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Design and Fabrication of 3-Axis Computer Numerical Control (CNC)Milling

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Research · April 2018

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Design and Fabrication of 3-Axis

Computer Numerical Control (CNC)Milling
Machine
1
Mr. Amir Khan, 2Aditya Kumar Shukla, 3Aashish Singh
1
Assistant Professor Mechanical, 2B.tech Mechanical Student, 3B.tech Mechanical Student
1
Department of Mechanical Engineering,
1
P.S.I.T. College of Engineering, Kanpur Uttar Pradesh, India
________________________________________________________________________________________________________

Abstract—The idea of making a compact and low cost 3 axis CNC MILLING MACHINE comes from increase in demand of low
cost and Portable machine..As the increase in rapid growth of technology and software available..It is not difficult so we decided
to make a machine which can mill the wood, plastics, thin sheet and alloy..Design and Fabrication is done using a Precision
Stepper Motor that combined with Belt and Pulley arrangement on the gantry type aluminum structure on which the x and y axis
is smoothly slide on rail bearing and for z axis we use Threaded rod and arrangement for up and down motion that increases and
more precisely result obtained..It is an Microcontroller (Arduino uno) based embedded system with a standard pc user interface
software for easy drawing..The System also features an offline G code parser and then interpretated on the microcontroller from a
USB. Improved procedures are employed in the system to reduce the computational overheads in controlling a 3-axis CNC
machine, while avoiding any loss in overall system performance.

Keywords—Mini CNC milling,3axis, Arduino

________________________________________________________________________________________________________
I. INTRODUCTION

C omputer numerical-controlled (CNC) milling machine is an industrial technology that uses a High rpm Spindle to cut
materials. Mini CNC machine is the machine that is similar to usual CNC machine but it’s limited by the area of machining. This
machine is designed for small and precise measurement. CNC can be grouped into two types, which are rotary machine and
milling machine. A rotary machine is basically a device that spins a material piece at a very high speed and the spinner moved
back and forth and in and out until the preferred shape is complete. A milling machine is a machine that has spindle
which consider as similar as the router, with a spindle that spines and cuts in various direction and moves in three directions
along the X, Y, and Z axis . Recently, the industrial world has become faster smaller and in highly advanced technology
to make things smaller, thinner and portable. As well as now the things in engineering and technology world have
microcontroller in NANO and micro size. This also goes to 3-axis CNC machine; these machines nowadays have range size in
the open market. Every type of machine has its own function, even still the size are big or small. Depends of the machine
specification CNC can machine a big work-piece or small work-piece which is to be considered as a mini CNC machine
according to the specification of the design. This paper work is to overcome the problem of machining the small part. Where the
mini CNC machine is going to give the small area of setup the work-piece and it will be easier to get the accurate result of the
work-piece.
Over decades, industrial technology has transformed many aspects of daily life. Several studies has been carried out for the
development of such a (CNC) machine on smaller thinner, lighter weighted and budget cost. From the related journal and
research, the main idea in carrying out this work of CNC development. As the technology of CNC machine characterized by
accessible price and technology so rip that even individuals can design and construct CNC controlled machine[1] . Advanced
facility and precision of control of CNC tools, if it’s compare with usual machine, has had a significant influence on the
development of function components, frame body, stepper motors, and control circuits. Construction and evaluation of Low-cost
table CNC milling machine by using low-price milling cutter for the main spindle due to a low voltage supply of the main cutting
forces it is possible to use the tools of smaller dimension to machine materials like wood, aluminium and plastic materials. Design
and Implementation of Three Dimensional CNC Machine [2] where it discusses the design of low cost three dimensional CNC.
The main function is a microcontroller based CNC machine and it’s communication between personal computer (PC) and CNC
machine by Software sub system that gets a set of commands and fetch it to the mechanical sub system in order to be control the
3-axis. Software sub system that is a PC that provides easy to use interface for user to program commands in such a language that
microcontroller accepts. The author conclude that using C++ as language on NET platform as an alternative of using any ROTS
which is expensive and not user friendly and not possible to execute in general PC which user has to get a separate operating
system. The design of this system is user friendly which give accurate results and flexibility to us

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For more Precision and Accuracy of CNC machine we are particular to pick segments Bipolar Stepper engines are utilized .It can
be viewed as brushless DC motor, whose rotor pivots in for high torque discrete rakish augmentations when it . Stepper engine
drive for PC numeric The stator conveys the attractive field which makes the rotor adjust itself to the attractive field The attractive
field can be modified by consecutively invigorating or "venturing" the stator curls which creates turning movement control
machine is genera reason stepper engines are evaluated with determination as. l low as 0.9°. Exactness, top of the line stepper
engines are capable to[3] accomplish up to 0.05°. It is significance to take note of that stepper engines weight and power
proportion is high, from where happens a most extreme achievable power too. PC based controller peruses G-code
instructions,the code is produced by EASEL and Milling Software which straight forwardly create the G code for that Design it
spares our chance make all procedure Easier.Large CNC frameworks, due to the overheads forced by an extensive G-code
increment the equipment cost of the framework which making it excessively expensive for use by little enterprises. At the prior
created microcontroller based CNC framework had numerous disadvantages. The GRBL G-Code interpreter[4] for instance,
actualized just a portion of the numerous g-codes .Numerous wanders like ROTS based Embedded CNC structure and An Open
Architecture Numerical control System Based on Windows have executed Operating structure on the embedded system[5] which
lessen the taking care of and memory breaking point of the structure. Along these lines, these structures required top notch and
exorbitant chip. It require for a G-code parser using an Arduino based microcontroller which is facilitated bit of the structure, is
separated, a tremendous diminishment in the cost is refined, as needs be making the system unobtrusive for little scale
organizations and individuals.
Program charges are made up by words . CNC controls utilize a word address design for programming. By word address
arrange, we imply that the CNC program is comprised of sentence-like orders. Each charge is comprised of CNC words, every
one of which has a note address and a numerical esteem. The note address (X, Y, Z, and so forth.) tells the control the sort of
word and the numerical esteem tells the control the estimation of the word. Utilized like words and sentences in the English
dialect, words in a CNC charge tell the CNC machine what it is we wish to do at the present time[6] The CNC developer must
have a capacity to imagine the activity of the machine and he says, in comparative way, a manual CNC software engineer must
have the capacity to picture the machining tasks that are to be performed amid the execution of the program[7] Then, in well
ordered request, the software engineer will give an arrangement of orders that influences the machine to carry on likewise.
As perceived, "programs are set up of requests and charges are contained words". Each word has a letter address and a
numerical regard. The letter address tells the control the word compose. CNC control makers do contrast concerning how they
choose word names (letter addresses) and their suggestions. The beginning CNC programming engineer must reference the
control maker's redoing manual to choose the word names and suggestions.
A pivot is a way of movement controlled by the CNC machine control. It can be direct (movement adjacent to a straight line)
or round (a turning movement). The aggregate of tomahawks a machine has finishes up its machining capacities. For machining
focuses, a three pivot CNC machine will have three straight tomahawks. A four or five pivot machine will have three straight
tomahawks and additionally maybe a couple turning tomahawks.
The 3-Axis machine was intended to give a proper section level instrument for testing with 3-hub machining and CAD/CAM
systems[8]. It has not been wanted to supplant present, higher end machines, for example, those made by Manufacturing
Corporation. The accentuation is on availability and enables the client to totally change the in assembled firmware on the machine
. With a specific end goal to build a three hub machine[8] there is a prerequisite to choose which the parts need to utilize so it can
accomplish easily and productivity comes about.
The systems and component that transfer, hold, and guide loads move in linear directions. Also the duration used to describe
computerized and semi-computerized mechanical systems that generate directions of x, y, z axes. Recent engineering process
integrates the use of linear component to allow for rapid low-friction accuracy movement. A liner system combined with stepper
motor, driver,Aluminium Extrusion,with Belt and Pulley makes filling these necessities conceivable.Stepper Motor used as the
driving and controlling instruments provide response, control, Linear motion systems have three basic categorize as 1) The
control, 2). The drive tool, 3).The support of components.
The drive or control devices include a selection of electric motors such as linear, stepper. The drive tool, in combining with the
drive, offers the thrust and axial positioning precision of the load. The guidance machines of the systems control travel direction
and linear accuracy as well as support the load
Machines are presented with the traditional floor plate and mobile gantry,as well as special gantry mills with integral table
providing heavy duty turning capabilities .the milling head rides over two rails(often steel tubes) which lie at each side of work
surface.
For The Gantry machine it have 5 types:
 Gantry type structure offers maximum structural height dynamic performance X axis travel can enlarge according to client
request y axis can travel the prepared with untested as crossbeam adjustment mechanism which can reach it off span at 7 m
 X axis has Aluminium Alloy Extrusion rail one Stepper Motor and 4 V Wheel synchronised with Belt and Pulley that
controlled driving system to ensure vital dynamic accuracyAdditional extraordinary rigidity roller style linear guide ways
for Y-axis cartel the benefits of both box way and linear guide ways which make the unit can do a heavy duty cutting, fast
movement and low abrasion capabilities.
 Z-axis have an extra-large size linear guide ways which along with larger saddle and high rigidity box structure
headstock which provides best cutting rigidity
 As we all know that there is a bit of argument about the name of a particular axis and the direction it moves. Both sides
of the argument have their merits [9]. The arguments begin when assigning axis to the device itself. Most people will call
the axis holding the spindle the Z-Axis. However, the X and Y axis becomes a debate.The X-Axis should be the longer of
these two axis [10]. In other words the X-Axis is the axis you are facing as you face the machine during operation. Now
this may be improper, but it makes it easy to visualize the coordinates as you look at the machine. It simply becomes a
Cartesian coordinate system that used to in high school algebra with the Z-Axis moving up and down. The main objective

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of this paper is to design and fabricate a Compact CNC MILLING Machine and to use software to control the 3-axis
machine. This project describes the design, fabrication and assembly requirement of the machine and the criteria required
to build the machine sufficiently. And also to construct the whole system with a limited budget
II-METHODOLOGY

The structural design of the machine including to wiring connection and the software adopted to generate codes and C+
language. Finally but not last is Development the base of the design that has been achieved.
A. Structure Design
The machine structure is the vital part of the machining tool. It merges all machine components into a single complete
system. The machine structure is vital to the efficiency of the machine since it’s directly affecting the total dynamic
stiffness and also affecting the damping response. Perfectly designed structure can afford high stiffness, which leads to
precise operation. Mini scaled machine tool required more precise stiffness than the regular large scale machine tool as
shown in Fig. 1.
The initial design will be drafting or sketching then when the design satisfied. The next level will be deciding the criteria
required which is firstly the length travel. The length travel is the length of the X, Y and Z axis that travels from one point
to another. The X axis move left & right, Y axis move front & back, Z axis moves Up and Down. Travel length that is to be
designed is X axis 10cm and Y axis 10cm and Z axis. This structure comes with less materials hence it’s very less
expensive to build which it’s designed to cut papers, engrave leather, wood & plastic cards.

Fig.1 Arduino UNO

Stepper Motor Driver Board: RMCS-1102 is micro-stepping drive designed for smooth and quiet operation is chosen to drive
the NEMA 17 stepper motor. Stepper motor Driver Board recieves the control signal form the micrcontroller board

Fig.2 Easy Driver v4.3 pins

C.MECHANICAL SYSTEM:

The mechanical system which is assembled in such a way that the 3-axis movement is achieved by using the linear rails
assembled with linear bearings.Stepper motors are mounted to the each axis which is source of motion acted according to the
control signal generated from the electronics circuit. Each stepper motor is coupled through the shaft couplers to each of the
Lead/Ball screw of each axis which is responsible for converting the rotational motion of the stepper motor to linear motion. The
linear motion of each axis is carried away smoothly by the linear rail assembly connected to the each axis which is capable of load
carriers and allow linear motion in each axis.The controlled motion in each axis is achieved directly by by controlling the rotation
of the stepper motor. The speed of the motion in each axis can also be controlled by direct control of the speed of the stepper
motor by giving required control signals. Thus the tool path of the spindle fixed to the end effector is controlled in each axis for
smooth carving or cutting action of work piece.
D. Design and Fabrication-
[1]Start from the Base install 4 to 6 rubber feet.
[2]Make a working area bed 500*500mm
[3]Install four gantry on each side.
[4]Make X and Y frame by fixing sliding rod to gantry.
[5]Make the Z axis frame.
[6]Assemble it with Threaded rod and nut assembly.
[7]Fix the timing belt and Sliding roller on each axis
[8]Assemble belt and pulley with Stepper motor.
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[9]Fix the spindle on z axis and power supply.
[10]Connect power supply to extension board and give the command by easel software.
D. Programming and Coding System :
The apparatus chain of CNC-based assembling is spoken to in the fig11. The part to be machined is outlined in a PC supported plan
(CAD) programming, whose yield is an attracting one of numerous worthy organizations most best configuration is .stl arrange.
This attracting is then nourished to the PC helped producing (CAM) programming, whose yield is the machine intelligible code
utilized for numerical control of the machine. Since execution of the G code is machine subordinate, it is important to try out
various decisions for an open source G code mediator for the Arduino, so the right movements are acquired for the machine
tomahawks through the stepper engine driver. We have utilized GRBL, an open source G-code mediator or processing controller
for the Arduino advancement board.
E-Computer aided design SOFTWARE: Computer-helped plan (CAD) is the utilization of PC frameworks to aid the creation,
alteration, examination, or advancement of an outline 3D sections for CNC cutting.CAD devices in the most genuine sense are
intended to enable you to effortlessly change and control parts in view of parameters. The most broadly utilized tradable work
document organize is .STL records are essential since, they are utilized by CAM instruments to create Gcode OpenSCAD,
FreeCAD, HeeksCAD PTC Creo (once in the past PTC Pro/Engineer), Dassault Solidworks, Autodesk Inventor, Auto CAD are a
few cases of CAD bundles

Fig.3Sequence of Programming
CAM SOFTWARE:Computer Aided Manufacturing, or CAM, devices handle the middle of the road venture of making an
interpretation of CAD records into a machine-accommodating configuration utilized by the Microcontroller board. CAM
programming needs a .STL record design from CAD programming to create machine agreeable GCODE. Some case bundles
resemble CAD/CAM, G-Simple, FreeMill, Dolphin CAD/CAM, CamBam, Vizion (ArtCam), OneCNC, VirtualGibbs,
MasterCAM , BOBCAD-CAM, MeshCAM, VisualMill, TurboCADCAM, DeskCNC, SheetCAM, OneCNC, SprutCam,
EdgeCAM, ArtCAM and so on.

CNC CONTROL SOFTWARE (GCODE Sender): Gcode Sender is utilized to send the G-code records to a coordinated
equipment interpreter(Atmega 328).Gcode Sender will take a G-code program in document and send it line by-line to the Atmega
328 microcontroller. The Gcodes will send over the serial ports through USB correspondence between the PC and microcontroller
.GRBLl Controller is programming that is intended to send GCode to CNC machines is ,, for example, 3D processing machines. It
isn‟t super brilliant, it simply needs to give the client a decent method to get summons down to whatever controller they are
utilizing

Fig. 4 Milling text by Easel Software

III.Result and Discussion

Software results
The machine process is using a graphical user interface (GUI) e.g., “EASEL” which is graphical software that runs into a PC
for creating and designing an image to be convert it into G-Code .nc file which used to run the design into GRBL Controller.

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Mechanical results
CNC machine mechanically which it required a surface flatness test and perpendicularity test as well as the repetition accuracy
of the axis movement. It is clearly to understand the accuracy of the geared stepper motor selected in this project to run the axis is
by using a quick calculation in order to obtain the accurate results.

The first thing is to have Step/ inch required for the stepper to move an inch which drives from a stepper motor and thedriver
which is the Easydriver. Typically stepper motors uses different steps per revolution as per the steping angle.
That stands for if the stepper motor turns 360° it steps 30 times.
Where the driver is capable increasing the number of steps, now the driver has been set to 1/16 microstepping which will equal
to
To get the pich circumference =

Axis Accuracy and repeatability

Using a stepper as an accurate movement for CNC is is role of machining success. A machining measuring tool is used to
measure how accurate is the stepper motor precision to get it to run. An experiment is held with controlling a stepper using an
arduino connected with an easy driver which it has a built in parameters for de-acceleration and acceleration.
Utilizing a G-code to move the pivot's is the way what measures the repeatability and this code are impleneted through GRBL
application which been gathered with arduino. With a specific end goal to get into the analysis the necessities are : DTI dail test
pointer as appeared in Fig. 5, Stepper engine, Arduino, Easydriver, GRBL application.
The results are in each repeated measurment been held is not only testing the stepper motor accuracy but it is the whole system is
perfectly accurate which will get the theoretically number in the real world numbers.
Table 1 shows the pulley specification used in this project
which the number of teeth is the core of calculation.
In this Fig.6 will show how was the axis’s are accurate in each repeat the X axis readings are given in Table 2 and the accuracy
of the y-axis has been promissing the prcision values that in each repeat the value was fixed every time testing the values of Y-
axis shown In this Fig. will show how was the axis’s are accurate in each repeat the y axis readings are given in Table 3.

that mean in one revolution we will able to travel 3 mm so to find out how many steps it takes to travel one inch which will get
the theoretically number in the real word numbers
Teeth profile GT2 No of Rep Values No of Rep Values
Teeth number 15 1st repeat 0.45 inch 1st repeat 0.4912 inch
Bore Diameter Ø3 2nd repeat 0.46 inch 2nd repeat 0.4914 inch
Belt Width 3mm 3rd repeat 0.45 inch 3rd repeat 0.4913 inch
Angle per Step 12° 4th repeat 0.48inch 4th repeat 0.4912 inch
5th repeat 0.46inch 5th repeat 0.4912 inch

Table-1 Pulley Specification

Table.2X axis Repeated Data Table-3 Y axis Repeated Data

Fig 20 ., Surface Of cutting Fig 21 . Surface Of cutting Fig.22 Surface of cutting

G CODE -
(ADITYA)
(A)
N10 G0 Z2
N20 G0 X0 Y0
N30 G1 Z-1
N40 G1 X10 Y30
N50 G1 X20 Y0
N60 G0 Z2
N70 G0 X17.222 Y8.333
N80 G1 Z-1
N90 G1 X2.778 Y8.333
(D)
N100 G0 Z2
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N110 G0 X30 Y0
N120 G1 Z-1
N130 G1 X30 Y30
N140 G1 X38.333 Y30
N150 G2 X46.667 Y21.667 I0 J-8.333
N160 G1 X46.667 Y8.333
N170 G2 X38.333 Y0 I-8.333 J0
N180 G1 X30 Y0
(I)
N190 G0 Z2
N200 G0 X58.333 Y0
N210 G1 Z-1
N220 G1 X58.333 Y30
(T)
N230 G0 Z2
N240 G0 X70 Y30
N250 G1 Z-1
N260 G1 X86.667 Y30
N270 G0 Z2
N280 G0 X78.333 Y30
N290 G1 Z-1
N300 G1 X78.333 Y0
(Y)
N310 G0 Z2
N320 G0 X96.667 Y30
N330 G1 Z-1
N340 G1 X106.667 Y16.667
N350 G1 X106.667 Y0
N360 G0 Z2
N370 G0 X106.667 Y16.667
N380 G1 Z-1
N390 G1 X116.667 Y30
(A)
N400 G0 Z2
N410 G0 X126.667 Y0
N420 G1 Z-1
N430 G1 X136.667 Y30
N440 G1 X146.667 Y0
N450 G0 Z2
N460 G0 X143.888 Y8.333
N470 G1 Z-1
N480G1X129.445Y8.333
IV. CONCLUSION
Due to more demanded for mini scaled 3-axix CNC machine with highly accuracy parts in different industry, the retail for 3-axis
mini CNC machine has noticeably been increased. For fabrication small parts need to be provided both flexibility and efficiently
in the manufacture assembling, the CNC machine has achieved the desired precision and accuracy.
In this work, a mini 3 axis cnc machine designed and fabricated with a low-priced of 18000 Rs. Throughout the structural
design stage there was many common CNC
approaches and reduce total cost which is affordable for individuals and small business. Due to a success selection of a body parts
and precision calibration, testing and
structures been found and tested. The most appropriate structure is the gantry type structure was chosen and designed through a
Autocad software. Precarious components such as liner guides, stepper motors, and microcontrollers and modules is precisely
choosen among a huge different choices in order to fit the requirements.

The best cost components are selected to provide accuracy and simplicity and as well as budget limitation. The assembling of a
mechanical parts and emerging it into an electronic components are perfectly been considered. A model of a CNC machine is
assembled in house using and in the lab to perform a testing criteria of the machine components before assembling it. The steps of
building a wooden structure are followed in detail from a CNC structures company has been followed to meet the accuracy while
merging it into an electronic as well as mechanical parts together. The configuration and calibration steps are clearly given with
all details. The complete machine functionality verified using a various of tests which flows from softwares test into a
mechanically tests, the errors has been initially clarified and determined to ensure reliability of the machine. As well as finding a
best possible solution in human monitor interface (HMI) rather than using a PC to be mobilized is using a touch screen from
Raspberry Pi as computer. Since Raspberry Pi equipped with it’s own embedded Operating system Linux, while the user can
practically copy a machine code G-Code file hooked on the system using a simple USB driver which will help to stream the
machine code to arduino Uno
In conclusion the exactness of the smaller than expected 3-hub CNC machine body parts amassing has prevailing to accomplish
the targets of this task in conservativeness precisionly and repeatability goal.It give and meet all necessity at little scale in
moderate cost

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V. FUTURE WORK:

It is wanted to scale up the model CNC machine as far as size, utilize all the more capable motors, fortify the edge and worktable
with materials like aluminum or cast iron, and expand the CNC control programming with programming for reenactment in front
of genuine run. For instructional purposes and for more exact task, it is desirable over form CNC machines with DC or AC
servomotors and encoder input utilizing PC-based movement controllers. It is intended to actualize the multi pivot around 4 to 6
hub CNC switch. The execution of 3D printing (Rapid prototyping) innovation to a similar equipment conceptual is progressing
plan for printing 3D models.we can likewise change over it into laser CNC machine.
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[3] V. V. Athani, Stepper Motors: Fundamentals, Applications And Design, 1st ed. Daryaganj: New AgeInternational, 1997.

Coll. Of Comput. Sci., 2010. The research of embedded CNC system component. In - Computer Application and System
Modeling (ICCASM), 2010 International Conference. Volume 7 – 22-24 Oct. 2010. Taiyuan: Shaogan University

[4] Ertell & Glenn G., 1969. Numerical Control. New York: Wiley-Interscience

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[6] Arduino Uno r3, 2015.Available from: http://www.arduino.cc/en/Main/ArduinoBoardUno. [25 may 2015]

[7] Lynch,M. 2016. mmonline. [ONLINE] Available at: http://www.mmsonline.com/articles/key-cnc-concept-1the-

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[8] Nicloas correa. 2007. Correa. [ONLINE] Available at: http://www.correa.es/en/0-news-page/20-nicols-correa-sa-extends-

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