR

2.6.1 TTTRR CONFIGURATION:

In this configuration, all rotation altogether is associated with the tool function, with one
rotation of 180o and the other rotation must be 45o to achieve all the points in the workspace.
The advantage of this configuration is that the greatest advantage of the travel column design
of the 5-axis machine is that it provides the design hardness.

Since the table is mounted directly on the base of the machine, it is more stable and less
mobile. Therefore, it maintains the highest level of accuracy and repeatability.

2.6.2 RRTTT CONFIGURATION:

In this configuration all the rotational motions involve are associated with
work bench and each rotation needs to be <90 o in order to attain all the
points on work piece.

Benefits of this configuration are:

Best cutting ability: rotate-30/110 degree on rotating head design/turn

table during gyro at 0.92 degree.

19
Larger working size: The Turn ion method helps to make a larger
working size than a rotating head because you don't have to use other
tools to compensate for the space used by the rotary head.

More torque at low speeds: When processed at low speeds, you get
more torque because the spindle is fixed to the tool's connection and
drive.

Transition from 3 to 5: The integrated turn ion table is the most popular
configuration in the 3-axis workshop and can be converted to 5-sided
machining because the parts are similar and require more edges to be
processed linearly at the same time.

2.6.3 RTTTR CONFIGURATION:

This is the most versatile configuration in which one rotation is associated
with tool post and other is with work-bench. It combines the benefits of
both of the above. Rotation of the work bench is limited to 180 o and that
of tool post is -/+ 90o. The benefits of this configuration are as below:

Benefits of this configuration are:

Dense parts: Because the table is fixed, use a rotary head/rotation table
with a heavier part.

Flexibility: Due to the size of the table, you can add adhesion to improve
versatility. Use extra space to complete the sixth side of the pane or
perform three-axis work.

Reduce tool interface: Rotate the head tilt tool so that there is no tool
intervention on the main axis of the machine.

Best chip control: With the rotating head/rotating table, you can turn
the machine horizontally to better control the chip.

20
 3 DESIGN CONDITIONS

3.1 DESIGN CONDITIONS OF ATC FOR 5 AXIS CNC

MILLING MACHINE

Succeeding are the design specifications of ATC for 5Axis CNC milling machine.

Table 2 DESIGN SPECIFICATIONS

Area of the foundation block 115*160

where work piece has been
clamped

Nominal Diameter of X, Y Axis 16

ball screws

Nominal Diameter of Z Axis ball 12

screw

Length of X axis ball screw 580

Length of Y axis ball screw 480

Length of Z axis ball screw 160

Pitch of X and Y axis ball screw 4.5

Pitch of Z axis ball screw 3.8

Lead of each ball screw 5

No. of Start of Ball Screw Single

Rotation of A-axis -90o – +90o

Rotation of B-axis 0 – 360o

Dimensions of 10 T slots Table 400*258

21
 Height of Table 20

Maximum Height of Machine 445

Maximum Length of Machine 605

Maximum Width of Machine 590

Note*: All dimensions are in mm

3.2 DESIGN CHARACTERISTICS

The five Axis prototype CNC milling machine consists of five Axis. X, Y & Z axis are
Translational where A (along X-Axis) and B (along Z-Axis) are rotational Axis which are
given to the table. Each Axis driven with the help of the stepper motors whom of three
translational Axis are connected with the ball screws.

The stepper motors are used in all the five Axis as an actuator for the movement of the Axis.
Stepper motors are interfaced with the computer with the help of stepper motor drive.
Further, the drive gets signal from the computer in which the Mach 3 Mill software is
functional to operate all the Axis.

22
 Figure 13 COMPLETE ASSEMBLY OF MACHINE

3.3 MATERIAL USED IN THE MANUFACTURING

3.3.1 ALUMINIUM
The material which is used for fabrication is Aluminum Alloy T (Treated) means Hard
Aluminum because of the following reasons:

1. Its low cost as compared to other materials.

2. It’s resistant to corrosion.
3. It is 100% recyclable
4. Aluminum has different alloys which are readily available and some are very
soft and some very strong. It comes in all variety, some of Aluminum alloys
are easy to weld and some are difficult to weld.

23
5. Aluminum is easy to work it can easy to be filed, drilled and molded in
different shapes.
6. Aluminum is light in weight, the machine is made up of Aluminum so that
stepper motors can easily translate it to the required position.
7. Aluminum is light in weight, easy to machine and can absorb vibrations.

Aluminum used on behalf of the built-up of ball screws, T-slot Bench, Frame
of Machine.

24
 4 CALCULATIONS

4.1 MILLING MACHINE CALCULATIONS

Following are the calculations that must be done for performing the

MILLING OPERATION

4.1.1 METAL REMOVAL RATE

The rate of metal removal for all types of milling (R) equals the size of the metal removed by
the cutting process at a given time, usually in cubic inches per minute (mm3/min). So,

R=W∗H∗f

Where,

R = removal rate, mm3/min

W = width of cut, mm
H = depth of cut, mm
f = feed rate, mm per minute

4.1.2 FEED PER TOOTH

The productivity of spare parts in the plant is directly related to the available feed rate. The
energy rate should be as high as possible, taking into account the rigidity of the device and
the energy available in the tool. To avoid overloading the device, you can calculate the flow
for each of the following qualifying ages:

K hp
F=
NCWH
Where,
h p = horsepower available at the cutter
K = machine ability factor
C = rotational speed of cutter, rpm
 N = number of cutter teeth

4.1.3 CUTTING SPEED

The cutting speed of tool milling is the linear speed of the terminals produced by tool
rotation. The cutting speed is expressed in mm/min (mm/min) and is determined by the
following factors:

π∗D∗N
S=
100
Where,
S = cutting speed, mm/min
D = outside diameter of the cutter, mm
N = rotational speed of cutter, rpm

4.1.4 NUMBER OF TEETH OF CUTTER

Tool teeth required for a particular application N can be found in simple expressions (not for
carbide or other high-speed gadgets)

f
N=
FC
Where
f = feed rate, mm/min
F = feed per tooth (chip thickness),
C = rotational speed of cutter, rpm
N = number of cutter teeth

It is recommended that you use the formula to calculate the number of teeth the tool needed
for a particular operation:

N=19.5 V ∗R−5.8
Where,
N = number of cutter teeth
R = radius of cutter

26
4.1.5 POWER AT THE CUTTING TOOL
Cutting power = Pc =K p∗C∗Q∗W (kW ∨hp)

Where,

K p = Power Constant

C = Feed Factor for Power Constant

W = Tool Wear Factor

4.1.6 POWER AT THE MOTOR

Pc
P m=
E
Where,
Pc = Cutting Power at the Tool (kW or hp)
E = Machine Tool Efficiency Factor

4.1.7 THRUST FORCE

T =( 0.05∗F f ∗Ft∗K d∗B∗W ) +¿

Where,
K d = Work Material Factor
F f = Feed Factor
Ft = Thrust Factor
B = Chisel Edge Factor
J = Chisel Edge Factor

4.1.8 MOTOR TORQUE

(9550∗P c )
M=
N

27
 5 COMPUTER AIDED DESIGN

5.1 OVERVIEW

In this chapter we will deliberate about CAD modeling and how 3-D solid models are created
in different CAD software’s. There are many CAD/CAM software’s available in the market.
The noticeable among them are Pro/Engineer, AUTODESK INVENTOR, Catia, Solid Edge,
Edge CAM, DELCAM, AutoCAD and various others.

5.2 CAD SOFTWARE

We selected the Pro-E wildfire 5.0 CAD software for solid modeling. Pro-E is powerful and
user friendly software that can perform the CAD/CAM operations. In Pakistan it is used in
various leading manufacturing industries including NDC, PAF Kamra, SABRO, NESCOM,
DESCON and etc. The reason for choosing Pro-E as CAD/CAM software is its user
friendliness and availability of licensed student version of Pro/Engineer in IIUI.

5.3 CAD MODELING

Pro-E enable user to design solid parts in 3-D environment. Pro-E provide the user friendly
environment to create models and can be changed by direct interference. Pro-E is provided
with exact dimensions and after that we select the proper tools(Commands) to fulfill our
design .Pro-E interprets the instructions and then display our design on the screen which we
can call the “Dash Board” .Pro-E guide the user by having the option ”HELP” to select the
proper commands which user can use to complete its model.

5.4 PLANNING OF DESIGN

Users can start designing professional/engineer models immediately, and it's easy to join and
start creating models after the product deadline. However, in order to create value in our
designs, we need to create ever-changing products driven by market demand. Flexibility is a
fundamental requirement of design. Flexibility is key to strong and friendly product design
while maintaining design intent and achievement through planning.

28
For planning and design, it is essential to have a basic understanding of a broad perspective
model. In other words, understand the general functionality, shape, and fit of the product.

This understanding includes:

Total size

Basic window function

How to group forms approximate number of components to be included in the conference

5.5 DESIGN CONCEPTS

Many different types of models can be designed in Pro/Engineer. However, before the user
begins his design project, a few basic design concepts needs to be understood

DESIGN INTENT

Before the model is designed, it is necessary to identify the “design intent”.

Design intent defines the purpose and function of the finished product based
on product specifications or requirements.

1. PARAMETRIC SCHEME/MODEL
The relationship between the features makes the forms parameter. Therefore,
if the feature sits and the change directly affects other related (dependent)
features, the Pro/Engineer dynamically changes those related features. This
parametric capability preserves the integrity of the parts and retains part of our
design intent and design intent.
2. ASSEMBLY

The Pro/Engineer retains the design structure outside the part mode by
"grouping". When you design a form, parts, ads, assemblies, drawings, and
other related objects, such as tubes, sheet metal, or wires, are automatically
updated. All of these functions are fully relevant to the professional/engineer.
Therefore, if the user changes the design at any level, the project dynamically
reflects all levels of change, maintaining the design intent.

29
5.6 PARTS MODELING

In this section we will discuss and explain about different solid parts of our project and how
they are created in Pro-E.

Figure 14 T SLOT TABLE

This part is called the bed of machine whom model is created by Pro-E. In creating this
model we use the different commands of software like “HOLE, MIRROR”.

Starting the model by sketching in the new project then extruding our part which give us the
T slot. After this we apply mirror command to create the similar pattern sideways. Following
are the dimensions of table:

Table 3 10 T SLOT TABLE

NAME DIMENSIONS(mm)

LENGTH 400

WIDTH 258

HEIGHT 20

30
 Figure 15 BALL SCREW

This section, called the screw ball X-axis, is the main part of the device and
moves on the machine. It is created by a program that supports E.

In this part of the modeling, we use different commands for the program, such
as "Cut ID 816, Mirror" and so on. Start drawing the part in drawing mode,
and then use the command discussed above to get the last part.

Figure 16 BALL SCREW NUT

This part is called ball screw nut and is important part of machine because ball
screws are connected to motors through these. It is created by Pro-E by using
the different commands of software like “HOLE, PATTERN, Cut id 816” etc.
Starting with sketching mode we proceed with the above mentioned
commands to obtain the final part.

31
 Figure 17 X & Y Axis Sliding Part

This part is called the x & y axis sliding part. This part is designed by simple
commands of software like “HOLE Extrude” etc. As you are seeing the part it
has three circular shaped holes one in center and two on sides which are
extruded outwards.

Figure 18 ball Screw End Support Part

This part is called ball Screw End Support Part. This part is designed in Pro E
(Creo) and is designed by simple and basic commands of that software like
Extrude and Hole etc.

32
As we can see there are pattern of hole on this part which are designed by
Hole Command and the center circle is extrusion and done by extrude
command.

Figure 19 Z-Axis Ball Screw

This part is called ball screw and this ball screw is of z-axis and having a
dimension of 12mm. This ball screw is designed in Pro E (Creo) and is
designed by simple commands of that software. This part is designed by the
extrusion and helical spring command.

As we can see in the part there are threads, these threads are done by using
extrusion command first and then by using helical spring command.

Figure 20 Z-AXIS BASE 2

33
This part is called z-axis base 2. This is used in z-axis and this base 2 is
designed in Pro E (Creo) and is designed by simple commands of that
software.

As we can see there are four holes on the side of this part and these holes are
made by Hole Command. And other process are done by extrusion Command
and some other basic commands.

Figure 21 XY-AXIS BASE 1

This part is called XY-Axis Base 1. The XY-Axis is designed in Pro E (Creo)
and is designed by simple commands of that software.

As we can see in this part there is center whole type thing which is done by
extrusion command and there are circles on this parts which are done by Hole
Command.

34
5.7 DESIGNING IN PRO ENGINEER

Following are the 5-Dimensional drawings of the CNC milling machine.

Figure 22 ISOMETRIC VIEW

Table 4 MACHINE PERIMETER

NAMES DIMESIONS
Maximum Height of Machine 445

Maximum Length of Machine 605

Maximum Width of Machine 590

Area of the foundation block 115*590

where work piece has been
clamped

Rotation of A-Axis 0-360 degree (Absolute Positioning)

Rotation of B-Axis -90 to +90 (Absolute Positioning)

STEPPER MOTOR CALCULTIONS

Voltage 2.8 Volts

Current 2A

Step angle 0.05° /step

35
Power 5.6 Watts=7.51*10−3 hp

36
Figure 23 FRONT VIEW

Table 5 X-AXIS T SLOT TABLE PERIMETER

NAMES DIMENSIONS

LENGTH 400 mm

WIDTH 258 mm

HEIGHT 20 mm

MAX MOVEMENT 0-285 mm (ABSOULATE POSITIONING)

MAX RPM OF MOTOR 1500

MAX TRAVELLING SPEED OF X-AXIS 23 mm/sec

37
Table 6 X -AXIS BALL SCREW PERIMETER

LENGTH 580

PITCH 4.5

DIAMETER 16

LEAD 5

Table 7 X-AXIS STEPPER MOTOR SPECIFICATIONS

STEP ANGLE 0.72

°

steps

VOLTAGE 0.98 Volts

CURRENT 1.4 A

POWER 1.372 Watts=1.84∗10−3 hp

38
Figure 24 SIDE VIEW

Table 8 Z-Axis SPECIFICATIONS

NAMES DIMENSIONS

TOLL DIAMETER 3mm

TOOL RPM 25000

MAX MOVEMENT 0-70 mm (Absolute positioning)

MAX RPM OF MOTOR 1500

MAX TRAVELLING SPEED 23 mm/sec

39
Table 9 Z-AXIS BALL SCREW

LENGTH 160mm

DIAMETER 12 mm

PITCH 3.8 mm

LEAD 5 mm

Table 10 Z-AXIS STEPPER MOTOR SPECIFICATIONS

STEP ANGLE 0.72

°

step

VOLTAGE 0.98 Volts

CURRENT 1.4 A

POWER 1.372 Watts=1.84∗10−3 hp

40
Figure 25 TOP VIEW

Table 11 Y-AXIS T SLOT TABLE SPECIFICATIONS

LENGTH 400 mm

WIDTH 258 mm

HEIGHT 20 mm

MAX MOVEMENT 0-225 mm(absolute positioning )

MAX RPM OF MOTOR 1500

MAX TRAVELLING SPEED OF Y-AXIS 23mm/sec

Table 12 BALL SCREW SINGLE START

LENGTH 480 mm

DIAMETER 16 mm

PITCH 4.5 mm

LEAD 5 mm

41
Table 13 Y-AXIS STEPPER MOTOR SPECIFICATIONS

STEP ANGLE 0.72

°

Step

VOLTAGE 0.98 Volts

CURRENT 1.4 A

POWER 1.372 watts=1.84∗10−3 hp

42
 6 FEM STRUCTURAL ANALYSIS

6.1 OVERVIEW

In this section we will deliberate about finite element method structural analysis and how
solid models are analyzed under the application of forces in the finite element method
software ANSYS Workbench. There are many FEM structural analysis software’s available
in the market. The noticeable among them are Abacus, COMSOL Multi physics, Cosmos
Works, CST Studio Suite, Autodesk Simulation, ADINA and various others.

6.2 ANSYS SOFTWARE

We selected the ANSYS Workbench 14.5 finite element method software for structural
analysis. ANSYS is powerful and user friendly software that can perform various types of
analyses. In Pakistan it is used in various leading manufacturing industries including NDC,
SABRO, NESCOM, and etc. The reason we chose ANSYS Workbench 14.5 as FEM
software is that its user friendly and we learned FEM analysis on this software in our FEM
elective course and also its licensed version was available in IIUI for students.

6.3 FEM ANALYSIS

ANSYS Workbench enables user to design solid parts in design modeler and apply forces,
moments and various types of forces needed and see the effects of applied forces in 3D
graphical interface. It provides the user friendly environment to see the effect of forces and
also to make models as well. The type of analysis we did is static structural. Pro-E model can
also be imported in ANSYS Workbench directly to analyze it. It uses different techniques to
by meshing the model into small element and approximation of each element stresses.

6.4 ANALYSIS CONCEPTS

We need to identify the type of analysis need to be done according to the situation of the post
working of the project. The concepts involved in the process are following.

6.5 ANALYSIS SYSTEMS

43
Before importing model geometry analysis system is selected that what type of analysis is
needed to be done there are many types of analysis systems available in the software e.g.
static structural, fluid flow, thermal, internal combustion engine and many more but in our
case static structural is selected.

6.5.1 GEOMETRY
Design modeler is available to design the 3D model in workbench but it will consume
more time. We can also import our project model geometry from Pro E files directly
so Geometry is imported from the Pro E.

6.5.2 ENGINEERING DATA

We need to specify that which material is being used in our project. We are using
Aluminum for our entire project so in the engineering data cell we need to add the
required material and specify the young modulus and Poisson’s ratio of the subsequent
material.

6.6 MESHING

Now Meshing is done of the appropriate size and shape according to the given model.
In complex models meshing take weeks to complete it takes a lot of time to mesh the
whole assembly

6.7 FORCES

First fixed supports are applied to the body to make it stable in the simulation the
required forces are applied on the surfaces in the desired direction, first type of force is
selected the surface is highlighted and then magnitude is fed.

6.8 SOLUTION

44
 The type of solution is then selected we need to know the total stress this model can
bear and after how much stress the model will be failed so we need to know the total
deformation and equivalent stress analysis and obtain the required result.

6.9 CNC WORKTABLE

Model of the CNC machine is given in the Fig 26.

Figure 26 CNC WORKTABLE

6.9.1 MESHING
Mesh of the work table is given in the Fig 27.

Figure 27 MESH

45
6.9.2 FORCES
Below the model the surfaces are fixed and on the work table forces are applied it is
shown in the fig 28.

Figure 28 FORCES AND FIXED SUPPORT

6.9.3 TOTAL DEFORMATION

Total Deformation analysis is given below

46
 Figure 29 TOTAL DEFORMATION

It is clearly seen that the red portion is very small.

6.9.4 EQUIVALENT STRESS

We need to see the portion of maximum stress in the model the analysis is shown in
the fig 30.

47
 Figure 30 EQUIVALENT STRESS

It is evident that the areas of maximum stress on the working model is negligible so that
our project is safe and feasible to manufacture and fabricate.

48
 7 PARTS MANUFACTURING &MECHANICALASSEMBLY

7.1 PARTS MANUFACTURING

Machine consist of different parts some are manufactured and some parts are purchased
from market because those parts are required of international standard that cannot be
manufactured by self-due to accuracy and standards.

Following parts are manufactured on CNC machine for achieving high accuracy.

 T slot table
 Fixture
 Connecting
 2-Side bases
 Ball screw support of each translational axes
 Frame plate 1
 Frame plate 2
 Frame plate 3
 Frame plate 4
 x-axes base plates
 Y-axes base plates
 Z-axes base plates
 x-axes rod
 Y-axes rod
 Z-axes rod
 Y-axes main cover plate
 Z-axes plate form
 X and Y axes main moving part
 Motor support foundation.
 Table base
 Motor support
 Base plate for AB axes

Following parts are purchased from market.

 X-axes ball screw

 Y axes ball screw
 Z axes ball screw
 3 stepper motors of .72 degree per step for translational axes
 2 stepper motors of .05 degree per step for rotational axes
7.2 T-SLOT TABLE

T slot table is manufactured through different CNC milling operations. First of all we
studied the drawing of t-slot table and select the material of Aluminum and blank size
length of 420 mm, width of 270mm and thickness of 30 mm. After that we clamp it on
the CNC milling machine table having a controller of Siemens and limitations of 600 in
X-axes and 500 in y axes and 400 in z axis.

7.2.1 SIDE AND SURFACE MILLING

OPERATION
After completing that procedure we make a CNC program of side milling operation
for making an accurate length and width (400*258) by choosing an End mill cutter
having a radius of 12 mm on Master cam software and send that program to the
machine by means of interfacing. We called a machine on reference point and make
work piece zero point and then close the safety door of machine and start the machine.
The program is completed in 30 mints and we checked the sizes with vernier caliper
and then we make a cnc program of surface milling operation for making a thickness
of 20mm by choosing a face milling cutter on Master cam software and then send it to
the machine and make a work piece zero point again and close the door and start the
machine operation of surface milling is completed in 35 mints.

7.2.2 SLOTTING OPERATION

After completing of surface and side milling operation we make CNC program for
slotting operation on software of Master cam. For making of t slots first we make
simple slots with end mill cutter and then we make a t slots with t slot cutter. T slot
table having 10 slots size of 11mm in width and 15mm in depth. We choose an End
mill cutter having radius of 10mm and make program of 10 slots and send it to the
machine by means of interfacing and make work piece zero point by touching of
cutter to the surface of work piece after that close the safety door of machine and start
the cycle of machine. After completed that slots we make a program of T slot by
choosing t slot cutter. And send it to the machine and start the cycle for completing
the operation.

After making of 10 slots on one side than we unclamp the work piece and
clamp the other side of work piece and repeat the slotting operation for
making of slots.

7.2.3 DRILLING OPERATION

50
 The last and final operation on T slot table work piece is drilling. For drilling
operation first we make CNC drilling program of 20 drills having diameter of 5mm
and through by choosing a drill size of 4.85mm on software and then send it to the
machine through networking. We make zero point of z axes and then start the drilling
operation cycle after closing the safety door. After drilling operation we make a
program of tapping by choosing the tap size of 5mm. T slot table is completed in 3
days of working.

Final shape of T slot table.

Figure 31 T-SLOT TABLE

7.3 FIXTURE

For making of fixture plate first we select material having blank size of 115mm in
length, 85 mm in width and thickness of 30mm. first we finish the size of fixture
according to size of drawing of fixture 110mm in length ,80mm in width and 27mm in

51
 thickness by CNC milling machine choosing end mill cutter having diameter of 10mm.
After that we make a CNC program of making the 4 half round sizes having diameter
of 12mm by choosing the cutter 8mm end mill cutter and send it to the machine and set
the work piece zero point and start the machine cycle after closing the safety door of
machine

After completing the 4 half round sizes according to the drawing we make a CNC
drilling program for making a through holes having diameter of 4mm. we send the
program to the machine and start cycle for completion of drilling operation by choosing
a drill size of 4mm. fixture plate is completed in 45 mints.

Figure 32 FIXTURE

7.4 AB AXES CONNECTOR

We select a rod having a diameter of 35mm and length of 40mm. we clamp the material
in CNC turning machine and make a CNC program according to drawing and sent it to
the machine by means of interfacing and start the cycle after closing the safety door.

52
After completing the program we got a final shape of connector.

Figure 33 AB CONNECTOR

7.5 BALL SCREW SUPPORT

We select a rod having a diameter of 50mm and tightened in the chuck of CNC turning
machine and final the turning operation by CNC program after that we clamp the work
piece in CNC milling machine and we make a CNC program of side milling. When we
saw that the side milling operation is completed then we make CNC drilling program
for making through holes having a diameter of 6mm. Finally we got the shape of Ball
screw support after completing of drilling operation.

Figure 34 Ball Screw Support

Similarly all the remaining parts are manufactured on CNC milling and CNC turning
machine with the help of Master CAM software.

53
7.6 BALL SCREWS

Ball screw is a mechanical device for translating rotational motion to linear motion. A
threaded shaft provides a spiral raceway for ball bearings which act as a precision
screw. As well as being able to apply or withstand high thrust loads they can do so with
minimum internal friction. They are made to close tolerances and are therefore suitable
for use in situation in which high precision is necessary the ball assembly acts as the
nut while the threaded shaft is the screw.

Figure 35 BALL SCREWS [17]

7.6.1 ADVANTAGES AND DISADVANTAGES OF

BALL SCREWS
Following are the advantages and disadvantages of ball screws.

7.6.1.1 ADVANTAGES OF BALL SCREWS

 High efficiency – over 90%

 Predictable life expectancy
 Precise and repeatable movement
 No tendency for slip- stick
 Minimum thermal effects
 Easily preloaded to eliminate backlash-with minimum friction penalty

54
 7.6.1.2 DISADVANTAGES OF BALL SCREWS

 Needs advanced levels of lubrication.

 Tend to overhaul- Essential extra halts if barring is obligatory
 Subject to impurity.
 For the similar capability ball screws are not as stiff as conservative control
screws.

7.6.1.3 PARAMETERS OF BALL SCREWS

7.6.1.3.1 PITCH

The distance from any point on the thread to the corresponding point on the adjacent
thread parallel to the axis.

7.6.1.3.2 BULLETS

The distance that moves the thread along its axis is full rotation, called a screw lead.

7.6.1.3.3 AXIS YARN

The length of the line is called through the center of the screw shaft thread.

7.6.1.3.4 THREAD ANGLE

The angle at which the two sides of the thread form (or drop) from each other.

55
7.7 BUSHING

This fuss has a bit of implication. It is a cylindrical lining designed to reduce friction
and wear in the hole, or to shrink and limit the movement of mechanical components.

Figure 36 BUSHING [17]

7.8 BEARINGS

A carrier is a device that allows relative movement restrictions (usually alternating or

linear) between two or more components. Bearings can be widely classified according
to the permissible and recorded operating principle and motion in the application load
direction. To reduce frictional resistance and wear, in some cases a layer of liquid
called lubricant is provided to remove the heat generated. Lubricants for separating
trunks and bearings.

7.8.1 BALL BEARING

Balls (shown below) are probably the most common type of tolerance. These bearings
can handle both radial loads and propulsion, and are typically suitable for applications
where loads are relatively small.

56
 Figure 37 BALL BEARING [17]

In a ball bearing, the load is transferred from the outside of the game to the ball, from
the ball to the internal game. As the ball, it touches Enfield and Outfield only a little
bit, which helps it spin very smoothly. However, this also means that there are not
many contact areas carrying the load, so if the load is overloaded, the ball may deform
or deform to run the bearing.

57
7.9 COMPLETE FABRICATION

The complete fabricated design of the machine is shown below.

Figure 38 COMPLETE FABRICATED MODEL

58
 8 ELECTRONICS AND CIRCUITRY

8.1 ELECTRONIC CONTROL SYSTEM

8.1.1 PROBLEM DEFINITION

Electronic circuit is required that could take data from the computer, analyze it and
then control the motor accordingly. Motor selection need to be done too. Five motors
would be required to move X, Y, Z, A & B Axis. The motors should be able to
provide enough torque for the bed to move smoothly in two directions. They should
also be able to provide varying speed.

8.1.2 BASIC APPROACH

Use stepper motor to regulate the motion of the slides through the parallel port of the
computer.

8.1.3 OBJECTIVES
The objectives set while starting work on the electronic section were:

 To design and implement the desired circuit.

 Motor selection and purchased.
 Developing the five motors operation independently.
 To establish parallel communication.
 Interfacing of the system.

8.1.4 MOTOR SELECTION

The most vital part of the project was the motor selection. The following motor
characteristics were considered.

 The motor should be able to provide us with a suitable amount of torque.

 The torque should sufficient to move about 5 kg of load with reasonable speed.
 The motor should be able to provide us both clockwise and anti-clockwise motion.
 The direction switching time should be minimum.
8.2 STEPPER MOTOR

A stepper motor is an electromechanical device that converts electrical impulses into

discrete mechanical motion. When the electric command pulse is applied to the stepper
motor in the correct order, the shaft or spindle rotates into the step engine in separate
step increments. The engine speed is directly related to the input pulse applied by the
frequency. The sequence of application of the pulse controls the direction of rotation of
the engine column. As a result, stepper motors are manufactured at steps 12, 24, 72,
144, 180 and 200 at 30, 15, 5, 2.5, 2 and 1.8 degrees per step.

8.2.1 BENEFITS OVER SERVO AND DC

MOTORS
 The stepper motor is strictly controlled in an open loop system.
 Open loop control means that no feedback is required on the site.
 This type of control eliminates the need for high-priced sensors and
feedbacks such as optical encoder.
 Since there is no contact brush in the motor life of the motor, it only
depends on the bearing life.
 The engine provides open loop control in response to digital input pulses,
making engine control simpler and less costly.
 The engine is directly related to the pulse input frequency.
 As long as the windings are activated, the engine provides full torque in
the rest.
 Specify a precise position and repeatable animation.
 If they exist, the errors are not cumulative from one step to the next.
 Unusual response to start/stop/reverse. A wide range of speeds can be
obtained.

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8.2.2 TYPES OF STEPPER MOTOR
Here are three simple stepper motor types. They are:

1. Variable-reluctance
2. Permanent-magnet
3. Hybrid

8.2.2.1 VARIABLE-RELUCTANCE

From a structural point of view, this type of stepper motor may be easier to
understand. Figure 4.1 shows the cross-section of the variable stepper motor.
This type of engine consists of a soft iron multi-tooth rotor and a stator device
for wounds. When a static winding starts in DC, the magnetic pole and
rotation occur when the rotating tooth encounters an attraction to the starting
static electrode.

Figure 39 CROSS-SECTIONAL DIAGRAM OF A VARIABLE RELUCTANCE

MOTOR WINDING [15]

61
 8.2.2.2 PERMANENT MAGNET

The permanent magnet stepper motor is a low-cost, low-resolution engine type with
a typical step angle of 7.5 to 15 degrees (48 X 24 steps/revolution). The permanent
magnet motor implied in the name adds a permanent magnet to the engine
structure. The rotor no longer has teeth, just like the magnetometer engine variable.
Alternatively, the rotor is magnetized, alternating between the North and South
Poles, in a straight line parallel to the rotor axis. These magnetic rotating poles
provide higher flow strength, so the permanent magnet motor will display the
optimum torque characteristics of the resistance magnet variable.

Figure 40 CROSS-SECTIONAL DIAGRAM OF A

PERMANENT MOTOR WINDING [15]

8.2.2.3 HYBRID

Hybrid stepper motors are more expensive than permanent magnet motors, but
provide better performance in terms of stepper resolution, torque and speed. The
characteristic step angle of the hybrid stepper motor is 3.6 to 0.9 degrees. The hybrid
stepper motor combines the best characteristics of the permanent magnet with the
variable magnet motor. The multi-tooth rotor is like a magnet variable of an anti-
motor, surrounded by a pivot magnetic center magnet. The teeth on the rotor provide a
better path to help guide the flow to the preferred position in the air gap. This
increases engine downtime, contract strength and dynamic torque characteristics
compared to variable and permanent magnet types of magnets. Some of the
advantages of the hybrid stepper are very low inertia and an optimized magnetic flow

62
 path with no coupling between the two stator windings. The hybrid stepper motor has
a toothed rotor. The rotor is divided into two parts, separated by a permanent
magnet, making half of the south teeth and half of the north-pole. The positive
polarity is equal to the number of teeth on one half of the rotor. The teeth of the
hybrid engine identification device also have teeth more than the two main poles in
the wound coil, allowing for more equivalent columns (smaller poles, equivalent
rods, 360/tooth spacing). Typically, 4 main columns are used for 3.6 mixed strips and
8 for 1.8 and 0.9 degree types.

8.2.2.4 PHASES AND POLES

Usually stepper motors have two stages, but three-phase and five-phase motors are
also present. The two-stage bipolar engine has a single winding / phase, and the single
pole motor has one winding, tapped at each stage. The uni polar stepper motor is
sometimes called a "four-phase motor" although it contains only two phases. Engines
can also be made with two independent twists at each stage driven either in bipolar or
uni polar mode. The magnetic pole can be defined as one of the areas where the
magnetic flow density is concentrated in the magnetized body. Stepper motor has
columns and statistics. Figure 4.3 contains a simplified image where the stepper motor
in two stages contains 2 poles (or 1 pole pair) on each stage of the dwelling and 2
poles (one pole pair) on the rotor. In fact, several columns were added to the rotor.

Figure 41 UNIPOLAR AND BIPOLAR WOUND STEPPER MOTORS [15]

63
8.2.3 PHASE CURRENT WAVEFORMS
The full wavelength step is to approximate the positive numbers and is the reason
for such a great vibration of the engine. Various drive techniques have been
developed to optimize the current drive waveform rounding.

8.2.3.1 WAVE DRIVE (ONE PHASE ON)

In this disk drive method, only one stage is started at a time. It has the same number
of steps as a full stepper motor, but the engine will be well below the rated torque .

8.2.3.2 FULL STEP DRIVE (TWO PHASES ON)

This is the common method of driving a full step car. Both phases are always on, so
the engine will provide maximum rated torque. Once you close one phase, the other
phase opens.

8.2.3.3 HALF STEPPING

When half linear, the motor rotates between two stages and one phase. This increases
the angular accuracy. Engine torque is also very small (about 70%) in full ladder
mode (only one open stage). This situation can be alleviated by increasing the current
in the active winding. The half-step advantage is that the electronics engine can be
supported without change.

64
 Figure 42 DIFFERENT PHASE CURRENT WAVEFORMS FOR STEPPER MOTOR [15]

8.2.3.4 POSITIONAL ERROR

The engine line starts n times from the initial position (n s 360 degrees / step angle)
and measures the angle of the first position of each step position. If the angle from the
initial position to the step n position is n, the error is s n, where:

∆Θn = ∆Θn - (step angle) x n

The positional fault is the change of the extreme and least but is generally stated with
a ± sign. That is:

Positional error = ±1⁄2 (∆Θ Max - ∆Θ Min)

65
8.3 STEPPER MOTOR SPECIFICATIONS

8.3.1 MOTOR X Y & Z AXIS

Voltage = 0.98 volts

Current = 1.4 A

Power = 1.372 Watts = 1.84 x 10-3 Hp

Step angle = 0.72o/step

8.3.2 MOTOR A & B

Voltage = 2.8 Volts

Current = 2 A

Power = 5.6 Watts = 7.51 x 10-3 hp

Step angle = 0.05o/step

8.4 STEPPER MOTOR WIRES

Figure 43 STEPPER MOTOR CONNECTOR [15]

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8.4.1 STEPPER MOTOR CIRCUIT
There are four stepper board circuits. Each is designed to drive the stepper motors.
The purpose of making these drive circuit is to provide enough current to the motors
so that they can sustain the load applied to them.

Figure 44 STEPPER MOTOR DRIVE [15]

The components which are used in circuit are:

 Vexta EIC 2032 (Qty 5).

 Vexta EIC 4011 (Qty 5).
 Resistor of particular values.
 Capacitors of particular values.
 Regulator.
 Jumper.
 Jumper array.
 Pin connector

67
 Figure 45 EIC 2032 [15]

Figure 46 EIC 4011 [15]

8.5 CONTROL BOARD IMPLEMENTATION

8.5.1 COMMUNICATION WITH PC

Parallel port is a type of border initiate on computers (personal and
otherwise) for relating numerous peripherals. It is also known as a
printer port or Centronics port. The IEEE 1284 standard explains the bi-
directional type of the port.

68
Table 14 PORT ADRESSES

SIGNAL STEP PIN # DIRECTION PIN #

X-AXIS 2 14

Z-AXIS 8 7

Y-AXIS 3 16

A-AXIS 5 6

B-AXIS 4 17

69
9 LIMITATIONS, RECOMMENDATIONS AND CONCLUSIONS

9.1 LIMITATIONS

Following are the limitations of the prototype 5 Axis CNC milling machine.

1. The motor attached to the cutter can only operate at one speed RPM which is
only suitable for soft work piece. Different materials require different RPM of
cutter.
2. The material used in machine is mostly Aluminum because of cost constraints.

9.2 RECOMMENDATIONS

To address these limitations, here are some suggestions.

i. In order to run the engine with a more step shift speed, the engine belt roller can be
used. In this way, Ham ill can lead to different materials by changing the engine
speed of the DC besides the mill.
ii. The ability to self-lock the work piece platform can be achieved by inserting the gear
worm between the stepping column and the platform.
iii. Nowadays, the milling speed is slower, but can be improved by increasing the speed
of the screw ball.
iv. With minimal modifications and proper maintenance, the device can be very useful
in understanding the true nature of the CNC.
v. It should include automation and the introduction of the actual work tool of the
CNC machine.
vi.

9.3 CONCLUSION

The conclusions drawn from the project are as follows.

Under the description of CNC machine tools, complex projects can be completed
accurately.
The 5-axis CNC milling machine model can be used to understand the operation and
operation of the actual CNC machine.

With the help of CNC machine tools, different organisms can be produced on a large scale.

Use CNC machine tools to reduce the cost of production for the project.

With increased automation of CNC processing and manufacturing processes, consistency and
quality have improved significantly without operator pressure.

The CNC operator automatically performs the CNC cut-off frequency error while performing
additional tasks.

1. Nylon GP 66
2. Aluminum
3. Brass

The usage of soft material is recommended for the machine because of

low power stepper motors.

9.4 G CODES

G00 = Rapid linear move

G01 = Feed linear move

G02 = Circular move CW

G03 = Circular move CCW

G04 = Dwell time

G10 = Zero offset shift

G11 = Zero offset shift cancel

G17 = Contour plane is XY (Z = spindle)

G18 = Contour plane is ZX (Y = spindle)

G19 = Contour plane is YZ (X = spindle)

G20 = Inch mode (G70 on older controls)

G21 = MM mode (G71 on older controls)

G28 = Return to RP

G29 = Return from RP

71
G61 = Exact stop cutting mode

G64 = Exact stop mode off

G90 = Absolute positioning.

G91 = Incremental positioning.

G94 = Feed rate. Used mostly for milling.

G95 = Feed rate. Used mostly for turning.

72
 10 APPENDIX A

10.1 JOB 1

N5 G90 G21
N15 G00 X0 Y0 Z0
N20X25 Y25
N25Z0
N30 X-25
N35 Y-25
N40 X25
N45 Y25
N50 Z2
N55 X15Y0
N60 Z-2
N65 B2
N70 B0
N75 Z2
N80 X-15Y0
N85 Z-2
N90 B2
N95 B0
N100 Z2
N105 X0Y15
N110 Z-2
N115 A2
N120 Z10
N125 M30

73
Figure 47 JOB 1

74
10.2 JOB 2

N5 G90 G21

N15 G00 X0 Y0 Z0

N20 X-50

N25 Z2

N30 Z-3

N35 X-30

N40 X-15

N45 Y-26

N50 X15

N55 X30 Y0

N60 X15 Y26

N65 X-15

N70 X-30 Y0

N75 X-50

N80 Z5

N85 X-15

N90 Z-3

N95 B40

N100 Z5

N105 X0

N110 A1

75
N115 Z-1

N120 Z10

N125 M30

Figure 48 JOB 2

76
10.3 JOB 3

N5 G90 G21

N15 G00 X0 Y0 Z0

N20 X-40 Y-15 Z50

N25 Z2

N30 Z-3

N35 X26

N40 X0 Y30

N45 X-26 Y-15

N50 X-40

N55 Z5

N60 X-13 Y-7.5

N65 Z-3

N70 B5

N75 Z5

N80 X0 Y0

N85 A-2

N90 Z-3

N95 Z50

N100 M30

77
Figure 49 JOB 3

78
 11 REFERENCES

[1] James Madison, CNC Machining Handbook: Basic Theory, Production Data, and
Machining Procedures, INDUSTRIAL PRESS INSURANCE

[2] Warren S. Seames, COMPUTER NUMERICAL CONTROL CONCEPTS AND

PROGRAMING (4TH EDITION)

[3] David A. Stephenson, John S. Agapiou, Metal cutting theory and practice

[4] Mach 3 user software manual

[5] Machinery’s Handbook

[6] Machine design by Shigley.

[7] Modern milling machines, their design, construction, and working; a handbook for
practical men and engineering students by Horner, Joseph Gregory, 1847-1927

[8] International journal for innovative research in science & technology| volume 1

[9] http://www.answers.com/topic/milling-machine-1

[10] http://en.wikipedia.org/wiki/Milling_machinE

[11] http://chestofbooks.com/crafts/mechanics/Mechanical-Processes/340-The-Milling-
Machine.html

[12] http://www.thefreedictionary.com/bearing

[13] http://chestofbooks.com/crafts/scientific-american/sup2/Aluminum-Its-Properties-Cost-
AndUses.html

[14] http://www.efunda.com/processes/machining/mill_cnc.cfm

[15] http://www.engineersgarage.com/articles/stepper-motors

[16] www.mech.utah.edu/~me7960/lectures/Topic4-BallscrewCalculations.pdf

[17]http://www.thomsonlinear.com/downloads/articles/
Selecting_Sizing_Ball_Screw_Drives_taen.pdf